BCI Falcon 45 OPs Manual.book

BCI Falcon 45 OPs Manual.book
FOREWORD
LZ Busline, LLC
OPERATION AND MAINTENANCE MANUAL
for
FALCON 45 MOTOR COACH
PREFACE
Please allow us to express our thanks for your choosing our new LZ
Falcon 45 Motor Coach. We would like to congratulate you for your
choice as well, as we believe you will be impressed by the excellent
performance of this product.
•
•
167 Lamp and Lantern Village,
No. 125, St. Louis,MO 63017
Tel: 314-579-9649
Fax: 314-878-6668
www.lzbusline.com
Every effort has been made to insure accuracy and quality in publication of this document. At the time of printing, content is the most current
available.
•
Our LZ Falcon 45 Motor Coach is economical, safe and comfortable. This manual will introduce you to some important how-to’s
about driving, operating, and maintaining your new LZ Falcon 45
Motor Coach. Please read it carefully. Please operate and maintain
your LZ Falcon 45 Motor Coach in accordance with this manual,
which will help you keep your LZ Falcon 45 Motor Coach in optimal condition and maximize its service life.
If any questions, comments or concerns arise in your operation or
maintenance of your new LZ Falcon 45 Motor Coach, please contact our National Service Group at (314) 45BYLZ or access our
dedicated support website at www.lzbusline.com. We strive to
provide optimal customer service as well as parts availability and
maintenance support. LZ Busline, LLC strives to continuously
improve and adapt in order to provide you with the highest
quality product, service and support.
Consider this manual a permanent part of this LZ Falcon 45 Motor
Coach. If the LZ Falcon 45 Motor Coach is sold or traded, also
include this manual to provide the next owner with important operating, safety, and maintenance information.
Due to technological advancements and continuous improvement of
our products and the products of our component suppliers, LZ Busline,
LLC reserves the right to change specifications without notification.
i
FOREWORD
NOTES
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
ii
TABLE OF CONTENTS
INTRODUCTION
SAFETY INSTRUCTIONS .......................................................... 1
HOW TO USE THIS MANUAL ................................................... 2
VEHICLE IDENTIFICATION NUMBER (VIN) PLATES .............. 2
MOTOR COACH SPECIFICATIONS ......................................... 3
BODY STRUCTURE .................................................................. 3
ELECTRICAL SYSTEM .............................................................. 3
ENGINE SPECIFICATION ......................................................... 4
TRANSMISSION SPECIFICATIONS ......................................... 5
SUSPENSION ............................................................................ 6
STEERING SYSYTEM ............................................................... 6
WHEELS AND TIRES ................................................................ 6
BRAKING SYSTEM .................................................................... 6
SAFETY
OPERATOR PRECAUTIONS .................................................... 7
PASSENGER SEATBELTS ....................................................... 8
WARNING LABELS .................................................................... 8
ROAD SAFETY .......................................................................... 8
FIRE EXTINGUISHER ............................................................... 9
EMERGENCY EXITS ................................................................. 9
COLLISION WARNING SYSTEM ............................................ 10
CONTROLS
INSTRUMENT PANEL ............................................................. 11
SWITCH PANELS .................................................................... 16
CLIMATE CONTROLLER ......................................................... 18
WEBASTO® HEATER .............................................................. 20
STEERING WHEEL AND COLUMN ........................................ 27
EXTERIOR MIRRORS SELECT/CONTROL KNOB ................. 27
PARKING BRAKE .................................................................... 29
EMERGENCY BRAKE ............................................................. 29
DELUXE TOUR GUIDE SEAT ................................................. 33
PASSENGER SEATS ............................................................... 34
GEAR SELECTOR ................................................................... 35
PASSENGER INTERIOR CONTROLS ....................................42
OPERATING
GENERAL INSTRUCTIONS .....................................................43
ENGINE STARTUP ..................................................................43
WINTER DRIVING TIPS ...........................................................45
DPF REGENERATION .............................................................45
AUDIO/VISUAL SYSTEM .........................................................48
LAVATORY ...............................................................................50
ELECTRIC DRIVER SUN SHADES .........................................52
ENTRANCE DOOR EMERGENCY RELEASE ........................52
REMOTE CONTROLLED ENTRANCE DOOR ........................53
LUGGAGE COMPARTMENT ...................................................53
SPARE TIRE COMPARTMENT ...............................................54
iii
TABLE OF CONTENTS
DAILY INSPECTIONS
ENGINE OIL LEVEL ................................................................55
ENGINE OIL PRESSURE ........................................................55
DRIVE BELTS AND BELT TENSION ......................................55
BATTERY .................................................................................56
WASHER FLUID ......................................................................56
WINDSHIELD WIPER ..............................................................56
AIR CLEANER .........................................................................56
AIR STORAGE TANK PURGE ................................................56
RADIATOR COOLANT ............................................................56
FUEL TANK .............................................................................57
PRIMARY FILTER-WATER SEPARATOR ..............................57
EXTERIOR LAMPS ..................................................................57
ELECTRICAL SYSTEM ...........................................................57
POWER STEERING ................................................................57
BITZER COMPRESSOR .........................................................57
TIRES AND WHEELS ..............................................................58
INSPECTION SHEET ..............................................................59
MAINTENANCE
GENERAL INFORMATION ......................................................61
MAINTENANCE RECORDS ....................................................62
SEAT BELT MAINTENANCE ...................................................63
CLEANING MOTOR COACH ..................................................63
ENGINE AND CHASSIS MAINTENANCE ...............................64
REMOTE START SWITCH/MASTER DISCONNECT .............64
AIR FILTER ..............................................................................65
RADIATOR ...............................................................................66
ENGINE COOLANT .................................................................66
BRAKE PEDAL .........................................................................69
TIRE ROTATION .....................................................................69
WINDSHIELD WASHER RESERVOIR ....................................69
iv
NEW MOTOR COACH BREAK-IN ...........................................69
ENGINE COMPARTMENT ......................................................71
ENGINE OIL .............................................................................72
GEAR LUBRICANT...................................................................73
POWER STEERING LUBRICANT ...........................................73
FINAL DRIVE UNIT LUBRICANT ............................................73
CHASSIS LUBRICANT ............................................................73
DIESEL FUEL ..........................................................................73
TROUBLESHOOTING .............................................................74
EMERGENCY STARTING USING JUMPER CABLES ............91
FUSE PANEL ...........................................................................92
SCHEDULED MAINTENANCE
GENERAL INFORMATION ......................................................93
COMPONENT MANUFACTURER REFERRAL .......................93
2,400 MILE (4,000 km) MAINTENANCE INTERVAL ...............94
4,800 MILE (8,000 km) MAINTENANCE INTERVAL ...............96
7,200 MILE (12,000 km) MAINTENANCE INTERVAL .............97
14,400 MILE (24,000 km) MAINTENANCE INTERVAL ...........98
21,600 MILE (36,000 km) MAINTENANCE INTERVAL ...........99
48,000 MILE (80,000 km) MAINTENANCE INTERVAL .........100
WARRANTY/CUSTOMER ASSISTANCE
CUSTOMER ASSISTANCE ...................................................101
PRODUCT WARRANTY
LZ Busline, LLC WARRANTY POLICY ..................................101
INTRODUCTION
INTRODUCTION
SAFETY INSTRUCTIONS
This manual contains information on systems operation, component
location, and scheduled maintenance procedures, which pertain to
standard and optional equipment on LZ Falcon 45 Motor Coaches.The
service procedures described and/or recommended in this manual are
effective methods for performing scheduled service or replacement of
components. Other information, which may be needed to supplement
this manual is contained in separate component manufacturer’s manuals. Specific information about the engine and transmission can be
found in the applicable manufacturer’s operator, service, and troubleshooting manuals. These manuals can be found at www.lzbusline.com.
Safety instructions are noted throughout this manual. Each safety
instruction is given as a WARNING or a CAUTION and is accompanied
by a safety symbol as shown below:
WARNING
Failure to observe a safety instruction noted by WARNING could
result in severe injury or death.
CAUTION
Failure to observe a safety instruction noted by CAUTION could
result in injury or damage to the equipment.
NOTE: Used throughout this manual, NOTES provide useful data, but
are never used to communicate safety hazards.
1
INTRODUCTION
HOW TO USE THIS MANUAL
This manual is divided into nine major sections:
SECTION 1 - FOREWORD
SECTION 2 - INTRODUCTION
SECTION 3 - INSPECTION
SECTION 4 - SAFETY
VEHICLE IDENTIFICATION NUMBER (VIN) PLATES
Motor Coach VIN Plate
The motor coach VIN plate is mounted inside the motor coach to the
driver’s left and on the passenger deck wall. The motor coach plate has
the following information on it: motor coach model, motor coach overall
weight, motor coach code, rated passenger capacity, VIN, chassis
code, engine model, rated power, manufacturing date and manufacturer.
Secondary Plate
SECTION 5 - CONTROLS
SECTION 6 - OPERATING
SECTION 7 - MAINTENANCE
SECTION 8 - SCHEDULED MAINTENANCE
SECTION 9 - WARRANTY/CUSTOMER ASSISTANCE
Some of these major sections may be divided into smaller subsections
dealing with specific components and/or operating systems.
NOTE: Some illustrations in this manual were provided courtesy of the
appropriate vendor. Typical illustrations may be used, therefore minor
illustration differences may exist when compared to actual parts or other
publications.
2
The secondary plate is located in the upper left engine compartment on
the cross member. The secondary plate has the following information
on it: VIN, vehicle type, LZ model number, date of manufacture, and
manufacturer name. The VIN has also been stamped on the body
understructure.
Engine Plate
The engine plate is located on the center of the engine and to the right
side of the fuel filter. The engine plate has the following information on
it: engine model, engine serial number, and arrangement numbers.
INTRODUCTION
Motor Coach SPECIFICATIONS
Overall Length . . . . . . . . . . . . . . . . . . . . . . .45 ft (13.7 m)
BODY STRUCTURE
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ft 11.5 in. (7 m)
The semi-monocoque body truss structure is closed by U-shaped body
assemblies. A skeleton is formed by welded rectangular galvanized
square tubing, made from Australian SupaGal dual galvanized steel,
giving rigidity, stiffness, and torsional resistance. Welded segments are
anti-corrosion treated before final assembly.
Under-floor Storage Capacity . . . . . . . . . . . . 377 cu ft (10.6 m³)
ELECTRICAL SYSTEM
Parcel Rack Storage Capacity . . . . . . . . . . . 60 cu ft (1.7 m³)
Controller Area Network (CAN) system architecture with MultIC and
four IOUs. TFT Multifunction display / instrument panel.
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 24VDC
Overall Height. . . . . . . . . . . . . . . . . . . . . . . . 12 ft 4 in. (3.7 m)
Overall Width . . . . . . . . . . . . . . . . . . . . . . . . 8 ft 6 in. (2.5 m)
Front Overhang (to front of bumper) . . . . . . 8 ft 2.4 in. (2.5 m)
Rear Overhang (to rear of bumper) . . . . . . . 8 ft 10.3 in. (2.7 m)
Turning Radius . . . . . . . . . . . . . . . . . . . . . . . 37 ft (11.3 m)
Fuel Tank Capacity. . . . . . . . . . . . . . . . . . . . 211 gal. (799 L)
Interior Height (average) . . . . . . . . . . . . . . . 6 ft 2 in. (1.8 m)
GVWR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49,000 lb (22,226 kg)
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . 17,080 lb (7,747 kg)
Alternator (dual) . . . . . . . . . . . . . . . . . . . . 24V 140A Prestolite®
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 24V 200Ah H2
Combination instrument panel includes: odometer, tachometer, intelligent signal processor, voltage meter, water thermometer, oil-pressure
gauge, fuel-level gauge, air-pressure gauge together with the indicators
such as steering indicator and high beam indicator.
Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . 26,400 lb (11,975 kg)
Tag Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17,080 lb (7,747 kg)
Approach/Departure angle (degrees). . . . . . 7.5/8.5
3
INTRODUCTION
ENGINE SPECIFICATION
Caterpillar® C13 12.5 Liter Heavy Duty Engine
Cylinders . . . . . . . . . . . . . . . . . . . . . . . 6 inline
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12 in. (130 mm)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . 6.18 in. (157 mm)
Displacement . . . . . . . . . . . . . . . . . . . 12.5 L (763 cu in)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . 2,270 lb (1,030 kg)
Horsepower . . . . . . . . . . . . . . . . . . . . . 410 @ 2100 rpm
Torque . . . . . . . . . . . . . . . . . . . . . . . . . 1450-1650 lb ft @ 1200 rpm
4
Standard Equipment
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Caterpillar® Regeneration System
Cooling: gear-driven water pump, oil cooler
Diesel particulate filter
Electronic Control Module (ECM)
Electronic Data Link, SAE/ATA, SAE/J1939
Electronically Controlled Unit Injection Fuel System
Fuel: spin-on secondary filter, transfer pump
Gear-driven water pump
Governor: full-range, electronically controlled
Hydraulic steering pump drive, SAE A
Lifting eyes
Lubrication: gear-driven pump, front or rear sump pan, full flow
spin-on filter, oil filler, oil level gauge (dipstick)
Open crankcase ventilation
Pad mount air conditioner compressor
Pad mount alternator
SAE No. 1 Flywheel Housing
Series-turbochargers
Vibration damper
INTRODUCTION
TRANSMISSION SPECIFICATIONS
Eaton® RTO-16910B-DM3
Fully Automated Heavy-Duty Transmission (no clutch pedal) for OnHighway application. Full automation (no clutch pedal) provides greater
driver comfort and less stress than manual shifting which increases satisfaction and safety. Allows for less time and expense to train new drivers.
•
•
Manual mode allows the driver to initiate and control shifts for flexibility during changing conditions or hold a gear as appropriate.
Low mode boosts the rpm point at which downshifts occur to maximize engine braking.
Type:. . . . . . . . . . . . . . . . . . . . . . . . . . . AutoShift 10-speed
Optional Cat® CX31 Transmission
The Cat® CX31 transmission combines the proven performance of a
Cat Engine coupled to the CX31 Transmission provides users with the
most advanced power train package available today. Cat Transmission
users will further benefit from single-source product support for the
power train package.
CX31 Features and Benefits:
•
•
•
Operating mode:. . . . . . . . . . . . . . . . . . Electronically controlled
Gear Ratios
•
1st gear . . . . . . . . . . . . . . . . . . . . . . . . . . 10.99
2nd gear . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
•
3rd gear . . . . . . . . . . . . . . . . . . . . . . . . . . 6.07
•
4th gear . . . . . . . . . . . . . . . . . . . . . . . . . . 4.46
5th gear . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
6th gear . . . . . . . . . . . . . . . . . . . . . . . . . . 2.46
•
Six forward speeds, one reverse.
Two standard side PTO locations and an optional high-output rear
PTO, for full-time uninterrupted driveline power - all live, all of the
time.
Lock-up torque converter couples the engine directly to the driveline for better fuel economy.
Optional remote-mounted oil filters for quick replacement. Exteriormounted Electronic Clutch Pressure Control (ECPC) valves for
easy access.
Adaptive shift control logic utilizes information from the driver's
operating style to balance performance and economy.
Optional integral hydraulic retarder can be used as a quieter secondary braking alternative.
Industry standard J1939 communication facilitates information
transfer between the transmission and engine, making diagnostic
codes available for efficient servicing of both components.
7th gear . . . . . . . . . . . . . . . . . . . . . . . . . . 1.83
8th gear . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36
9th gear . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00
10th gear . . . . . . . . . . . . . . . . . . . . . . . . . 0.74
Transmission Shaft
Open-type, one universal joint in each shaft (see serial number). Rigid
universal joint pin with needle roller bearings.
Reverse gears . . . . . . . . . . . . . . . . . . . . . 11.23 and 2.52
5
INTRODUCTION
SUSPENSION
Front Axle
STEERING SYSYTEM
Power Steering
ZF RL85E
ZF8098
Double A-shaped beam axle, airbag suspension, two leveling valves
with two airbags, two telescopic shock absorbers and lateral stabilizer.
Recirculating ball-type power steering system.
Front wheel orientation: Wheel camber 0.5º - 1º. Approaching 1º is recommended. The angle difference should not exceed 0.3º on both sides.
Kingpin inclination . . . . . . . . . . . . . . . . . . .7.5º+/- 0.5º
Castor . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30º
Toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . .0mm +/-1mm
Driving Axle
ZF A132
Integrated press-welding axle housing, full-floating axle shaft, single
reduction final drive hyperbolic gear.
Final gear ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54/1
All airbag suspension, two leveling valves with six airbags, six telescopic shock absorbers and lateral stabilizer.
Tag Axle
ZF RL85A TAP
Integrated I-shaped beam, with adapted steering control. Airbag suspension, two airbags, two telescopic shock absorbers and air pressed
control braking system disc brake.
6
WHEELS AND TIRES
Wheel type Hub Pilot Alcoa® wheels.
Tire specifications (front and rear) . . . . . Michelin 315/80R22.5
BRAKING SYSTEM
Dual-circuit air braking ABS and self-correcting adjusting arm. Air pressure servo assist with identical disc brakes at all wheels. Manual valve
operated parking brake, energy storage spring works on rear brake.
Emergency brake effected with parking brake.
SAFETY
SAFETY
OPERATOR PRECAUTIONS
The following precautions have been prepared for your safety and the
safety of your passengers and fellow motorists. Read and understand
this information before operating the motor coach.
The safe and reliable operation of this vehicle includes a thorough
working knowledge of all its components. When checking the vehicle
over or driving it, you should be able to recognize problems when they
exist and determine if your motor coach can be driven without affecting
its safe operation or causing more serious mechanical problems. When
work is required, you should be able to report accurately on the problem.
WARNING
Use extreme caution while under motor coach, as motor coach
can suddenly drop when air is intentionally or unintentionally
removed from the suspension. Ensure parking brakes have been
applied and the wheels remaining on the ground are secured with
wheel chocks. Use properly sized jacks with the appropriate lifting
power. Always use proper chassis stands under a jacked up motor
coach.
WARNING
Never open the engine cooling system or the interior heating system while the system is hot. Never add cold coolant to an overheated engine. Do not place unprotected hands on a hot engine,
transmission, or exhaust.
WARNING
Before starting engine, ensure the transmission is in neutral and
the parking brake is engaged.
WARNING
Safely depressurize systems containing compressed air or liquid
under pressure prior to opening system.
WARNING
Prior to performing any checks, maintenance or repair procedures, ensure that motor coach is disabled to avoid serious injury
or death. When conducting checks, remember to keep a safe distance away from moving parts.
WARNING
Refuel outdoors and use extreme caution while refueling.
WARNING
Do not unnecessarily idle the engine. Do not operate the engine
without an efficient exhaust removal system. Carbon monoxide
gas is toxic. Breathing it can cause unconsciousness and even
death.
WARNING
Batteries contain highly corrosive acid. Battery vapors are explosive. To avoid short circuits, always disconnect the negative cable
first. Reconnect the negative cable last.
7
SAFETY
PASSENGER SEATBELTS
Each passenger seat is equipped with a lap belt. Designed to comfortably keep each passenger safely in the seat.
Why wear seat belts
•
•
•
•
•
•
•
Seat belts are the single most effective safety device for adults and
larger children (infants and smaller children must be properly
restrained in child seats.
Not wearing a seat belt properly increases the chance of serious
injury or death in a crash.
When properly worn, seat belts:
Keep you connected to the vehicle so you can take advantage of
the motor coaches built-in safety features.
Help protect you in almost every type of crash; including side, rear
impacts, and rollovers. In a rollover crash, an unbelted person is
more likely to die than a person wearing a seat belt.
Help keep you from being thrown against the inside of the motor
coach and against other passengers.
Keep you and your passengers from being thrown out of the motor
coach.
Of course, seat belts cannot completely protect you or your passengers
in every crash. But in most cases, seat belts can reduce your risk of
serious injury.
What should you do:
•
8
Always wear your seat belt properly and make sure your passengers do as well.
WARNING
If a seat belt does not seem to work as it should, it may not protect
the occupant in a crash. No one should sit in a seat with an inoperative seat belt. Anyone using a seat belt that is not working properly can be seriously injured or killed.
Contact LZ Busline, LLC as soon as possible for parts or
repairs.
WARNING LABELS
Warning labels warn you of potential hazards that could cause serious
injury. Read all warning labels carefully and follow instructions on them.
Learn and watch for labels.
If a label comes off or becomes hard to read, contact LZ Busline, LLC
as soon as possible
ROAD SAFETY
The motor coach has been equipped with an three reflective roadside
emergency safety triangles that are to be deployed while motor coach is
disabled. After opening the kit, unfold the triangle and ensure it locks
into place.
SAFETY
FIRE EXTINGUISHER
EMERGENCY EXITS
Emergency Roof Escape Hatch
WARNING
Inspect the fire extinguisher monthly to make sure it has a sufficient charge. Look at the gauge at the top of the extinguisher to
verify proper charge.
WARNING
Safely evacuate motor coach prior to fire extinguisher use.
A fire extinguisher is installed next to the tour guide seat. To remove,
release latch and lift. Follow instructions on fire extinguisher.
There are two escape hatches located in the roof for emergency exit of
the motor coach. The hatch is also a ventilation fan for the passenger
compartment.
In case of emergency, rotate red handle left or right and push hatch
open fully. Proceed to exit the motor coach safely.
9
SAFETY
Emergency Escape Window
COLLISION WARNING SYSTEM
This driver warning system uses doppler radar to sense when vehicles
get too close. It will also alert a driver if the motor coach is veering into
traffic in another lane, and can track the position and movement of up to
20 vehicles at a time. With the Eaton Vorad warning system, drivers
have more time to assess and correct dangerous situations. The doppler radar is also able to alert the driver to traffic that he may not be able
to see due to inclement weather, such as fog.
SmartCruise
This safety feature is integrated with the Vorad anti-collision system and
will alter the speed of the motor coach to match the speed of traffic
when the cruise control is activated. It will also alert the driver when the
motor coach is dangerously close to the vehicles in front of it, or when
the motor coach is approaching slower moving traffic.
Integrated Backup Camera
The motor coach is equipped with four emergency exit windows on the
left side and three on the right side. The emergency window can be
opened by lifting the red handle and pushing the window out. Proceed
to exit the motor coach safely. Instruction labels are on each escape
window. Regularly inspect all emergency windows to ensure latch is
secure.
10
This backup camera and radar sees not only what is behind the motor
coach, but also gives an estimated distance to the nearest object.
CONTROLS
CONTROLS
INSTRUMENT PANEL
The instrument panel and controls are designed to provide the driver with the ability to monitor and control the operation of the motor coach.
11
CONTROLS
Table 1: Instrument Panel Face
Number
Item
Item
8
1
Speedometer
Outside Mph
Inside Km/h
2
Over Speed Indicator (75 Mph - 120 Km/h)
When the vehicle speed is more than 75 mph - 120 Km/h,
the red LED (Light Emitting Diode) inside will turn on and
at the same time the buzzer will beep for 1 second.
Service Needed Indicator
If any faults are detected, the yellow LED inside will turn
on and at the same time the fault message will be displayed on the TFT screen.
For example, if the low beams encounter a fault, the service light will turn on and a fault message will display on
the TFT screen.
9
3
Left Turn Indicator
The green LED will flash and the buzzer will beep with left
turn indicator.
High Beam Indicator
When the high beam is on, the blue LED inside will turn
on.
10
4
Hand Brake Indicator
When hand brake is on, the red LED inside will turn on.
5
Low Beam Indicator
When the low beam is on, the green LED inside will turn
on.
6
Low Air Pressure Alarm Indicator
If air pressure is too low, the red LED inside will turn on
and at the same time, the buzzer will sound.
Stop Indicator
If any of the following faults are detected, the red LED
inside will turn on and at the same time, the buzzer will
beep for 3 seconds. If the driver finds this light is on, he
must stop the coach and resolve the problem.
Low Air Pressure
High Coolant Temperature
Low Oil Pressure
Low Coolant Level
Disc Brake pad wear indicator
11
Engine Fault Code Indicator
This yellow LED will flash according to the engine fault
code.
NOTE: For more information, please visit www.lzbusline
.com for manufacturer’s manual.
12
Front Fog Light On Indicator
When the front fog light is on, the yellow LED inside will
turn on.
Table 1: Instrument Panel Face
Number
7
12
Engine Preheat Indicator
When the engine is preheating, the yellow LED inside will
turn on.
CONTROLS
Table 1: Instrument Panel Face
Number
Item
13
Rear Fog Light On Indicator
When the rear fog light is on, the yellow LED inside will
turn on.
14
ABS Warning Indicator
When ABS encounters a fault, the yellow LED inside will
turn on.
15
Right Turn Indicator
The green LED will flash and the buzzer will beep with
right turn indicator.
16
Maximum RPM Indicator
When the engine RPM is more than 3000 RPM, the red
LED inside will turn on.
17
Tachometer
The tachometer shows the engine speed in revolutions
per minute.
18
Fuel Gauge
This shows how much fuel you have. It is most accurate
when the coach is on level ground.
19
Low Fuel Level Alarm Indicator
If the fuel level is less than 10%, the red LED inside will
turn on.
20
High Coolant Temperature Alarm Indicator
When the coolant temperature is high, the red LED inside
will turn on.
21
Coolant Temperature Gauge
Displays the engine coolant temperature.
Table 1: Instrument Panel Face
Number
Item
22
Reset Button
This button has two functions:
In normal screen: press this button for 3 seconds, the trip
can be reset to zero;
In diagnostic screen: press this button for 3 seconds, the
fault count can be reset to zero.
23
Brightness Button
When the TFT screen is used for reverse monitor, this
button is used to turn on the Brightness Function.
24
Contrast Button
When the TFT screen is used for reverse monitor, this
button is used to turn on the Contrast Function.
25
Adjust Button (+)
This button has four functions:
When the TFT screen is in monitor state and the Brightness Function is turned on, each press will make the TFT
brighter, until the TFT reaches it’s brightest.
When the TFT screen is in monitor state and the Contrast
Function is turned on, each press will make the TFT’s
contrast lighter until the TFT is at its highest contrast.
When the position light is turned on, each press will
adjust the backlight.
When the TFT screen is in it’s diagnostic screen state,
each press will shift the screen page.
13
CONTROLS
Table 1: Instrument Panel Face
Number
Item
26
Menu Button
This button is used for shifting the normal screen and
diagnostic screen, press this button for 3 seconds and the
screen will shift to the diagnostic screen. Because the
diagnostic screen has multiple pages, use the Adjust +
Button or Adjust – Button to scroll through the pages of
the diagnostic screen.
27
Adjust Button (-)
This button has four functions and all of the functions are
opposite functions of the Adjust + Button.
28
Oil Pressure Gauge - Displays the oil pressure.
29
Low Oil Pressure Warning Indicator
If the oil pressure is less than 15 psi, the red LED inside
will turn on.
30
Low/High Voltage Warning Indicator
If the voltage is lower than 23V or higher than 30V, the
red LED inside will turn on.
Normal TFT Screen
Table 2: Normal TFT Screen
Number
Item
1
Displays Left Air Pressure Gauge
2
Displays Outside Motor Coach Temperature
3
Displays InsIde Motor Coach Temperature
WARNING
When the Stop Light is on, you must stop the motor coach and
solve the problem.
4
The Front Door On Motor Coach Is Open Display
5
Displays Right Air Pressure Gauge
CAUTION
When you are welding on the motor coach, you must disconnect
the MultIC and IOUs from the power supply and disconnect the
batteries. Do not directly spill or spray any liquid on the MultIC and
IOUs. Do not allow objects to touch lens of MultIC.
6
Odometer Display (in miles)
7
Trip Odometer Display (in miles)
8
Displays Engine Compartment Temperature
31
14
Voltage Gauge - Displays the current battery voltage.
CONTROLS
TFT Screen Indicator Symbols
Table 3: TFT Screen Indicator Symbols
Letter
Item
H
Low Air Pressure Warning (Air Pressure 1 Warning and
Air Pressure 2 Warning) - Red Color.
If both system pressures are in the red on the Bar Graph
Display, an exclamation ( ! ) mark is shown until one of
the system pressures goes into the green on the Bar
Graph Display.
I
Disc Brake Warning Indicator - Red Color. They are
shown in the same place, the theory is the same as the
Air Pressure Warning symbols.
FL: Front Left Brake Disc Warning
FR: Front Right Brake Disc Warning
ML: Middle Left Brake Disc Warning
MR: Middle Right Brake Disc Warning
RL: Rear Left Brake Disc Warning
RR: Rear Right Brake Disc Warning
J
Air Filter Warning - Red Color
K
Low Level Freshwater Tank Alarm - Green Color
L
Kneeling Indicator
Body Up Indication - Yellow Color
Body Down Indication - Yellow Color
Engine Retarder Working Indication - Red Color
They are shown in the same place on TFT screen.
M
Reverse
N
Alternator Fault Indicator - Green Color
Table 3: TFT Screen Indicator Symbols
Letter
Item
A
Low Coolant Level Warning - Red Color
B
Reverse
C
ASR Working Indicator - Yellow Color
D
Position Light Working Indicator - Yellow Color
E
Charging Indicator - Red Color
F
Engine Compartment Open Indicator - Red Color
G
Gear Selection Indicator
Only the neutral gear is green color, other gears are white
color.
15
CONTROLS
SWITCH PANELS
Upper Left Switch Panel
Table 4: Upper Left Switch Panel
Number
Table 4: Upper Left Switch Panel
Number
16
Item
1
Dash Dimmer Switch
2
Engine Brake Indicator
3
TOP-Webasto Heater On/Bottom-Toilet Emergency Button
Activated
4
Top-Service ABS Light/Bottom-Anti-Skid Activated
Item
5
Top-Hest Lamp/Bottom-DPF Lamp
6
Top-Stop Engine For Service Lamp/Bottom-Check Engine
Lamp
7
Transmission Gear Indicator
8
Manual Back-up Camera Switch
9
Fog Lights Switch
10
Wireless Microphone Transmitter Switch
11
Blue LED Aisle Strip Lights Switch
12
Heated Mirrors Switch
13
Blank
14
Blank
CONTROLS
LOWER LEFT SWITCH PANEL
Table 5: Lower Left Side Switch Panel
Number
Item
1
Kneeling System Switch
Allows the coach to kneel, providing a lower step well
height at the passenger door.
2
Left Sun Shade Switch
To raise and lower left sun shade.
3
Right Sun Shade Switch
To raise and lower right sun shade.
4
Front Ventilator Fan Switch
5
Rear Ventilator Fan Switch
6
Diesel Particulate Filter Manual Regeneration Switch
7
Cruise Control Set Switch
8
Activate Cruise Control Switch
9
High Speed Radiator Fan Switch
10
Engine Diagnostics Switch
17
CONTROLS
CLIMATE CONTROLLER
Table 6: Driver Climate Controller
Driver Climate Controller
Table 6: Driver Climate Controller
Number
1
2
18
Number
Item
3
Mode Switch
Selects the A/C system operating mode between:
OFF - Set switch to middle position.
DEMIST - Set switch to upper position.
A/C - Set switch to lower position.
In DRIVER mode, the unit provides ventilation / cooling /
heating operation depending on the temperature control
setting and the return air temperature. Fans operate at
the selected speed.
In DEMIST mode, the unit operates at the heating level
selected, with or without cooling, depending on the temperature control setting and the return air temperature.
Fans operate at the selected speed. An output signal for
an external damper motor is also provided.
4
Fan Speed Switch
Selects the operating speed of the fan blowers during
DEMIST and A/C modes.
5
Temperature Control
Provides for adjustment of the set point temperature.
Item
A/C ON/OFF Switch
Illuminates when the A/C system is providing cooling
operation. When switched on, the compressor clutch
engages, regardless of ambient conditions.
Mode Lights
Illuminates when the switch is set to DEMIST or A/C to
indicate operation.
NOTE: For more information, please visit www.lzbusline.com for
manufacturer’s manual.
CONTROLS
Motor Coach Climate Controller
The FAN-OFF-A/C and LOW-HIGH switches and the WARM-COOL
temperature rocker potentiometer on the dash panel are the only three
external controls to operate the system.
FAN-OFF-A/C Switch Positions (three-position)
FAN:
•
Evaporator blowers are on.
•
Air conditioning is off.
•
Dash temperature display and set point is on.
OFF:
Table 7: Motor Coach Climate Controller
Number
Item
1
FAN-OFF-A/C Switch
2
WARM-COOL Temperature Setting Switch
3
Temperature Display
4
LOW-AUTO-HIGH Fan Speed Switch
•
Air conditioning system is off.
•
Dash temperature display and set point is on.
A/C:
•
Air conditioning system is on.
•
Dash temperature display and set point is on.
19
CONTROLS
LOW-AUTO-HIGH Switch Positions (three-position)
WEBASTO® HEATER
Only functional if FAN-OFF-A/C switch is in FAN or A/C positions.
LOW:
•
Evaporator blowers are on low speed, 60%.
AUTO:
•
Evaporator blowers are on variable speed, 60% to 100%.
HIGH:
•
Evaporator blowers are on high speed, 100%.
WARM-COOL Rocker Potentiometer Function
Table 8: Webasto Timer Controls
Number
Item
1
7-Day Digital Timer Display
Only functional if ignition is activated.
2
Day/Time Advance Button
WARM:
3
Day/Time Reverse Button
•
4
Heater On/Off Button
5
Program Selection Button
6
Clock Button
Increases the set point temperature in 0.5°C intervals when held.
COOL:
•
Decreases the set point temperature in 0.5°C intervals when held.
Pressing the switch on either WARM or COOL momentarily will cause
the temperature set point for 30 seconds only. The display will then
revert to the default return air temperature display.
NOTE: For more information, please visit www.lzbusline.com for manufacturer’s manual.
20
WARNING
Due to the danger of poisoning and suffocation, the heater must
not be operated in enclosed areas, such as garages or workshops,
without an exhaust-venting system, not even if the start-up is activated by the timer or remote start device.
CONTROLS
WARNING
At filling stations and fuel depots, the heater must be switched off
as there is a potential danger of explosions.
WARNING
Where flammable fumes or dust may build up (e.g. in the vicinity of
fuel, coal, wood, cereal grain deposits, or similar situations), the
heater must be switched off to prevent explosions.
CAUTION
Before switching the Webasto heater on, open any shutoff valves
and set vehicle heater controls to the HOT position.
The digital timer with three time settings permits the Webasto heater to
be switched on and off instantly, or automatically at 3 programmable
starting times.
The operating time of the heater can be pre-selected. It is possible to
program three different heating times according to your individual
needs.
Only one preset starting time can be activated at any one time. When
the ignition is switched on, the current time of the day and the day of the
week are displayed.
When the heater is in operation, the display and the buttons of the timer
are illuminated.
Programmed Heater Operation
Three memory locations numbered 1 to 3 are available. Each memory
location can be assigned a given time together with the day of the
week.
Pre-selected Starting Times
The pre-selected starting time is the time at which the heater will be
switched on automatically.
NOTE: Recommended that memory locations 1 and 2 be used for presetting starting times within a 24-hour period of setting the timer. Memory location 3 can be reserved for a starting time within the next seven
days of setting the timer. Location 3 is useful for occasional weekend or
field trip operations outside of the normal schedule. By repeatedly
pressing the program selection button on the timer, starting time program 1, 2 or 3 can be viewed and preset.
Operating Time
The period of time during which the heater is in operation is referred to
as the operating time. The heater remains in operation for as long as
the operating time has been preset. Heater operation can be preselected for any time from a minimum of 1 minute (a minimum of 10
minutes is recommended) to a maximum of 120 minutes (factory preset
is 60 minutes).
21
CONTROLS
Remaining Operating Time
Heater Start-up Sequence
The remaining operating time refers to the period of time the heater still
continues to remain in operation. It can only be changed while heater is
in operation.
Upon switching on, an operating indicator light will illuminate. The combustion air fan, fuel pump and circulation pump start operation. After
approximately 15 seconds the fuel solenoid valve opens allowing fuel to
flow to the nozzle where it is atomized and sprayed into the combustion
chamber. At the same time, a high voltage ignition spark is generated at
the electrode tips simultaneously igniting the fuel air mixture. A photo
control device detects a flame in the combustion chamber and deactivates the ignition system (combustion process is self-sustaining). At
this point the heater is working and producing heat. The Webasto
heater will cycle on and off until:
Setting the Digital Timer
After the power has been connected, all symbols on the digital display
are flashing. The time of the day and the day of the week must be set.
All flashing displays and symbols of the timer can be set by means of
the reverse and advance buttons. If the reverse and advance buttons
are not pressed within five seconds, the currently displayed time or
function will be stored. When the reverse and advance buttons are
pressed for more than 2 seconds, the quick digit advance mode is activated.
22
•
•
•
•
System coolant reaches operating temperature.
The Webasto heater is switched off.
Time has elapsed on the timer.
The vehicle battery voltage drops below 10.5V for 12 volt systems
or 20.0V for 24 volt systems.
• The Webasto heater runs out of fuel.
• A fault lock out occurs, indicated by the operating indicator light
being off during the cool down cycle (as would happen during an
overheat situation.
NOTE: The engine coolant temperature must fall below 140° F (60° C)
or 155° F (68° C) at the heater before the heater will begin heating
operation.
CONTROLS
Switching Off
Engine Preheating
When heating is no longer required, switch the Webasto heater off. The
fuel solenoid valve interrupts the fuel supply and combustion stops. The
indicator light turns off. The Combustion air fan and the water pump
continue operation for approximately 150 seconds (after-run cycle)
purging the combustion chamber of any fumes and cooling the heater.
Engine preheating procedure:
NOTE: Switching the Webasto heater on during the cool-down (afterrun cycle) period is allowed. The heater will revert to normal operational
mode.
1. Set the timer 10 minutes to 120 minutes before you want to start the
engine. The heater will start up at the set time (see timer operating
instructions). Or switch the toggle switch or instant on switch on your
timer in the vehicle dash to on. The heater will start up.
2. When the run time has elapsed on your timer or engine preheating is
no longer required, switch the Webasto heater off. The heater will begin
the after-run (cool-down) cycle.
CAUTION
Make sure all coolant and cab heater valves are open before operating the heater in the preheat mode.
23
CONTROLS
Seven-Day Digital Timer Programming and Operating Instructions
Table 9: Programming and Operating Instructions
Setting the time and
day of the week
Press the Clock button for more than 2 seconds. Time display flashes.
Press the Advance/Reverse button to set time of day. Wait five seconds. Time is now stored.
Day of week flashes.
Press the Advance/Reverse button to set day of week. Wait five seconds. Day of week is now stored.
Viewing the time
With ignition on:
Continuous display of current time and day of the week.
With ignition off:
Briefly press Clock button. Display of current time and weekday appears for five seconds.
Switching heater on
for instant heater
operation
With ignition on:
Press button. Heater is switched on (continuous heating) and continues to operate until button is pressed again or ignition
is switched off.
With ignition off:
Press button. Heater is switched on for the preset operating time
(the factory-set heater operating duration is 60 minutes).
Switching the
heater off
Press On/Off button. Heater begins cool-down (after-run) cycle and is switched off thereafter.
Programming
heater starting time
Press Program Selection button. Memory location number flashes.
Press Advance/Reverse button to preset starting time. Wait five seconds. Starting time is now stored.
Day of week flashes.
Press Advance/Reverse button to set day of week. Wait five seconds. Day of week is now stored.
The number of memory location remains on the display.
The timer is now in the programmed mode and switches heater on at the preset time.
24
CONTROLS
Table 9: Programming and Operating Instructions
Recalling/canceling
pre-selected times
To recall: Press Program Selection button until the desired memory location number is displayed.
Read off preset time.
To cancel: Press Program Selection button repeatedly until the memory location numbers are no longer visible on the display.
Programming
duration of
operating time
The heater must be switched off. Press the Reverse button.
Operating time flashes.
Press Advance/Reverse button to set operating duration time between 1 and 120 minutes (minimum 10 minutes recommended).
Setting the
remaining
operating time
Heater must be in operation.
Press button. Remaining operating time flashes.
Press Advance/Reverse button to set remaining operating time. Wait five seconds. The remaining operating time is now
stored.
NOTE: For more information, please visit www.lzbusline.com for manufacturer’s manual.
25
CONTROLS
Right Side Switch Panel
Table 10: Right Side Switch Panel
Number
26
Item
Table 10: Right Side Switch Panel
Number
Item
1
Entrance door open and close switch
7
Mid-Coach Video Display drop down switch
2
Electric Horn/Air Horn
8
Rear Video Display drop down switch
3
Interior Light - low
9
Luggage Compartment light switch
4
Interior Light - high
10
Toilet Flush switch
5
Passenger Reading Lamp switch
11
Wastewater Tank dump switch
6
Front Video Display drop down switch
CONTROLS
STEERING WHEEL AND COLUMN
EXTERIOR MIRRORS SELECT/CONTROL KNOB
The two levers on the steering column contain controls for driving features you use most often.The left lever controls the turn signals, headlights, and hazard warning lights. The right lever controls the windshield
washer and wipers.
Headlights
The rotating switch on the left lever controls the lights. Turning this
switch to the first position turns on the parking lights, taillights, instrument panel lights, side marker lights, and rear license plate light. Turning the switch to the second position, turns on the headlights.
To change from low beams to high beams, lift the turn signal lever up
until you hear a click. The blue high beam indicator will light on instrument panel.
To return to low beams, push the turn signal lever down.
Turn Signals
Exterior mirrors have separate upper and lower segments. The convex
lower portion is for wide angle view. Adjust the exterior mirrors so that
you can see the side of the coach in part of the mirror. This helps determine the relationship of the coach to objects seen in the mirror. The left
side and right side mirror control is on the upper left hand console
switch panel . Use the mirror select/control knob to select which mirror
is to be adjusted. Adjust the mirror using the same control knob. Move
the knob to the left to adjust the mirror to the left and to the right to
adjust the mirror to the right. Defrost the mirrors using the mirror heat
switch located below the mirror controls on the upper left switch panel.
To signal a lane change, push lightly on the turn signal lever in the
proper direction. The turn signal lever will return to the center position
upon completion of turn.
Hazard Warning Flashers
The left lever controls the hazard warning flashers. Push the button on
the end of the lever to turn on the hazard warning lights (four-way flashers). This causes all four exterior turn signals and both indicators in the
instrument panel to flash.
Use the hazard warning lights if you need to park in a dangerous area
near heavy traffic, or if your motor coach is disabled.
27
CONTROLS
Windshield Wiper Controls
Steering Wheel Height Control
Windshield Wipers
WARNING
Adjusting the steering wheel position while driving may cause you
to lose control of the motor coach, and to seriously injure you and
your passengers. Adjust the steering wheel only when the motor
coach is stopped.
CAUTION
Do not operate wiper in dry conditions. Activate the washers for
proper lubrication before wiper operation.
The rotating switch on the right lever controls the windshield wipers,
including the intermittent wiper control. The rotating switch has four
positions:
•
•
•
•
OFF-Wiper is off.
INT-Wiper on intermittent setting.
LO-Wiper on low speed setting.
HI-Wiper on high speed setting.
Turning this switch to the first position turns on the wiper intermittently,
frequency of the wiper blades depends upon the setting of the delay
switch. In intermittent, the wipers operate every few seconds.
Turning this switch to the second position turns the wiper on a low
speed. In low speed, wipers run continuously.
Turning this switch to the third position turns the wiper on a high speed.
In high speed, wipers run continuously.
Windshield Washer
The right lever controls the windshield washer. To clean the windshield,
push the button on the end of the lever to turn on the windshield
washer. The washer will spray until you release the button.
28
Turn lock-handle located on left side of steering column counterclockwise to adjust steering wheel height. Tighten by turning lock-handle
clockwise.
WARNING
Make sure you have securely locked the steering wheel in place by
trying to move it.
Steering Wheel Angle Control
Turn lock-handle located on right side of steering column counterclockwise to adjust steering wheel angle, then tighten by turning lock-handle
clockwise.
WARNING
Make sure you have securely locked the steering wheel in place by
trying to move it.
CONTROLS
Ignition Switch
PARKING BRAKE
WARNING
Do not turn the ignition key to the OFF position while the motor
coach is moving.
NOTE: In the event of failed start, wait 2 minutes before attempting to
re-start.
NOTE: If a re-start fails, check the fuel supply before any further
attempts.
The ignition switch is located on the right side of steering column. The
ignition switch has five positions. The following is an explanation of
those ignition switch positions:
The parking brake knob is located on the left console of the driver seat.
When the vehicle is stopped, pull out knob to set the parking brake.
When ready to start moving with engine running and primary air supply
at 90 psi, beeper and low air pressure light off. Place foot on brake
pedal and push in knob to release the brake.
•
EMERGENCY BRAKE
•
•
•
LOCK - This position is used for inserting the key into the ignition
and for withdrawing the key from the ignition. This position is also
used for turning off the engine.
ACC - This position is used for powering only the radio and other
accessories.
ON - This position is used for the continuous period of engine operation.
START - This position is used for engine startup only. Key will automatically return to the ON position when released.
Horn
To use the horn, press either horn button located on the top of the steering wheel center pad. The horn should sound while pressing down on
either button. The horn can be an electric or air horn, the electric/air
horn switch is located on the right switch panel.
CAUTION
Motor coach must be stopped prior to activating emergency brake.
Pull the handle up to engage the emergency brake. Press the handle
down to release emergency brake. In case of parking brake malfunction, the emergency brake will return to the original position automatically.
29
CONTROLS
Grammer® Driver’s Seat
The dFriver’s seat can be moved forward and backward. The backrest
angle can be fully adjusted.
Table 11: Grammer Driver’s Seat
Number
Item
Number
Item
1
Height Adjuster
8
Seat Angle Adjuster
2
Lumbar Support
9
Seat Depth Adjuster
3
Lateral Support
Adjuster
10
Fore/Aft Adjuster
4
Backrest Adjuster
11
Swivel
5
Seat Heater
12
Quick Lowering
6
Armrests
13
Shock Absorber
Adjuster
7
Armrest Adjuster
WARNING
Do not adjust the driver’s seat while the motor coach is moving.
The seat could suddenly and unexpectedly move, causing the
driver to lose control of the vehicle.
CAUTION
After making a seat adjustment, always test to ensure that the
adjusters have latched. An improperly latched mechanism could
impair driver abilities.
30
CONTROLS
General Information
WARNING
No objects should be placed within the moving area of the driver’s
seat to prevent injury.
WARNING
Settings must be checked to ensure they are correctly engaged
before the motor coach is driven. Adjustments must not be made
while driving.
A correctly functioning and individually adjusted driver’s seat is essential to good health. Seat is maintenance free. Take adequate care of
your seat to ensure that it functions properly.
CAUTION
Dirt can impair the function of the seat. Keep the seat clean.
Check seat frequently to ensure proper function. Regularly check that
seat is tight. If seat wobbles, check for loose bolts or other faults. To
ensure proper function of the driver’s seat and to prevent damage of
pneumatic spring, adjust the loaded driver’s seat to the highest height
position.
Seat Operation
Height Adjustment
The seat height can be adjusted continuously within a range of 3.9 in.
(99 mm). Pull or press the handle for height adjustment to move the
seat upwards or downwards.
NOTE: Always release the handle after reaching the upper or lower
stop.
Lumbar Support
Upholstery does not need to be removed from the seat frame for cleaning.
With front and back switch, the curvature in the upper and lower area of
the backseat upholstery can be adjusted individually.
NOTE: Do not soak through upholstery during cleaning. Do not use
pressure washer to clean seat.
The air compartments will be filled by setting the respective switch to “+”
and emptied by setting it to “-”.
CAUTION
Use standard commercially available upholstery or plastics cleaning agent. Test for compatibility on a small, concealed area.
Lateral Support Adjustment
By actuating the switch, the curvature of the lateral guide right and left
of the backrest can be adjusted individually by means of compressed
air.
By setting the switch to “+”, the air compartments will be filled. By setting it to “-”, they will be emptied.
31
CONTROLS
Backrest Adjustment
Seat Pan Angle Adjustment
Pull up the locking lever to release the backrest catch. The backrest is
brought into the desired position by simultaneously exerting or relieving
pressure. Release the locking lever to lock the backrest.
Adjust the angle of the seat pan by pulling the left handle upwards. The
seat pan can be moved to the desired position by pressing or relieving
the seat to the front or to the rear.
NOTE: It should not be possible to move the backrest into another position after it has been locked.
NOTE: The adjustment range can be made between minus 6º and 10º.
Seat Depth Adjustment
Seat Heater
By operating the seat heater switch, the heating mats in the backrest
and seat cushion can be heated in two steps.
•
•
•
0 = Heater Off
1 = Heating step 1 ON
2 = Heating step 2 ON
Armrests
The armrests can be folded up if required.
Armrest Adjuster
The inclination of he armrests can be modified by turning the adjustment knob. When turning the knob to the outside “+”, the front part of
the armrest will be tilted. When turning the knob to the inside “-”, it will
be lowered.
32
Pull the right handle upwards to adjust the depth of the seat cushion.
Move the seat cushion backwards or forwards so the desired seating
position can be reached.
NOTE: Adjustment range of 2.3 in. (58 mm) is in six increments.
Fore/aft Adjustment
The forward/aft adjustment can be made by pulling the locking handle,
while simultaneously sliding the seat forwards or backwards to the
desired position.
WARNING
The seat must lock into place with an audible click when the lever
is released.
NOTE: The adjustment range can be made in ten steps of 0.78 in. (20
mm) each.
CONTROLS
Swivel
DELUXE TOUR GUIDE SEAT
Press the key while simultaneously turning the seat left or right until
stop is reached. Release key during swiveling.
NOTE: The seat will automatically lock into driving position.
Quick Lowering
The seat can be lowered to lowest position by pressing the key and
locking it.
Vertical Shock Absorber Adjustment
The vertical vibration behavior of the seat can be adjusted continuously
from soft to hard by using the turning knob.
•
•
•
1 = Soft shock absorption
2 = Medium shock absorption
3 = Hard shock absorption
The deluxe tour guide seat is a folding seat located at the entrance
door. The tour guide seat is conveniently located near the audio/video
controls and next to the fire extinguisher for safety, guide seat is standard leather-covered. Seat is equipped with retracting armrests and a
lap belt for safety.
Push the seat downwards and sit on the seat. When folding up the seat
cushion, the seat automatically slides back as far as possible.
33
CONTROLS
PASSENGER SEATS
The passenger seats are self-righting, adjustable recline, high back
seats. These seats are equipped with folding footrests. Passenger
seats are outfitted with retractable armrests and reclining handles. Each
seat back is equipped with a convenient magazine holder.
Fasten and position the seat belts
Insert the latch plate into the buckle, then tug on the belt to ensure belt
is securely fastened. Also check that the belt is not twisted, because a
twisted belt can cause serious injuries in a crash.
Table 12: Passenger Seat Controls
Number
34
Item
1
Seat Recline Handle
2
Lap Safety Belt
3
Retracting Armrest
WARNING
Not wearing a seat belt properly increases the chance of serious
injury or death in a crash. Be sure you and your passengers
always wear seat belts and wear them properly.
CAUTION
In case of malfunction with parking brake, the emergency brake
knob will return to original position automatically.
CONTROLS
GEAR SELECTOR
WARNING
It is a requirement that the driver of a commercial vehicle specified
under paragraph A sections 1-6 of FMCSA regulation 392.10 need
only cross railroad grade crossings in a gear that permits the vehicle to complete the crossing without a change of gears. This can
only be achieved by utilizing the Manual M mode.
CAUTION
Do not release the parking brake or attempt to select a gear until
the air pressure is at the correct level.
CAUTION
Battery (+) and (-) must be disconnected prior to any type of welding on any UltraShift™ equipped vehicle.
WARNING
Before starting a vehicle always be seated in the driver's seat,
select N on the shift control, and set the parking brakes.
WARNING
If engine cranks in any gear other than neutral, service your vehicle immediately!
WARNING
Before working on a vehicle, parking the vehicle, or leaving the
cab with the engine running, place the transmission in neutral, set
the parking brakes, and block the wheels.
Gear selector lever has a five position operating panel.
•
•
•
•
•
R - Reverse. Selects reverse gear once vehicle is less than 2 Mph.
N - Neutral. Selects neutral.
D - Drive. Selects the default starting gear and automatically selects
gears between the starting gear and the top gear.
M - Manual. Allows the driver to hold the current gear and manually
select the appropriate gear for road conditions using the up/down
buttons on the gearshift handle. Manual mode should be used
whenever the driver wants to select the shifts instead of letting
UltraShift™ select them automatically. For example, when the
driver is moving over railroad tracks or steep grades.
L - Low. Transmission downshifts at the earliest opportunity for
maximum engine braking.
WARNING
For safety reasons, always engage the service brakes prior to
selecting gear positions from neutral.
35
CONTROLS
Start-up
Power Down
1. Turn the ignition key to ON and allow the UltraShift to power-up.
1. Select N on the shift control.
•
NOTE: Neutral should always be reached before UltraShift power down
is performed except in cases of emergency.
Engine cranking is delayed until the transmission power-up is complete.
2. Start the engine.
2. Set the vehicle parking brakes.
3. Apply service brake.
3. Turn off the ignition key and allow the engine to shut down.
•
Driving Tips
If the service brake is not applied while selecting a starting gear, the
initial start gear will not be found and the driver will have to re-select
Neutral and press the brake while re-selecting the desired mode.
4. Select the desired mode and starting gear on the shift console.
Proper Starting Gear
5. Release the vehicle parking brakes.
Choose a starting gear appropriate for the load and grade conditions
while at a stop in either D or M mode by using the up/down buttons.
Refer to D mode for detailed information.
6. Release service brake and apply accelerator.
Optimal Engine Braking
•
The L mode can be selected while moving. This initiates downshifts as
soon as possible at a higher rpm. Refer to the L mode section for
detailed information.
The transmission is not intended to provide hill-hold capability. The
service brakes should be used to stop and hold the vehicle on an
incline. To prevent the vehicle from rolling when starting on an
incline, place both feet on the brake pedal before sliding the right
foot to the throttle pedal. Gradually back off the brake while applying as little throttle as necessary to move along the incline.
Skid Conditions
If a skid condition occurs, the UltraShift senses the vehicle speed dropping rapidly. In this case, the UltraShift delays downshifting.
36
CONTROLS
Cruise Control
The UltraShift is totally compatible with cruise control. If a shift is
required while cruise control is active, cruise is temporarily interrupted
while the shift is performed and then automatically resumed after the
shift.
CAUTION
If the vehicle is operated for long periods between engine idle and
1000 rpm during take off, the driver is slipping the clutch which
gets the clutch HOT. This is an indication that the driver is abusing
the clutch and it is getting too hot to operate, potentially resulting
in a failure.
Manual Mode
In Manual mode, UltraShift allows the driver to hold current gear and
manually select the appropriate gear for road conditions using the up/
down buttons. Manual mode should be used whenever the driver wants
to select the shifts instead of letting UltraShift select them automatically.
Examples include when the driver is moving around the yard, over railroad tracks, or on steep grades.
Coast Mode
When coasting to a stop in lower gears with your foot off the throttle,
UltraShift may not finish downshifting until the driver gets back on the
throttle. The system will automatically track vehicle and engine speed
during this time and engage the appropriate gear when the throttle is reapplied. This is normal operation for the UltraShift when in drive “D”
mode only.
CAUTION
Clutch Protection: Even though this motor coach does not have a
clutch pedal, it still has a mechanical clutch. As the driver slowly
increases and decreases engine rpm from a stop, the clutch is
engaging and disengaging, just like slipping the clutch with an
AutoShift or a manual transmission.
Repeated incidents of clutch abuse may cause the clutch to fail and
render the truck immobile, resulting in extended down time.
Below is an example of a situation that may initiate clutch abuse, and
instructions on how to avoid them:
Example
How To Avoid
Holding on hills using the
throttle rather than the service brake
Use the service brakes to hold on the
hill. To start moving, apply the throttle
and release the brakes as you feel the
truck start to pull.
Clutch Calibration
The ASW system automatically adjusts for clutch wear. An automatic
calibration occurs each time the unit is powered up when the following
conditions are reached: the engine is at normal operating temperature,
the vehicle must be stopped, the engine is at idle, N is selected on the
shift console. Calibration may take up to 2 minutes to complete. You
may notice the engine slows and returns to normal idle several times
during calibration. It is acceptable to stop calibration by selecting a driving mode.
37
CONTROLS
Reverse Mode
Selecting Manual from Neutral:
The vehicle should be stopped before R is selected. If the driver
requests R above 2 Mph, the shift is not performed until the speed has
dropped below 2 Mph.
•
Each time R is selected from N, the default R gear is engaged.
•
•
Drive Mode
Depending on the transmission model and shift configuration there may
be alternate forward starting gears available. While the vehicle is
stopped in D, the up/down buttons are used to change the starting gear.
This selection becomes the default starting gear until it is changed by
the driver again, or the UltraShift is powered down.
In D mode, all upshifts and downshifts are performed automatically
based on vehicle and transmission conditions.
As described in D mode, the starting gear can be changed in
exactly the same way in M mode.
If M mode is selected from a stop, the starting gear is maintained.
No automatic shifts are performed, except for conditions noted
below.
The driver can request shifts using the proper up/down button (up
for upshifts, down for downshifts). The upshift or downshift is performed by the UltraShift provided the resulting engine speed is not
outside of defined limits. For upshifts, the resulting engine speed
must be greater than 900 rpm; for downshifts, the resulting engine
speed must be less than engine rated speed.
Selecting Manual from Drive or Low while moving:
•
•
If M mode is selected while moving, the current gear is maintained.
No shifts are performed, except for conditions noted below.
As described above, the driver can request shifts using the proper
up/down button (up for upshifts, down for downshifts) within the
same limits described.
The driver can advance a shift (by about 75 rpm) by pressing the proper
up/down button (up for upshifts, down for downshifts) when the transmission is within 75 rpm of the load based shift point.
Transmission Manual Override:
Manual Mode
•
M mode should be used whenever the driver wants to select the shifts
instead of letting UltraShift select them automatically. For example,
when the driver is moving around the yard, over railroad tracks, or on
steep grades.
•
38
If the vehicle is being back driven (vehicle coasting and being
pushed by the load) and the engine is approaching a higher than
normal level (approximately 300 rpm above rated speed), the UltraShift overrides the M position and performs an upshift to prevent
engine damage.
If the gear being maintained is higher than the starting gear, and the
driver depresses the throttle pedal, the UltraShift system will override the M mode and shift to the best available gear if the engine
lugs excessively.
CONTROLS
Low Mode
Selecting L from D or M while moving:
L mode should be used any time you want to maximize engine braking
and minimize the use of the brake pedal. For example, when driving
down long grades or when coming to a stop.
•
•
Selecting Low from Neutral:
•
•
If L mode is selected from N while stopped, the starting gear is
always the lowest available gear. The starting gear cannot be
changed in L mode.
If L mode is selected from N while stopped, the lowest available
gear is maintained - no shifts are performed, except for conditions
noted below.
NOTE: L mode can be used while climbing steep grades to achieve
higher downshift points (transmission will downshift sooner).
If L mode is selected while moving, no upshifts are performed,
except for override conditions noted below.
Downshifts are performed at higher rpm’s than normal to enhance
engine braking. The downshift point is chosen so engine speed
after the shift is about 50 rpm below engine rated speed.
Transmission Low Override
•
•
If the vehicle is being back driven (vehicle coasting and being
pushed by the load) and the engine is approaching a higher than
normal level (approximately 300 rpm above rated speed), the UltraShift overrides the L position and performs an upshift to prevent
engine damage.
If the gear being maintained is higher than the starting gear, and the
driver depresses the throttle pedal, the UltraShift system will override the L mode and shift to the best available gear if the engine
lugs excessively.
39
CONTROLS
Troubleshooting
Locked in Gear
Diagnostics
If the motor coach is shut down or stalls in gear, the UltraShift may
become locked in gear. The transmission will attempt to get to N during
the next power up if the shifter is in Neutral. If N cannot be achieved,
the engine will not start. Try the following:
In the event there is a problem with the UltraShift, there are three primary tasks the driver should perform:
1. Note the driving condition under which the problem occurred.
1. Select N. Turn the key OFF and let the transmission power down for
at least 2 minutes.
2. Note the condition of the UltraShift under which the problem occurred
(i.e. operation mode (D, M, L), current gear, engine speed, etc.).
2. Depress the brake pedal.
3. Reset system.
3. Release the parking brake.
Transmission Reset Procedure
4. Select N.
In some cases, proper transmission operation can be restored by
“resetting” the transmission Electronic Control Unit (ECU). Use the following procedure to reset the ECU.
5. Turn the key to the ON position.
1. When it is safe to do so, stop the vehicle.
6. The transmission will attempt to shift into N once you turn the key
ON, but you may have to slightly release the brake pedal to help let the
torque off the drive line.
2. Place the transmission shift lever in N and turn the ignition key to the
OFF position.
7. If N is not achieved after this procedure, take the vehicle to a local
service center.
3. Wait at least 2 minutes.
NOTE: For more detailed information, please visit www.lzbusline.com
for manufacturer’s manual.
4. Restart the engine.
5. If the problem continues, contact a service facility to have the vehicle
and transmission system evaluated.
40
CONTROLS
PASSENGER INTERIOR CONTROLS
Table 13: Passenger Controls
Number
42
Item
1
Speaker
2
Individual Reading Lamp Switches
Push button to turn On/Off
3
Omni-directional Individual Reading Lamps
Push in any direction to direct light
4
Omni-directional Individual Ventilation Ports
Push in any direction to direct air flow
OPERATING
OPERATING
ENGINE STARTUP
GENERAL INSTRUCTIONS
After performing the daily inspection and safety checks, you are ready
to operate the motor coach. Safety on the road also depends on you.
Observe weather and road conditions, then drive accordingly. Be physically and mentally alert.
Engage parking brake. Put the gearshift in the neutral position, making
sure that the rear compartment doors are closed (or engine is prevented from starting). Insert the key into the ignition start switch and
turn clockwise to the start position. The engine should start within 30
seconds. If starting fails, wait 2 minutes for starter motor to cool down.
Repeat start procedure until the engine starts.
WARNING
Do not run engine for long periods of time in a closed or poorly
ventilated building, where exhaust gases can accumulate.
Do not run a cold engine at high rpm. Idling too fast during warm-up will
cause too rapid and uneven expansion, resulting in premature engine
wear. The rpm should be increased gradually after starting a cold
engine.
If, while driving the motor coach, any of the items below are noticed,
correct condition immediately.
Do not operate the motor coach at high rpm until the engine water temperature reaches 158°F (70°C).
•
•
•
STEERING ACTION - Binding, wander, shimmy, excessive steering
wheel play, and pulling to one side.
BRAKING ACTION - Increased pedal travel, slow response, chatter, grabbing, weak, pulling to one side, and excessive air pressure
drop for brake application.
VIBRATION - From engine, driveline, accessories, and wheel
imbalance. Scan the instrument panel frequently and be alert for
any changes from normal gauge readings.
Refer to appropriate subject in troubleshooting section of this manual
for detailed data.
CAUTION
Damage may occur if engine idles for more then 10 minutes at low
rpm. Idling the engine too slowly does not allow sufficient splash
lubrication of cylinder walls and may result in excessive wearing
of pistons and liners.
There must be a display of the oil pressure on the instrument panel
within 15 seconds after starting the engine, otherwise stop the engine
and correct problem immediately.
If the parking brake indicator on the instrument panel is illuminated, the
parking break is engaged.
43
OPERATING
Engine
After starting the engine, but before operation, be sure the indicator
lights and all gauges work. The braking system air pressure should
read at least 71 psi (490 kPa) or above. Coolant temperature should be
158° F (70° C) or above, and the parking brake released. You can now
operate the motor coach in a safe manner.
Normal Driving Conditions
Ensure the following are with in their acceptable limits.
•
•
•
Oil pressure should be within the range of 42 to 71 psi (290 to 490
kPa ).
Water temperature should be within the range of 176 to 194° F (79
to 90° C).
The indicator of the air pressure gauge should be within the green
range of 78 to 113 psi (538 to 779 kPa).
If you encounter any abnormal sounds or smells, stop and check the
motor coach. Avoid any abrupt acceleration or braking if possible. Avoid
engine over-speed.
This will allow circulating coolant and lubricating oil to carry heat away
from cylinder head, valves, pistons, cylinder liners, and bearings, thus
preventing warping of valve stems or distortion of other parts resulting
from uneven cooling.
NOTE: Refuel before final shutdown. The less air space in the fuel tank
means that there is less opportunity there will be for water to condense
in the tank.
Stopping The Engine
CAUTION
Do not shift into neutral until vehicle is stopped!
Perform the following procedures:
1. Bring the motor coach to a complete stop using the service brakes.
2. Shift transmission into neutral. The transmission should be set to
the neutral position before shutting off the engine to prevent an
error report display.
3. Set parking brake by pulling out control knob.
Before Stopping Engine
4. Allow the engine to cool below 194° F (90º C). Do so by letting the
engine idle no more then 10 minutes.
CAUTION
Do not shut off the engine while vehicle is in motion. This will
cause eventual brake and immediate power steering failure.
5. Shut engine down by turning the ignition key to the ACC position.
The accessory position cuts off the fuel supply and shuts down the
engine.
A hot engine has a great deal of heat stored up in its iron mass. Let the
engine idle for no more than 10 minutes before shutting down the
engine.
44
OPERATING
WINTER DRIVING TIPS
DPF REGENERATION
Perform the following winter driving tips for enhanced motor coach performance needed during cold weather
A diesel particulate filter, sometimes called a DPF, is a device designed
to remove diesel particulate matter or soot from the exhaust gas of a
diesel engine.
•
•
•
•
•
Add long life coolant into the cooling system.
Check the fluid level, specific gravity, and voltage output of the battery.
Use soft water in engine cooling system.
Do not operate the vehicle until the engine has had time to warm
up.
Do not operate if any malfunctions are present.
In addition to collecting the particulate, a method exists to clean the filter.This is known as filter regeneration. Regeneration is the process of
removing the accumulated soot from the filter.
WARNING
To avoid serious personal injury or property damage, ensure that
no persons or objects are at or within 2 feet of the exhaust outlet
at any time during a regeneration.
WARNING
Ensure that exhaust and outlet are clear of any trash, grasses, or
other vegetation or debris.
WARNING
Use extreme caution during a stationary regeneration, as exhaust
gas tail pipe outlet temperatures can exceed 900° F (482° C).
WARNING
Stationary regenerations are to be performed outdoors only.
WARNING
DO NOT perform inside a garage or maintenance facility. DO NOT
attach an exhaust extraction hose to the exhaust outlet.
45
OPERATING
46
OPERATING
47
OPERATING
JVC™ KD-DV7300 DVD/VCD/CD/MP3/USB Receiver features:
AUDIO/VISUAL SYSTEM
JVC™ DVD/CD
•
•
•
•
•
•
•
•
•
Table 1: JVC™ Audio/Video Player Basic Controls
Number
48
Item
Number
Item
1
Select source
8
USB Input
2
Select band
9
Panel detach
3
Power
10
Display information
4
Adjust sound mode
11
Function mode
5
Display window
12
Station preset
6
Select sound mode
13
Station search
7
Eject disc
14
Station preset
DVD/VCD/CD/MP3 Player
GIGA MP3 multi-play MP3
WMA
WAV Files Burned on DVD
MOS-FET Power Amp
iPod™ Ready
Satellite Radio Ready
Optional Bluetooth with KS-BTA200
DivX™ Compatible.
NOTE: See manufacturer’s manual at www.lzbusline.com for additional information
Microphone
The Falcon 45 audio system comes with a state of the art wireless
microphone. The microphone is located on motor coach dash in a convenient holder. In conjunction with public address system, the wireless
microphone will allow mobile announcing. Microphone requires a 9V
battery.
NOTE: See manufacturer’s manual at www.lzbusline.com for additional information
OPERATING
Public Address System
LCD Monitors
NOTE: See manufacturer’s manual at www.lzbusline.com for additional information.
The coach is equipped with three strategically placed drop down LCD
monitors that are controlled by the JVC audio/video remote. Each monitor is raised and lowered by an individual switch on the right dash
panel.
NOTE: See manufacturer’s manual at www.lzbusline.com for additional information.
49
OPERATING
LAVATORY
Pre-Trip Procedures
General Information
Ensure that the freshwater tank is full.
For safety and convenience, the toilet module has been installed with
safety handles inside and out of the module.
The dashboard contains an indicator for the following:
•
•
•
•
When The module is vacant or occupied.
For The status of the wastewater holding tank.
To alert the driver that the alarm button in the toilet module has
been activated.
Then The wastewater holding tank is full.
NOTE: If wastewater holding tank indicator is on, stop using toilet
immediately and ensure door is properly locked.
The toilet module door has a seal strip which prevents odors from entering the motor coach. The toilet module is equipped with dual fans. Low
fan speed will vent constantly when the module is vacant. The fan will
change to high speed when the module is occupied. The outer fan
works to keep fresh air moving automatically.
The power to the toilet is controlled by the driver at the dashboard. If the
toilet is not functioning properly, the driver can turn off power and temporarily put the toilet out of order.
NOTE: If the toilet is to be out of service for an extended time, turn off
the main power to the toilet.
50
Freshwater tank is positioned in behind the right side wheel skirt. Fill
freshwater tank by attaching water hose and opening valve. Fill full and
close fill valve. Fold wheel skirt down and securely latch.
Check that wastewater tank is completely drained and drain valve
closed prior to trip. Make certain trash bin is empty prior to trip.
Check that toilet paper, paper towels, and other supplies are fully
stocked prior to trip. Toilet module needs to be cleaned and maintenance regularly.
OPERATING
Toilet Module Operation
Wastewater Holding Tank
Ensure the toilet system is functioning properly by locking the door. The
occupied light is controlled by the door lock. The occupied light will
make other passengers aware of the toilet status. Toilet is unoccupied if
the occupied light is off. If the toilet is occupied, the occupied light will
be on.
The dome light inside the toilet module has a dual status. The low light
level is on as long as the power to the module is on. The high light level
is on whenever a passenger enters the toilet module, closes, and locks
the door. The door lock triggers a switch that activates the high level
light.
Sensor will automatically produce a flush that will go through the drain
valve into the wastewater holding tank.
Post Trip Procedures
After motor coach arrives at wastewater evacuation area, flip switch of
evacuation valve to drain holding tank.
WARNING
Do not spray water at the electrical junction box, fans, or other
electrical equipment. Doing so could damage equipment and seriously injure personnel.
Remove all trash and restock supplies. Use a damp cloth to wipe the
surfaces. Sliding valve on holding tank should be cleaned regularly to
ensure smooth operation.
Wastewater holding tank is located in the right rear access panel of the
motor coach.
Flip switch back after evacuation.
When cleaning inside of toilet module, remove the cover of the floor
drain. The water then can be drained directly out of the motor coach
through the floor drain.
WARNING
Refer to local health regulations for proper disposal procedures
and equipment.
51
OPERATING
Cold Weather Procedures
Shut down toilet module for sub-freezing temperatures. Drain all water
from freshwater and wastewater holding tanks. Ensure toilet flushes
several times to drain water from bowl. Toilet module cannot be put
back in service until sliding valve and all components are thawed.
ENTRANCE DOOR EMERGENCY RELEASE
Interior Emergency Release
CAUTION
Never try to open a frozen valve by force. Use warm water to
defrost valve before use.
ELECTRIC DRIVER SUN SHADES
Sun shades have been installed at the left and right behind the windshield. Each shade has its own control switch on the lower left switch
panel console.
In case of emergency or door power failure, locate emergency release
handle in entry way next to tour guide seat. Rotate handle clockwise
and push door outwards.
Exterior Emergency Release
CAUTION
Do not try to operate manually, this could cause gears to break.
In case of emergency or door power failure, locate emergency air dump
valve located on right side behind front bumper. Turn valve handle onequarter of a turn clockwise to release door. Two second delay will follow
before door opens. Once door is open, turn the interior emergency
release handle in entry way open before closing exterior emergency air
dump valve. Passenger door will now stay open.
52
OPERATING
REMOTE CONTROLLED ENTRANCE DOOR
LUGGAGE COMPARTMENT
WARNING
Always apply the parking brake before having the passengers
embark/disembark.
CAUTION
Entrance door must be shut prior to turning steering wheel. Leaving door open and turning wheels can severely damage motor
coach entrance door or right tire.
The entrance door can be operated by the dash panel switch or a by
remote control. The remote control feature only functions when parking
brake is applied.
NOTE: Ensure outside mechanical lock is in the unlocked position
before attempting to open door.
You can open the passenger door from the outside by means of the
push button located on the body wall inside the right side fuel access
door.
The transverse luggage compartment may be accessed through eight
aluminum luggage bay doors. There are four luggage bay doors per
side. Each luggage bay has an overhead light for safety and convenience. Luggage compartment overhead lights are controlled by the
switch on the driver’s right switch panel.
Table 2: Entrance Door Exterior Switch
Number
Item
1
Open Entrance Door Switch
2
Close Entrance Door Switch
The luggage compartment contains three emergency road reflectors for
roadside emergencies. The compartment also includes a tool kit for
minor repairs.
53
OPERATING
SPARE TIRE COMPARTMENT
To remove the spare tire, perform the following:
1. Fold bottom door completely down.
2. Loosen ratchet straps, allowing excessive slack for strap to be placed
above tire as it is being removed.
3. Pull the tire forward so it slides along the rollers, using caution as the
tire exits the support rollers.
To place the spare tire back, perform the following:
1. Place tire flat on first roller.
The Falcon 45 has an easily accessible spare tire compartment located
behind the front motor coach body panel. The spare tire compartment
latch can be released by lifting both spare tire compartment release
handles.
2. Lift straps over tire while lifting and pushing tire back into the compartment.
3. Pull down ratchet straps to tire tread face.
4. Tighten ratchet straps against tire tread face.
5. Close spare tire compartment doors, closing the bottom door first.
The spare tire compartment release handles are located inside the
motor coach dash and behind an access panel. The access panel is on
the far right side of dash. Push the two access panel release latches
and remove panel.
54
INSPECTION
DAILY INSPECTIONS
ENGINE OIL LEVEL
To make sure your motor coach is ready for service, make the following
daily inspections.
CAUTION
Do not overfill the crankcase. NEVER operate the engine if oil
quantity is below the add mark.
NOTE: Inspection check sheet is available at the end of this section,
and can be copied for reuse.
NOTE: Please become aware of all SAFETY PRECAUTIONS and
additional information stated in component manufacturers’ Operation
and Maintenance manuals at www.lzbusline.com.
With the engine stopped, pull out the oil level dip stick and clean it with
a clean cloth. Insert the dipstick into the crankcase completely, then pull
it out again. The fluid level should be between the add and full marks. If
engine had been running recently, allow at least ten minutes for oil to
drain into crankcase. Use only recommended engine oil.
ENGINE OIL PRESSURE
WARNING
Before checking, park the motor coach on a flat roadway.
Before starting each day, check or inspect the following to ensure trouble-free performance:
•
•
•
Make visual inspection of entire unit.
Check under motor coach for signs of leaks. If any are noted, correct condition causing leaks.
Check all fluid levels on chassis: engine and transmission oil, coolant level, power steering fluid, and all other oil and liquid levels.
Also check engine belts, hoses, and wiring for condition and adjust
as needed.
NOTE: For more details, read the following:
The oil pressure will be high soon after cool-starting the motor coach; oil
temperature will be increasing, and engine rotation speed will be normalizing. The oil pressure should be in the range of 25-55 psi. If the
indicator is low or does not register within 15 seconds, stop and check
oil level/condition and for any needed repair.
DRIVE BELTS AND BELT TENSION
Check condition and tension of the belts on the engine, fan, and compressor. If any relaxation, tighten belts. If there is any belt damage is
present, replace belt.
Check for intersecting cracks on belts. Cracks are acceptable along the
width of the belt, but if these transversal cracks intersect with longitudinal (belt length) cracks, replace belt. Also replace if the belt shows
extensive wear.
CAUTION
Over-tight or excessive slack in belt tension can be harmful to the
engine.
55
INSPECTION
BATTERY
WARNING
Do not start the engine when adding liquid to the battery.
If too much water is in the tank, check the dryer and pre-dryer for proper
operation and service if needed.
Air storage tanks are located on left side, inside the access panel and
behind wheel skirts.
Open the lid of the battery; liquid should be added when the level is
lower than the height sign on the battery box.
NOTE: The core of the air dryer must be replaced at least once a year.
WASHER FLUID
RADIATOR COOLANT
Park on a flat, level surface. Open the outside hatch at left, front side of
motor coach where the washer fluid reservoir is located. Add washer
fluid if low.
NOTE: Washer fluid tank location may vary.
WINDSHIELD WIPER
Check that wiper arms and blades are secure, not damaged, and operate smoothly.
AIR CLEANER
Wipe away the dust that may have accumulated over the air intake and
outlet once a weak. Check that all hose connections are tight to prevent
dust from being sucked into the intake system and reducing engine life.
NOTE: Replace air cleaner filter when air filter warning light indicates.
AIR STORAGE TANK PURGE
Open the discharging valve at each tank to relieve water from tanks.
Push finger up into black rubber diaphragm releasing trapped moisture.
56
Check Radiator fan inlet for debris. Check fan blade condition.
WARNING
Scalding Hazard - Do Not Open Lid Of Expansion Tank When
Engine Coolant Is Hot!
CAUTION
Check the coolant level only when the engine is off and cool.
Add coolant when below full. Be sure to check coolant temperature
gauge.
INSPECTION
FUEL TANK
POWER STEERING
CAUTION
Use recommended diesel only.
Check fuel gauge while ignition key is in “on” position or engine is running. Add clean diesel when needed. If the motor coach operates in a
humid area, keep the fuel level full to prevent moisture on the inside
surface of the fuel tank. Ensure filters are clear of water deposits.
Ensure there are no leaks in the fuel line and the fuel cap remains
tightly closed. Ensure fuel cap is clean before opening or closing.
PRIMARY FILTER-WATER SEPARATOR
Drain the primary filter-water separator system.
EXTERIOR LAMPS
Check that all external lights and reflective equipment are clean and
functional.
With motor coach on level ground, open the engine compartment door
and inspect the oil level from the viewable window on the power steering system reservoir. If low, add power steering fluid.
After adding power steering fluid, start the engine. The fluid will be
driven throughout the entire system and some air may be present. Turn
the steering wheel to the left and right limiting positions several times.
This will extract the air from the system. Shut down engine to allow air
to rise and escape the fluid in reservoir. Repeat bleed procedure if
needed.
BITZER COMPRESSOR
ELECTRICAL SYSTEM
Check functioning of all instruments and indicators, including headlights, steering lamps, braking lamps, reversing lamps and emergency
blinkers.
NOTE: Clean instrument panel cover to ensure indicators can be seen
clearly.
WARNING
Use extreme caution near compressor; hair, hands, or clothing
can be caught in drive belt. Serious injuries are possible.
Check oil level on sight glass. Oil level should be one-fourth to threefourths the height of sight glass.
57
INSPECTION
TIRES AND WHEELS
WARNING
Always maintain your tires in good condition. Frequently check
and maintain correct inflation pressures as specified by the tire
manufacturers. Inspect periodically for abnormal wear patterns
and replace/repair cut or broken tire casing. Always use experienced, trained personnel with proper equipment and correct procedures to mount or remove tires. Failure to adhere to these
warnings could result in tire malfunction, damage to the motor
coach, personal injury, and possibly death.
NOTE: Correct inflation pressure should be:
•
•
•
•
Front axle 115 psi.
Drive axle 90 psi.
Tag axle 95 psi.
Spare 115 psi.
Check and maintain the correct inflation pressure for each tire every
morning or when tires are cool. Check tire pressures ONLY when the
tires are cool. Warm or hot tires cause pressure buildup. Do not deflate
a warm tire to specified pressure. Tire thumping during the walk around
inspection will tell you if a tire is deflated, but the only way to check tire
pressure is with an accurate gauge. If any tires are found to be considerably under inflated, the motor coach should not be driven until cause
of the leak is determined and repairs have been made.
58
Regular and frequent inspection and proper care will give you the
assurance of safe, reliable tire operation. Most tire wear problems are
caused by under inflation such as a slow leak. Low pressure is a tire's
worst enemy. It allows tires to flex badly and this causes high temperatures to build up. Heat causes early tire damage, such as flex breaks,
radial cracks, and ply separation. Furthermore, low tire pressures can
affect control of your motor coach, particularly at the front wheels.
Look for bumps, blisters, cuts, punctures, cracks, uneven wearing, and
tread depth. Verify that lug nuts are tight. Adjust to specifications if
loose.
NOTE: After driving a new motor coach approximately 31 miles (50
Km), an adjustment of the lug nuts should be performed according to
torque specifications. The fastening sequence should be cross symmetrical. The fastening sequence and torque specifications can be found in
the maintenance section.
INSPECTION
INSPECTION SHEET
F Check engine oil level.
F Check for fluid leaks. Engine oil, power steering,
transmission, axle oil, and coolant.
F Check power steering fluid.
F Check coolant system level.
F Inspect drive belts.
F Check belt tensions.
F Check cooling fan.
F Inspect coolant hose condition.
F Inspect condenser fan inlet for debris.
F Check transmission fluid level, if applicable.
F Visually check battery .
F Check washer fluid.
F Check windshield wipers.
F Check air cleaner restriction indicator.
F Check primary filter-water separator.
F Check mirrors.
F Check headlights (high and low beams).
F Check taillights.
F Check brake lights.
F Check turn signals.
F Check 4-way flashers.
F Check clearance lights (red on rear, amber elsewhere).
F Check red reflectors on rear and amber reflectors
elsewhere.
F Check wheel nuts.
F Check tire inflation.
F Check tire condition.
F Check A/C compressor oil level at sight glass.
F Check that all compartment doors are shut tight.
F Drain air tank.
F Check fuel tank.
59
INSPECTION
F Check that all equipment is secured.
F Check steering system free play.
F Check all emergency equipment.
F Check driver’s and passenger seat belts.
F Check horn.
F Check foot and hand brakes (parking and emergency)
for proper operation.
F Visually inspect motor coach ride height.
F Check instrument lamps.
F Check voltmeter reading with engine running.
F Check brake air pressure.
60
MAINTENANCE
MAINTENANCE
Please read all safety precautions and additional maintenance information outlined by all component-specific operation and maintenance
manuals at www.lzbusline.com.
WARNING
To avoid property damage, personal injury, or death when servicing the motor coach, park on a flat level surface, set the parking
brake, turn off the engine, and chock the wheels.
GENERAL INFORMATION
This manual contains information on systems operation, component
location, and periodic maintenance procedures which pertain to standard and optional equipment on LZ Falcon 45 series motor coaches.
Proper maintenance is important to the safe and reliable operation of all
LZ motor coaches. The service procedures described and/or recommended in this manual are effective methods for performing routine service or replacement of components. Other information, which may be
needed to supplement this manual, is contained in separate parts of the
operator’s manual.
Specific information about the engine and transmission can be found in
the applicable manufacturer’s service and troubleshooting manuals.
NOTE: Check www.lzbusline.com for additional operation and maintenance services that may apply.
WARNING
Failure to perform proper maintenance and service could result in
property damage, personal injury, or death.
Your motor coach has been engineered and manufactured to provide
economical service. However, it is the responsibility of the owner to see
that the motor coach receives proper care and maintenance to assure
high performance.
WARNING
To avoid property damage, personal injury, or death; take care
when performing maintenance, making any inspections, or repair.
Some of the materials in this motor coach may also be hazardous
if used, serviced, or handled improperly. If you have any questions
pertaining to service, have the work done by a skilled technician.
Check the motor coach periodically as recommended by this Operators
Manual and by the component-specific Operation and Maintenance
manuals. Perform function checks as well as a test run after performing
maintenance.
NOTE: See manufacturer’s manual at www.lzbusline.com for additional information.
Shorten maintenance intervals if motor coach use is severe or under
severe conditions. Keep all fluid reservoirs full and clean as needed.
61
MAINTENANCE
MAINTENANCE RECORDS
When servicing your motor coach always perform the following:
It is the responsibility of the owner to keep accurate maintenance and
repair records; including receipts. Should the lack of required maintenance be the reason for repair, a warranty claim may not be accepted.
LZ Busline, LLC reserve the right to request your maintenance
and repair records for verification of compliance with required
maintenance practices and intervals.
1. Turn off the ignition switch unless the procedure calls for a running
engine.
LZ Busline, LLC recommends that the maintenance and
repair records/receipts be maintained as permanent records. All
records must state the date service was performed, mileage, vehicle
identification number, and service performed.
WARNING
Always use floor stands to support the motor coach before working under it. Using only a jack could allow the motor coach to fall,
resulting in property damage, personal injury, or death.
WARNING
When welding on the motor coach is required, always disconnect
the ground battery terminal first. Then disconnect the positive
cable prior to electric welding. Attach the welder ground cable as
close to the part being welded as possible. If welding close to an
electronic component, temporarily remove that component. Failure to follow this warning will result in a fire or explosion hazard
which could result in property damage, personal injury, or death.
62
2. Set the parking brake and chock the wheels.
3. Use support stands, never a jack, whenever you must be under a
raised vehicle.
4. Do not smoke.
5. Wear safety glasses for eye protection.
6. Operate engine in a well-ventilated area.
7. Do not work on brakes unless proper precautions are taken to avoid
inhaling friction material dust.
8. Do not wear loose clothing, hanging jewelry, watches, or rings. Tie
up long hair and avoid rotating components.
9. Avoid contact with hot surfaces. Allow hot components to cool
before working near or working on components.
10. Correct any problems that were revealed during inspection, prior to
operating motor coach.
MAINTENANCE
SEAT BELT MAINTENANCE
Interior
For safety, you should check the condition of your seat belts regularly.
Sweep or vacuum cabin daily. Clean up spills as soon as possible to
prevent injury and to prevent permanent stains. If necessary, handwash belts in warm water with neutral soap. Keep buckles dry! Rinse
thoroughly and allow to dry.
Pull each belt out fully and look for frays, cuts, burns, and wear. Check
that the latches work smoothly and that the belts retract easily. Any belt
not in good condition or not working properly will not provide good protection and should be replaced as soon as possible.
CLEANING MOTOR COACH
The coach body should always be kept clean. Wash the coach at the
end of every driving day. Do not use any type of harsh chemicals or
utensils to prevent damage to the body and paint.
•
•
•
•
•
•
Keep the seal strips of the doors and windows in good condition.
Inspect for damage and replace if needed.
Do not wash or rinse the painted surface of the bus with hot water,
alkaline water, kerosene or any type of oil. These types of products
could damage or ruin the paint.
Check the connecting portions between the chassis and the body
and repair any abnormal conditions that may be discovered.
Check the fasteners within the interior components of the coach
and tighten them as needed.
Check the condition of the passenger doors and make adjustments
as needed.
Check the lights and lamp conditions of the coach. If any damage is
discovered, replace it immediately.
Exterior
Please clean your motor coach at approved washing sites. Do not wash
motor coach in direct sunlight. Use clean water to rinse motor coach
from top to bottom. Ensure that water does not pass through the air filter into the engine. Do not spray water on the radiator grilles on the right
or left sides of the motor coach.
Wash the motor coach as needed. To remove light dust, wipe off with a
clean damp cotton towel or chamois. Always use a separate cloth or
sponge when washing the painted surfaces. The other areas, such as
steps, bumpers, and tread plate; could leave abrasive materials on the
cloth or sponge that could scratch the painted surfaces. Never use shop
rags.
Wash off all salts, highway deicers, petroleum, industrial fallout, and
chemicals as soon as possible. All exterior surfaces should be washed
(top, sides, and underbody).
To wash, use warm water and mild soap. Use caution when pressure
washing. Always use a wide fan, and care must be taken not to get too
close to the vehicle or any striping, lettering, labels, or vinyl overlay.
After washing, rinse the body thoroughly with water. Soap residues can
damage the finish.
63
MAINTENANCE
ENGINE AND CHASSIS MAINTENANCE
REMOTE START SWITCH/MASTER DISCONNECT
WARNING
NOTE: Engine will not start while engine compartment access
panel is open. The engine access panel safety switch will disable
the ignition switch to prevent serious injury or death.
Engine access panel safety switch.
Table 1: Remote Start and Master Disconnect Switches
Number
1
Remote Engine Start Button
Transmission must be in “N”, parking brake applied, and
ignition key must be in the “On” position to remote start
the engine. If area is safe, push start button to start
engine.
2
Master Disconnect Switch
Flip switch to disengage all power circuits.
3
Remote Engine Stop Button
Push stop button to shut off engine.
Clean engine and transmission every 10,000 miles. After every 50,000
miles, the following items of the intake manifold and the exhaust manifold should be checked:
•
•
Check the nuts and bolts at various positions to determine if they
are loose. The torque should be even and uniform while fastening
the nuts and bolts. Otherwise, leakage may occur.
Check for cracks or holes on the intake manifold and the exhaust
manifold. If there is any damage or washout at the washers, replace
the parts as needed.
NOTE: See manufacturer’s manual at www.lzbusline.com for additional information.
64
Item
MAINTENANCE
AIR FILTER
The air filter should be checked and maintained after each 5,000 mile
increment. When the vehicle runs in a heavy dust environment, the
replacement cycle of the filter should be shortened. The engine must be
off when the intake system is being serviced. Do not start the engine
once the filter has been removed. Restart only after the filter has been
replaced.
Take off the butterfly-nut, remove the outer filter and lid. Remove the
dust in the unloading valve. Clean the filter by tapping lightly with hand,
wooden tool, or by blowing air into the filter with an air compressor.
Remove C-clip holding inner filter to lid. Clean the lid and the inside surface of the shell with a dry, clean cloth. When replacing outer filter,
remove rubber lid gasket to put on new filter.
Remove cotter-pin holding the inner filter butterfly-nut. Remove butterfly-nut. Take out inner filter. Clean the filter by tapping lightly with hand,
wooden tool, or by blowing air into the filter with an air compressor.
CAUTION
Do not blow air on the outside surface of the filter core.
When using compressed air, be sure the air pressure is lower than 72
psi (496 kPa). Blow the air from inside the filter to the outside, until the
dust is no longer visible.
NOTE: Replace the filter if damaged.
When the filter indicator lamp is activated on the instrument panel, it
means that the filter should be cleaned or replaced. A dirty filter will
cause insufficient power and wear of the engine. In order to ensure the
service life and normal operation of the engine, the air filter must be
maintained carefully and periodically.
Clean the surface using a clean, dry cloth. The filter should be checked
by using an examining lamp to make sure there is no damage before
installing it. Check for damage or cracks on the sealing ring.
NOTE: Do not start the engine without the air filter in place.
65
MAINTENANCE
RADIATOR
ENGINE COOLANT
Keep the outside of the radiator clean by using compressed air or a
water hose. This will ensure proper air circulation and cooling of the
engine.
WARNING
Never open filler cap if coolant is hot. When opening filler cap, first
turn it carefully counterclockwise to the first stop and let the pressure escape. Then turn it to the second stop and remove the cap.
For the vehicles equipped with the inter-cooling device, keep the fins of
the radiator clean at all times. Normally compressed air or water is used
to clean the radiator. When there is hard scale on the radiator, steam
should be used. In order to avoid damaging the radiator fins, the flow of
air, water, or steam should be vertical to the surface of the radiator.
Coolant tank.
NOTE: It is essential to keep the radiator system clean and clear of any
obstructions, so the engine will cool adequately.
In areas, where there may be numerous flying insects, clean the radiator fins more often.
CAUTION
Not abiding by this operating requirement could cause poor
engine cooling, and possibly severe damage to engine components.
66
Table 2: Coolant Reservoir
Number
Item
1
Coolant Reservoir Level Window.
2
Coolant Reservoir Fill Cap.
MAINTENANCE
Add the long-life anti freeze and anti rust liquid into the radiator. The
coolant is all-purpose and need not be charged/discharged in the winter. When selecting the freezing point of the coolant, it should be 5° C
lower than the minimum ambient temperature. Different types of coolants should not be mixed.
Long term operation of the engine may cause lime scale to build up in
the cooling system. Cooling system must be cleaned by the following
method:
NOTE: The coolant should be replaced every 2 years.
•
•
•
•
•
•
An antifreeze and a rust inhibitant solution (a mixture of the glycol and
water) should be added to the cooling system to prevent settling, freezing, and oxidizing as well as to raise the boiling point.
•
Blend the causticity sodium of 24/28 oz (700/800 gm) with kerosene of 5.25 oz (150 gm)
Pour the liquid mixture into the radiator.
Let the engine run for 5 to 10 minutes at a middle rate.
Let the engine rest for 10 to 12 hours.
Restart and run the engine for 10 to 15 minutes.
Drain the solution.
Once this is complete, flush the radiator with clean water.
CAUTION
Add the same type of coolant to prevent settling. If the coolant is
substandard or the freezing point is too high, replace it immediately.
67
MAINTENANCE
Table 3: Coolant Mixture Chart
Temperature
Maximum Boiling Point
Glycol Content
Water Content
Additive Content
-49º F (-45º C)
226.4º F (108º C)
58%
32%
10%
-40º F (-40º C)
225.5º F (107.5º C)
54%
36%
10%
-31º F (-35º C)
224.6º F (107º C)
50%
40%
10%
-22º F (-30º C)
223.7º F (106.5º C)
46%
44%
10%
-13º F (-25º C)
222.8º F (106º C)
42%
48%
10%
-4º F (-20º C)
221.9º F (105.5º C)
38%
52%
10%
5º F (-15º C)
221º F (105º C)
34%
56%
10%
14º F (-10º C)
220.1º F (104.5º C)
30%
60%
10%
NOTE: You may also choose to use the coolant that is recommended in the engine manufacturer’s manual located at www.lzbusline.com.
68
MAINTENANCE
BRAKE PEDAL
NEW MOTOR COACH BREAK-IN
Adjust brake pedal clearance by loosening the locking nut of the brake
pedal and adjust the adjustable nut. Measure the vertical distance with
a steel strip ruler. The distance between the pedal free play position and
the position at which the pressing pressure would distinctly increase
should be 0.32 to 0.48 in. (8 to 12 mm). Tighten the locking nut securely
after adjusting.
CAUTION
The engine must not be run at its maximum output power during
the break-in period.
TIRE ROTATION
Pay attention to any unusual noises, vibrations, or handling characteristics, at all times during break-in period. The mileage for the break-in
period is usually 1,500 miles (2,500 km).
To extend the use and life of the tires, they should be rotated every
4,800 to 6,000 miles (8,000 to 10,000 km), depending on driving conditions. If there is unusual or irregular wear, the tires should be rotated
immediately, as well as checking the orientation of the wheels and the
dynamic balance.
The rear axles wheel skirt can be easily lifted out of the way, allowing
for clear access to jack up the axles and wheel replacement.
•
•
To lift wheel skirt, pull on each bottom skirt corner to release skirt
from latch. Lift wheel skirt out of the way.
To reposition wheel skirt, pull skirt all the way down. Push on each
bottom skirt corner to secure into latch.
WINDSHIELD WASHER RESERVOIR
Maintain windshield washer reservoir level with a high quality washer
fluid. Washer reservoir is located in the first left access panel under the
driver’s window.
In order to maintain the excellent performance and efficiency of the
motor coach, as well as ensure an extended service life.
New Motor Coach Preparations
It is advisable to perform the following procedures:
1. Clean the motor coach.
2. Check the connections and fasteners of various components.
3. Check the coolant storage of the cooling system and look for any
leakage.
4. Check the fluid levels in the engine, the gearbox, the driving axle
and the steering system. If fluids are low, add the appropriate fluid
being careful to not overfill.
5. Check for any leakage in each system.
6. Check to see if the brake system is normal and look for any leakage
among the valves and the various pipeline connections.
7. Check the steering system for loose or blocking parts.
8. Check the electric appliances, lamps, and instruments as well as
the electrolyte level in the battery.
9. Check tire pressure to ensure proper inflation.
69
MAINTENANCE
New Motor Coach Break-in Maintenance
Perform the following procedures.
NOTE: The vehicle should be driven on well-maintained roadways during this period.
•
•
•
•
•
•
•
•
•
Drive the motor coach appropriately for a new vehicle and accelerate smoothly. Do not place the motor coach in neutral when coasting. As much as possible; do not brake in an urgent manner during
the break-in period.
The speed limit during this time is less than 30 Mph. (50 Km/h).
Drive the bus empty for the first 150 miles (250 km). Do not overload the bus after the 150 mile (250 km) break-in period.
Check the fluid levels in the engine, the gearbox, the driving axle,
and the steering system. If fluids are low, add the appropriate fluid,
but do not overfill. Check for any leakage in each system.
Check to see if the brake system is normal. Look for any leakage
among the valves and the various pipeline connections.
Check the steering system for loose or blocking parts
Check the electric appliances, lamps, and instruments. Check the
electrolyte level in the battery.
Pay attention to the temperatures on the gearbox, the driving axle,
the wheel hubs, and the brake discs frequently. If there is any overheating problems, find the cause and correct immediately.
Pay special attention to the oil pressure and engine coolant temperature. They should remain in the normal range.
Replace the engine lubricant according to the engine manufacturer’s manual. The engine lubricant should be drained while the
engine is hot.
NOTE: Replace the lubricant according to the recommendations in the
engine manufacturer’s manual located at www.lzbusline.com.
70
WARNING
Take extreme precautions to drain engine oil while engine is hot.
The hot components or hot oil can cause severe burns which can
lead to permanent injury or death.
Post New Motor Coach Break-in Maintenance
Perform the following procedures.
•
•
•
•
•
•
•
Ensure proper nut and bolt torque on cylinder head, valve cover,
manifold bolts, etc.
Check the valve lash.
Replace the lubricant in the engine, the gearbox, and the reduction
final drive, as well as the filter core in the oil reservoir.
Check the connecting positions in the steering system for any loosening or damage.
Tighten the bolts and nuts in the front and rear suspension systems
according to the specified torques.
Check the installation and fastening of the various components in
the hydraulic system of the steering mechanism. Lubricate and
maintain the motor coach according to the this basic maintenance
check list.
Check for any oil, water, or air leakage within the various portions of
the motor coach.
NOTE: Refer to component manufacturer’s manuals for detailed information. Manuals located at www.lzbusline.com.
MAINTENANCE
ENGINE COMPARTMENT
Table 4: Engine Compartment Components
Number
Item
1
Fuel/Water Separator
2
Motor Coach Chassis Plate
3
Air Filter (Inner/Outer)
4
Coolant Sight Glass
5
Coolant Fill Cap
6
Engine Oil Dipstick
7
Master Disconnect Switch/Remote Start Switch
8
Engine Oil Fill Tube
9
Engine Plate
10
Power Steering Reservoir
71
MAINTENANCE
ENGINE OIL
The preferred engine oil is an equivalent of the American Petroleum
Institute API CI-4 15W-40.
The engine oil will need to be replaced at specified intervals due to oil
consumption, contamination of the oil as it flows through the engine,
and the break down of chemical additives. The recommended frequency for changing the oil is approximately every 15,000 to 20,000
miles (24,000 to 32,000 km). Based on the driving conditions, quality of
fuel and environmental conditions the frequency may increase or
decrease based on the individual use of each motor coach.
Engine Oil level
CAUTION
Never operate the engine with oil level below the ADD mark or
above the FULL mark on the dipstick.
Oil dipstick and oil filler tube.
Place motor coach on level surface. Pull out dipstick and wipe it clean
with a clean cloth. Insert dipstick and pull out again. The oil level should
be between the ADD and the FULL marks on the dipstick.
If the oil level is too low, add oil through the oil filler tube. Bring level up
to FULL mark.
Engine Oil Viscosity
Since the viscosity of the engine oil changes with the temperature, the
average ambient temperature at the operating site of the engine is very
important for us to choose oil viscosity grade. Occasionally, if temperature drops below the lower limit, it may reduce the cold staring capability
of the engine but not cause any damage to the engine.
The engine oil with an excessively high viscosity would cause engine
starting difficultly. Therefore, the ambient temperature while the engine
starts is the main basis on which to choose an engine oil. You may also
avoid replacement of the engine oil due to the temperature changes
provided the multi-functional engine oil is used.
NOTE: Adding any additive into above-mentioned engine is unnecessary. Avoid mixing and using different types of engine oil. Performing oil
changes on time is crucial.
72
MAINTENANCE
GEAR LUBRICANT
DIESEL FUEL
Always use synthetic gear lubricant that conforms to the API GL5 SAE
80W-90 grade. Using the recommended brands from EATON is acceptable.
POWER STEERING LUBRICANT
Allison C-3, DEXRON-II hydraulic transmission oil should be chosen
when the power steering mechanism operates under temperatures
lower than 50° F (10° C); If above 50° F (10° C) then choose C-3/10W;
the C-3/10W grade oil is an all-season oil in freezing zones; The C-3/30
grade oil is all-season oil in non-freezing areas.
FINAL DRIVE UNIT LUBRICANT
The lubricant for reduction final drive should meet the applied conditions of the GL-5(SAE90) grade of API for the heavy load, the hyperbolic surface gear as well as meet the applied ambient temperature
conditions.
CHASSIS LUBRICANT
The #2 lithium-based lubricant grease (suitable for ambient temperature
of -22° to 248° F ( -30° to 120° C ) should be applied to the various
components.
Fuel tank fill caps are located behind small locked panels. The small
locked panels are located on both sides of motor coach. Use only high
purity diesel, with a content of sulphur that is not more than 0.3 percent.
CAUTION
Avoid driving with an extremely low fuel level. Running extremely
low or out of fuel could cause engine damage.
73
MAINTENANCE
TROUBLESHOOTING
Engine
Please refer to the engine manufacturer’s manual located at www.lzbusline.com.
Chassis Transmission Shaft
Table 5: Chassis Transmission Shaft
Problem
Possible Cause
The transmission shaft shakes (vehicle vibrating during travel).
The sliding–fork of the transmission shaft has
been improperly assembled.
Disassemble and make both the sliding–fork
and fixing-fork the same level
The transmission shaft is twisted or bent
Adjust or replace the transmission shaft
The universal joint journal or the needle bearings have been worn down or damaged.
Replace the bearings.
The transmission shaft is loose.
Fasten the transmission shaft according to the
specified torque.
74
Possible Solution
MAINTENANCE
Table 5: Chassis Transmission Shaft
Problem
Abnormal sound from transmission shaft
(There is abnormal noise during vehicle starting and traveling).
Possible Cause
Possible Solution
The universal coupling has been worn down
or damaged.
Replace the universal coupling.
The sliding–fork has been worn down or damaged.
Replace the sliding–fork.
The transmission shaft has loosened.
Fasten the transmission shaft according to the
specified torque.
The needle bearings, the sliding–fork and the
middle supporting bearings are not lubricated.
Lubricate.
The obliquity of engine or rear axle changed.
Technically the obliquity remains 40.
Re-adjust the obliquity of engine or rear axle.
75
MAINTENANCE
Rear Axle
Table 6: Rear Axle
Problem
There is unusual noise at the rear axle (abnormal sound), when starting the engine.
There is unusual noise at the rear axle (abnormal sound), when steering the vehicle.
76
Possible Cause
Possible Solution
The clearance between differential
gears is too large.
Adjust the clearance.
The teeth clearance between the drive and
driven gear is too large.
Adjust the clearance.
The connection between the flange and the
transmission shaft is loose.
Fasten connection according to the specified
torque.
The pre-tension at the bearings of the drive
gear is too small.
Adjust the pre-tension.
The fixing bolts and nuts on the active gear
wheel are loose.
Fasten them according to the specified torque.
There is wear and tear or damage on the halfaxle gear, the drive gear, the crossing shaft,
the thrust washer, and the half-axle bearings.
Adjust or replace.
The oil level is low.
Add lubricant.
MAINTENANCE
Table 6: Rear Axle
Problem
There is unusual noise at the rear axle (abnormal sound), when the vehicle is moving.
There is unusual noise at the rear axle (abnormal sound), while the vehicle is on cruise.
Possible Cause
Possible Solution
The clearance between the drive and driven
gear is too large.
Adjust the clearance.
The bearings have been worn down or damaged.
Replace the bearings.
The gears have been worn down or damaged.
Adjust or replace them.
The oil level is too low.
Add lubricant.
The clearance between the drive and driven
gear is too small.
Adjust the clearance.
The bearings have been worn down or damaged.
Replace the bearings.
The contacting position of the gear wheels is
incorrect.
Adjust or replace the parts.
The oil level is too low.
Add lubricant.
77
MAINTENANCE
Table 6: Rear Axle
Problem
The lubricant in the rear axle leaks out.
78
Possible Cause
Possible Solution
The oil seal has been worn down, loosened,
or damaged.
Replace the oil seal.
The locking bolts in the differential are loose
or the pad has been damaged.
Fasten them according to the specified torque.
Replace the pad.
There is damage at differential interface.
Repair it, or replace the differential housing if
necessary.
The drain screws are loose or the liner has
been damaged.
Replace the liner. Fasten the drain screw
according to the specified torque.
The venting plug has been blocked or damaged.
Clean or replace the venting plug.
There are cracks on the rear axle housing.
Repair or replace the rear axle housing.
The sealing surface of the flange is damaged
or deformed.
Adjust or replace the flange.
The flange Radial run-outs are due to a problem with the bearings.
Replace the bearings.
The rear-axle housing has deformed due to
overload.
Adjust or replace the rear-axle housing.
MAINTENANCE
Table 6: Rear Axle
Problem
Wheel hub bearings have been jammed.
Possible Cause
Possible Solution
The pre-tension at the wheel hub bearings is
too tight.
Adjust the pre-tension.
The bearings are short of lubricant, or the
applied lubricant grease is incorrect.
Lubricate frequently, or replace the
lubricant grease.
The bearings have been stained by dust.
Clean and lubricate frequently.
Water leaked in due to seal ring problem.
Replace the sealing ring.
79
MAINTENANCE
Front Axle and Steering System
Table 7: Front Axle and Steering System
Problem
Steering wheel shimmy.
80
Possible Cause
Possible Solution
The bolts of the steering gear case or the
steering column support are loose.
Fasten them according to the specified torque.
The connection of the steering system has
loosened.
Adjust the connection position.
The clearance of the steering gears is too
large.
Adjust the clearance.
The wheel rim, wheel rib, and wheel are not
balanced or worn out.
Balance all the parts, or replace the worn
parts.
The front wheel bearings are worn.
Replace the bearings.
The kingpin and liner are worn out.
Adjust or replace the wrong parts.
The steering knuckle has deformed.
Replace the steering knuckle.
The orientation of the wheels is improper.
Check and adjust the orientation of the
wheels.
The front leaf spring fatigued, the U-bolts are
loose, or the central bolts are damaged.
Replace the defective parts.
MAINTENANCE
Table 7: Front Axle and Steering System
Problem
Steering wheel return ability failure.
Steering wheel deviation.
Possible Cause
Possible Solution
Difficult to engage gear.
Adjust the gear engaging.
The power steering system malfunctioned.
Disassemble, check, and fix the malfunction.
The contacting of the dynamic piston is
improper.
Adjust or replace the dynamic piston.
The reaction spring is worn.
Replace the spring.
The sliding valve has malfunctioned.
Check the diameters of the sliding valve and
the shell. Replace the sliding valve or the shell
if necessary.
Caster angle is wrong.
Check and adjust the orientation of the front
wheels.
Adjusting of the front wheel orientation is
incorrect.
Check and adjust the orientation of the front
wheels.
The front leaf spring is worn or damaged.
Replace the spring.
The front axle is bent.
Adjust or replace the front axle.
Braking is not smooth.
Please see brake manufacturer’s manual
located at www.lzbusline.com.
The bearing nuts at the front wheel hub are
loose.
Fasten bearing nuts according to the specified
torque.
The tire air pressure is over-inflated or underinflated.
Test and adjust pressure.
A tire is the wrong size.
Replace the tires with correct size.
81
MAINTENANCE
Table 7: Front Axle and Steering System
Problem
The wheels have been worn down unevenly
or untimely.
82
Possible Cause
Possible Solution
The orientation of the front wheels is
incorrect.
Check and adjust the orientation of the front
wheels.
The bearings at the wheel hub have been
worn down or broken. The bearing nuts have
loosened.
Replace the bearings or fasten the nuts
according to the specified torque.
The ball-head pin, the kingpin, and the bush
are too loose or too tight.
Adjust or replace the faulty parts if necessary.
The wheel inflation pressure is not correct.
Test and adjust pressure.
The tires and the wheels are not concentric.
Replace the tires or the wheels.
The vehicle has been suddenly accelerated or
urgently braked.
Correct the driving manner.
Overloaded
Load according to the specified capacity.
MAINTENANCE
Table 7: Front Axle and Steering System
Problem
The steering wheel is feels heavy (resistant).
Possible Cause
Possible Solution
The oil level is low.
Add the lubricant to the specified level.
The lubricant has gone bad, or there are impurities in the lubricant.
Replace the lubricant.
The connecting joint for the steering
system has worn.
Replace ball-head pin.
The power steering system is wrong.
Disassemble, check, and eliminate the faults.
The resistance of the lubricant flow is too high
due to hollowing of the pipe route.
Measure the back pressure. If the back pressure exceeds the specified value, repair or
replace the pipe. The oil pressure is low due
to the hydraulic pump not working. Measure
the oil pressure and branch-flow amount. If
the oil pressure and branch-flow amount
inclines the specified value, disassemble or
repair the hydraulic pump.
There is air in the lines.
Exhaust air and add oil.
The rotating valve does not work.
Disassemble and repair the rotating valve.
The dynamic oil cylinder has been worn down
or damaged. The O-shaped sealing ring of the
piston is damaged.
Disassemble and repair them.
The oil-leaking amount in the steering gear
shell is too large.
Disassemble and repair the steering gear
shell.
The orientation of the wheels has been
improperly adjusted (caster angle too big).
Check and adjust the orientation of the
wheels.
83
MAINTENANCE
Table 7: Front Axle and Steering System
Problem
The steering wheel is feels heavy (resistant).
(cont).
There is some overflowed oil on the steering
tank.
84
Possible Cause
Possible Solution
The clearance between the kingpin and the
sleeve is too small.
Check and adjust the clearance.
The thrust bearing has been oppositely
installed.
Adjust the assembly.
The parts at the front axle are short of lubricant.
Lubricate the front axle.
The ball-connection is too tight or too loose.
Check and lubricate the ball-head pin.
The tire inflation pressure is too low.
Increase to specified pressure.
The wear and tear of the wheel is excessive.
Replace the wheels.
The filter screen or the filter core has been
blocked.
Clean the filter screen or replace the filter
core.
There is air in the system.
Add oil and exhaust the air.
MAINTENANCE
Braking System
Table 8: Braking System
Problem
Brakes feel hesitant.
Possible Cause
Possible Solution
There is air in the breaking system.
Check and adjust the exhausting valve of the
quick-release valve.
The camshaft has been poorly lubricated or
the regulating arm has been improperly position.
Adjust and lubricate necessary parts.
The brake shoes or the reaction spring of the
brake chamber have been damaged.
Replace the damaged parts.
The spring-braking takes effect.
Eliminate the cause for the springbrake
release failure.
The exhausting outlet of the quick release
valve has been blocked.
Disassemble and clean.
The primary piston or the secondary piston of
the braking valve failed to return.
Disassemble and clean the braking valve.
Replace defective parts if necessary.
85
MAINTENANCE
Table 8: Braking System
Problem
There is unusual noise while the brake pedal
is stepped down.
86
Possible Cause
Possible Solution
The brake lining is worn/broken causing the
rivets or the bolts to break.
Replace the brake lining.
The surface of the brake lining is hard.
Replace the brake lining.
The surface of the brake lining has gone bad.
Replace the brake lining.
The contact between the braking shoes and
the brake lining is improper.
Fasten accordingly.
There is uneven wear and tear on the inner
surface of the braking drum or the installation
of the inner surface is not secure.
Adjust and fasten the brake drum.
The anchor pins of the brake shoes are loose.
Adjust the clearance of the brake shoes and
tighten the locking nuts.
The bearings of the wheel hub have been
worn down.
Replace the bearings in the wheel hub.
The braking drum is deformed.
Check or replace the brake drum.
MAINTENANCE
Table 8: Braking System
Problem
The braking is not stable.
Possible Cause
Possible Solution
The tire inflation pressure is uneven or the
size of the tires is not uniform.
Operate according to the regulations. Make
changes if necessary.
The brake shoes have been improperly
installed, or the reaction spring has been damaged.
Fasten the screw nuts of the anchor pins on
the brake shoes and replace the reaction
spring.
The brake line has been improperly connected.
Adjust the connection of the brake line.
The left and right brakes have been improperly adjusted.
Adjust the brakes.
The brake line is damaged.
Replace the brake line.
There is oil on the brake line.
Clean and inspect for leaks.
The soleplate of the brake has been damaged.
Replace the soleplate of the brake.
The U-shaped bolt on leaf spring is loose.
Fasten the U-shaped screw nuts.
87
MAINTENANCE
Table 8: Braking System
Problem
Braking cannot be completely executed in all
situations.
88
Possible Cause
Possible Solution
The air line leaks.
Repair the air line.
The air compressor does not work.
Disassemble and repair the air compressor.
The air pressure regulator has been improperly adjusted, or does not work due to impurities.
Adjust and clean it.
The brake valve leaks air.
Disassemble and repair the brake valve.
The stroke of the brake valve is too short.
Check and replace the braking valve, if necessary.
The camshaft cannot rotate. The sleeve is
short on lubricant.
Check the operating condition of the camshaft. Replace the camshaft, if necessary.
The stroke of the thrust-rod in the brake chamber has been improperly adjusted.
Adjust the stroke.
The sliding connection of the relay valve is
improper.
Disassemble and repair it.
The brake line is overheating or has gone bad.
Replace the friction disc.
The engaging of the brake line is improper.
Adjust the engaging position of the friction
disc.
There would be oil on the friction disk or the
brake drum.
To clean the oil stains with a suitable detergent and replace the friction disc.
Water has gotten into the brake drum.
Apply brakes gently while driving the vehicle.
MAINTENANCE
Electric Equipment
Table 9: Electric Equipment
Problem
The power-charging indicator lamp does not
go out. Vehicle is hard to start.
Battery power is insufficient and is not charging while vehicle runs at a low speed.
There is abnormal noise when the generator
rotates.
Vehicle is hard to start.
Possible Cause
Possible Solution
Generator has been damaged.
Replace the generator.
Short in power-charging indicator circuit.
Check the circuit.
Belt is slipping.
Adjust the belt.
Battery has been damaged.
Service or replace the battery.
Generator has been damaged.
Replace the generator.
Belt is slipping.
Adjust the belt.
The belt is too loose, needs replacing, or
shakes when operating.
Adjust belt.
The bearings have been damaged or the
clearance in the bearings is too much.
Replace the bearings, or replace the generator.
The battery has no charge, an insufficient
charge, or the terminals may be dirty or
loosely connected.
Charge battery; ensure battery terminal connections are clean and securely fastened.
The starter switch contacts may be
dirty, there could be a short, or the starter
solenoid could need replacing.
Clean, repair or replace the switch or solenoid.
89
MAINTENANCE
Table 9: Electric Equipment
Problem
Engine turns over very slowly while starting.
Starting gear and starter ring gear do not
engage.
90
Possible Cause
Possible Solution
Battery power is insufficient, terminals are
loose or dirty.
Charge battery; clean, fasten, or replace terminals.
Connecting points of the switch on the engine
have been burned out and eroded. The armature shaft has bent or the copper sleeve has
been burned out.
Replace switch.
Electric brush has been worn down or elasticity of the electric brush is insufficient.
Replace brush.
Engine has not been preheated before starting when weather is too cold/lubricant viscosity is too high.
Preheat engine or replace lubricant suitable to
ambient temperature.
Igniting switch contact is bad or loose.
Clean/refasten the contact.
Relay wiring and the electromagnetic switch is
loose.
Secure wiring.
Starter solenoid winding is broken.
Replace solenoid winding.
Starter starting gear or starter ring gear has
been damaged.
Repair teeth, replace gear.
Synchromesh gear damaged.
Repair/replace gear.
Starter armature shaft is bent.
Replace armature shaft.
MAINTENANCE
Table 9: Electric Equipment
Problem
The starting gear of the starter remains
engaged.
Possible Cause
Possible Solution
The shaft sleeve of the starting gear is too
tight/jammed.
Replace, clean, and correct the shaft sleeve.
Too little clearance between the starting gear
and the flywheel tooth ring, or starter gears
have been damaged.
Adjust the clearance or replace the starting
gear.
The solenoid winding is dirty.
Clean winding.
The transmission fork-shaft has been jammed.
Clean/adjust the transmission fork shaft.
The synchromesh gear has been jammed.
Replace synchromesh gear.
EMERGENCY STARTING USING JUMPER CABLES
WARNING
The following procedures must be performed exactly as outlined, otherwise a fire or a battery explosion could result in property damage,
personal injury, or death.
1. Do not allow metal tools to contact positive terminal of battery to prevent shorting of the electrical system.
2. Place transmission in Neutral and set parking brake in both vehicles.
3. Shut off lights, heater, air conditioner and any other electrical loads in both vehicles.
4. Wear eye protection.
5. Make sure vehicle bodies are not touching.
6. Connect one of the first jumper cables to the positive terminal of the dead battery and then other end to the positive terminal of the booster battery.
7. Connect one of the second jumper cables to the negative terminal of the booster battery and then other end to the chassis of the dead battery
vehicle.
8. Reverse above procedure when removing the jumper cables.
91
MAINTENANCE
FUSE PANEL
WARNING
Electrical circuits are designed with a particular wire gauge to
meet the fuse and circuit breaker current rating. Do not increase
the size of fuse or circuit breaker, or change type of breaker supplied with your motor coach. To do so could cause wiring to overheat and possibly burn, resulting in a fire which could cause
property damage, personal injury or death.
CAUTION
No modification should be made to any motor coach control system without first contacting your LZ dealer.
Fuse panel can be found on wall at the rear of the luggage bay. Refer to
the schematic located on the fuse panel cover.
92
SCHEDULED MAINTENANCE
SCHEDULED MAINTENANCE
COMPONENT MANUFACTURER REFERRAL
GENERAL INFORMATION
The following maintenance schedule is supplied as a guideline. Refer to
each Original Equipment Manufacturers (OEM) maintenance manual
for the most updated and accurate information. This information is
readily available at www.lzbusline.com. Check www.lzbusline.com
for additional operation and maintenance services that may apply.
Maintenance must be performed to keep your motorcoach in good
operating condition. It is necessary to perform maintenance checks,
inspections, lubrication, cleaning, or other types of service. Regular
maintenance helps avoid potential problems and may help correct problems before they become serious.
The following maintenance schedule is arranged into mileage intervals.
The intervals listed are the maximum mileage intervals and should not
be exceeded. If your motorcoach is operated in a hilly terrain, or in a
dusty or sandy environment, you may need to reduce the time between
scheduled maintenance intervals. The maintenance schedule may be
copied and used as a checkoff sheet.
NOTE: Perform maintenance at whichever interval occurs first. When
reaching a particular level, inspect and perform all previous maintenance items that may be due.
OEM List
•
•
•
•
•
•
•
•
•
•
•
•
CATERPILLAR® C13 ENGINE
EATON ULTRASHIFT® TRANSMISSION
BENDIX® DISC BRAKES
ZF AXLES
MERITOR® ABS/ATC
PRESTLITE® ALTERNATORS
AIT HVAC
ACTIA® MULTIPLEX
ALCOA® RIMS
MICHELIN® TIRES
JVC® DVD/CD/RADIO
PUBLIC ADDRESS SYSTEM
93
SCHEDULED MAINTENANCE
2,400 MILE (4,000 km) MAINTENANCE INTERVAL
This maintenance interval includes the 2,400 mile (4,000 km) maintenance items.
Table 1: 2,400 Mile (4,000 km) Maintenance Interval
Item
Check
Accelerating and decelerating performances.
X
Engine exhaust system.
X
Leakage of air, fuel, lubricants, and coolant.
X
Lubricant levels and cleanliness.
X
Clean out the sediment in the fuel pre-filter.
X
Check belts for damage and tension.
X
Free play in the brake pedal.
X
Oil leakage in the steering mechanism and all power steering hydraulic lines. Power steering fluid/filter change intervals every 70,000 miles (112,655 km) is acceptable.
X
Oil leakage in the reduction final drive unit.
X
Clean the front and rear axles as well as the wheel assembly.
X
Check axle oil levels.
X
Torque of the various nuts/bolts in the steering system.
X
Free play of the steering wheel.
X
Torque of the steering gear.
X
Braking efficiency and the parking springs.
X
94
Clean
Lubricate
Replace
SCHEDULED MAINTENANCE
Table 1: 2,400 Mile (4,000 km) Maintenance Interval
Item
Check
Air leakage, damage, and connection condition in the soft and hard lines of the brake system.
X
Torque of the connecting bolts on the flange of the transmission crossing shaft.
X
Torque of the half-axle bolts.
X
Air pressure of the tires. Front axle 115 psi. Drive axle 90 psi. Tag axle 95 psi. Spare 115 psi.
X
Torque of the bolts and nuts on the wheels. 410 to 480 lb ft (550 to 650 Nm)
X
Unusual wear and tear on the tires.
X
Torque of the battery terminals and add distilled water to batteries as needed.
X
Torque of the connecting bolts on the chassis frame.
X
Clean
Lubricate
Replace
95
SCHEDULED MAINTENANCE
4,800 MILE (8,000 km) MAINTENANCE INTERVAL
This maintenance interval includes the 4,800 mile (8,000 km) maintenance items.
Table 2: 4,800 Mile (8,000 km) Maintenance Interval
Item
Check
Clean/replace the core of the air cleaner/filter. After initial service, 5,000 mile (8,047 km)
intervals is acceptable.
Inspect complete brake system operation.
96
Lubricate
X
X
X
Replace
X
X
Lubricate slack adjusters, if applicable.
Transmission and wet clutch service. See manufacturer’s manual at www.lzbusline.com
for additional information.
Clean
SCHEDULED MAINTENANCE
7,200 MILE (12,000 km) MAINTENANCE INTERVAL
This maintenance interval includes the 7,200 mile (12,000 km) maintenance items.
Table 3: 7,200 Mile (12,000 km) Maintenance Interval
Items
Check
Clean
Lubricate
Fuel filter and the oil-water separator.
X
Lubricant level of the reduction final drive and clean the ventilation plug.
X
Driveshaft U-joint and slip-joint every 10,000 miles (16,093 km).
X
Check for any loosening, or damage with the connecting components of the steering gear.
X
Check the tightness of the various components in the hydraulic system.
X
Check tightness and operation of the cross-shaft bearings on the transmission shaft and
on the flange nuts.
X
Check tires for irregular wear.
X
Lubricate the various lubricating points of the coach. After initial lubrication, 50,000 mile
(80,467 km) intervals is acceptable.
First Aid kit should be replenished every 10,000 miles (16,093 km).
Replace
X
X
X
97
SCHEDULED MAINTENANCE
14,400 MILE (24,000 km) MAINTENANCE INTERVAL
This maintenance interval includes the 14,400 mile (24,000 km) maintenance items.
Table 4: 14,400 Mile (24,000 km) Maintenance Interval
Item
Check
Check final drive unit fluid level and condition. After initial check; 250,000 mile (402,337
km) interval fluid change is acceptable.
X
Inspect the hydraulic oil in the power steering system as well as the filter core in the oil
reservoir. 70,000 mile (112,654 km) intervals to change filter & fluid is acceptable.
X
Check the wear of the brake disc and the brake pad lining.
X
Check air compressor operation.
X
98
Clean
Lubricate
Replace
SCHEDULED MAINTENANCE
21,600 MILE (36,000 km) MAINTENANCE INTERVAL
This maintenance interval includes the 21,600 mile (36,000 km) maintenance items.
Table 5: 21,600 Mile (36,000 km) Maintenance Interval
Item
Check
Check the condition of shock absorbers.
X
Inspect engine belt tensioner operation. After initial inspection, 25,000 mile (40,233 km)
intervals is acceptable. Daily belt tension check is required.
X
Check the operation & condition of the oil-feed pump.
X
Check the operating condition of the temperature regulator.
X
Check the operating conditions of the various bearings of the steering gear, the reduction
final drive, and the bearings of the rear axle.
X
Check the steering gear clearance and inspect for leakage.
X
Check for any wear or damage in the connecting portion of the tie rod and the steering
knuckle arm.
X
Check for any cracks on the steering knuckle, steering knuckle arm, and the connecting
portion between them.
X
Check the clearance between the steering knuckle and front axle.
X
Check tires for abnormal wear.
X
Check the steering angles of the front wheels.
X
Check the hydraulic oil pump.
X
Check the sealing efficiency of the brake valve as well as all other valves.
X
Clean
Lubricate
Replace
99
SCHEDULED MAINTENANCE
Table 5: 21,600 Mile (36,000 km) Maintenance Interval
Item
Check
Check the wheel braking chambers. After initial inspection, 100,000 mile (160,935 km)
interval inspection is acceptable.
X
Check the operating condition of the air dryer.
X
Check for any cracks on the welding seams of the chassis frame, body structure and all
other welded components. Check the tightness of the connecting bolts and the rivets.
X
Check oil cooler flow and temperature every 25,000 miles (40,233 km).
X
Clean
Lubricate
Replace
Clean
Lubricate
Replace
X
X
48,000 MILE (80,000 km) MAINTENANCE INTERVAL
This maintenance interval includes the 48,000 mile (80,000 km) maintenance items.
Table 6: 48,000 Mile (80,000 km) Maintenance Interval
Item
Check
Disassemble, clean and lubricate parking brake control valves.
Inspect accelerator pedal assembly every 48,000 mile (80,000 km).
X
Check function of shock absorbers.
X
Disassemble and check the parking and service brakes.
X
Grease axle bearings.
100
X
WARRANTY/CUSTOMER ASSISTANCE
WARRANTY/CUSTOMER ASSISTANCE
PRODUCT WARRANTY
CUSTOMER ASSISTANCE
LZ Busline, LLC
WARRANTY POLICY
Users should strictly adhere to operating manual recommendations.
Detailed warranty information is contained in the warranty supplements
delivered with the vehicle. Also see the Vehicle Identification Number
(VIN) specific warranty information for your motor coach available at
www.lzbusline.com.
LZ Busline, LLC
167 Lamp and Lantern Village,
No. 125, St. Louis,
MO 63017
Tel:314-579-9649
Fax: 314-878-6668
Limited Warranty
We encourage owners and operators of coaches sold by LZ Busline,
LLC. (hereinafter shown as “LZ”) to review this Limited Warranty.
Buyers submitting claims to LZ should have a clear knowledge
of the Limited Warranty coverage. The Buyer expressly accepts
this warranty as the sole warranty applicable to any new LZ coach
sold. PRODUCT IMPROVEMENT, SERVICE INFORMATION, FIELD
CHANGE, or CAMPAIGN PROGRAMS.
LZ publishes Product Improvement, Service Information Bulletins, and
Field Change Programs. When published, these bulletins and programs
will be posted online at www.lzbusline.com and also distributed to the
buyer on file with LZ.
www.lzbusline.com
101
WARRANTY/CUSTOMER ASSISTANCE
Limited Warranty Statement
Limited Warranty Coverage
THIS LIMITED WARRANTY IS FINAL, COMPLETE AND EXCLUSIVE.
THIS LIMITED WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER
WARRANTIES, EXPRESS OR IMPLIED, WHICH ARE HEREBY DISCLAIMED AND EXCLUDED BY LZ, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE OR USE, INCLUDING BUT
NOT LIMITED TO ANY AND ALL OBLIGATIONS OR LIABILITIES ON
THE PART OF LZ FOR DAMAGES ARISING OUT OF, OR IN CONNECTION WITH THE USE, REPAIR, OR PERFORMANCE OF THE
COACHES, TO THE EXTENT ALLOWED BY LAW. LZ SHALL NOT
BE LIABLE FOR INCIDENTAL, CONSEQUENTIAL OR PUNITIVE
DAMAGES. IN ADDITION, THE CUSTOMER WAIVES ALL LIABILITY
OF LZ FOR COMMERCIAL OR PERSONAL CONSEQUENTIAL AND
INCIDENTAL DAMAGES ARISING FROM CONTRACT, NEGLIGENCE, OR STRICT LIABILITY IN TORT. LZ NEITHER ASSUMES,
NOR AUTHORIZES ANY PERSON TO ASSUME FOR IT, ANY OTHER
OBLIGATION, OR LIABILITY IN CONNECTION WITH SUCH
COACHES.
LZ Bus' sole obligation and Customer's EXCLUSIVE REMEDY is limited to reimbursing Customer for the part(s) found to be defective in items manufactured by LZ
Bus. LZ Bus may at its option, furnish replacement part(s) for any such defective
part(s) to Customer and/or to reimburse Customer for reasonable direct labor cost
involved in removing and repairing or replacing any such part(s) which after examination disclose to LZ Bus's reasonable judgment to be thus defective within the
time period or mileage, whichever comes first, as specified in the Coverage Schedule. LZ Bus will reimburse the Customer for costs incurred in the removal and
replacement of defective part(s) based on the number of labor hours designated in
an industry standard Labor Time Guide. Guidelines for such work at the Current
warranty labor rate of $75/hr. All parts will be paid for prior to shipment. Upon
receipt of the Warranty cliam form and defective parts at the Chesterfield, MO
location all approved claims will be reimbursed.
This limited warranty is issued to the original buyer and will be transferred to subsequent owners only following an inspection of the coach
by a qualified LZ Technician and the payment of a three hundred-fifty
dollar ($350.00) transfer fee. The inspection must be done within 60
days of the sale of the coach. Subsequent owners will be charged for
this inspection. Coaches receiving a transferred limited warranty will
carry the remaining time of the original Limited Warranty.
102
Note:
Valid warranty claims must be filed and sent to LZ Bus within 30 days of the failure
date.
No labor will be reimbursed unless the failed part is returned to LZ Bus within 30
days
WARRANTY/CUSTOMER ASSISTANCE
Limited Warranty Coverage Schedule
Limited Engine And Transmission Coverage
Engine/Transmission Warranties are provided by Engine/Transmission
Manufacturers ONLY.
Table 1: Limited Warranty Coverage Schedule
Item
Limited
Warranty
Period
(Months)
Mileage
(MI)
Parts
Labor
General Coach
X
24
200,000
100%
100%
Structural Integrity
X
24
200,000
100%
100%
HVAC Systems
X
24
200,000
100%
100%
NOTES:
•
•
•
•
•
•
Limited Warranty is for the time (Months) or mileage (MI), whichever occurs first from the in-service date, as evidenced on the new
coach acceptance form completed at time of delivery to Owner.
Repairs under warranty are to be performed by a pre-authorized
facility at LZ’s sole discretion or by an authorized dealer of the
failed part manufacturer. Owner is entitled to perform the warranty
repair/replacement when qualified through appropriate training, service literature and service tools, as authorized by LZ at its sole discretion.
If a LZ Service Center makes repairs, a reasonable time is to be
allowed.
Limited Warranty Coverage does not apply to outside manufacturer- or dealer-installed options.
Warranty on the replacement part is limited to the remaining period/
mileage of the original part.
Add on options are subject to the original warranty from the Supplier.
Engine and transmission warranty service should be obtained directly
from the appropriate engine- or transmission-authorized dealer or distributor, which may be a LZ location. Refer to their Engine/Transmission manuals for the proper procedures.
•
•
•
For CATERPILLAR engine and transmission information and assistance 24 hours a day, 7 days a week, call 1-800-447-4986 and have
your engine serial number available when you call.
For CUMMINS engine information and assistance 24 hours a day,
7 days a week, call 1-800-DIESELS (1-800-343-7357).
For EATON transmission information and assistance 24 hours a
day, 7 days a week, call 1-800-826-HELP (4357).
103
WARRANTY/CUSTOMER ASSISTANCE
Extended Coverage
Paint
If not obtained at time of purchase, engine and transmission extended
coverage may be purchased through the manufacturer's dealer or distributor within the following time frame:
•
•
Table 2: Extended Coverage Schedule
Manufacturer
Duration
Cummins Engine
Within the first 90 days
Caterpillar Engine and Transmission
Within the first 12 months
104
•
If paint repairs are to be made, and the cost estimate exceeds
$300, pre-authorization from LZ is required.
For such repairs, submit a complete estimate with pictures and a
completed Warranty Claim Form to LZ Busline, LLC,
167 Lamp and Lantern Village,No. 125, St. Louis,MO 63017.
Upon approval, LZ reserves the right to examine the repair or send
a technician to observe the repair.
WARRANTY/CUSTOMER ASSISTANCE
Limited Warranty Shall Not Apply To:
•
•
•
•
•
•
•
•
Failures to observe or follow applicable manuals and directives,
including engine operation and maintenance manuals, transmission
operation and service manuals, and any other manuals or manufacturer's directives, including normal maintenance schedules and/or
intervals or lack of maintenance.
Any misuse, negligence, alteration(s), accident, etc., other than
normal commercial use, over-speeding or loading beyond the applicable weight ratings, or any other conditions that, in LZ's sole discretion, affect adversely the coach's performance and reliability.
Any aftermarket or other part or modification not supplied to Customer with the coach or resulting from conversion or installation of
non-LZ equipment and part(s).
Normal maintenance services (such as engine tune-up, fuel and
cooling system, cleaning, brake adjustments and wheel alignment
and balancing) or any replacement parts specified in the maintenance manual or instructions, such as hoses, belts, seals and filter
elements and lubricants (used in connection with normal maintenance services) or lubricants, anti-freeze or all maintenance items
used in the repairs or replacements of defective parts.
The normal wear and tear of parts such as, but not limited to, tires,
batteries, clutches, brake linings, brake rotors, shock absorbers,
voltage regulators, wiper blades, and air cushions.
Glass breakage.
Any parts which are modified or rebuilt without prior written
approval by LZ.
Damage to another part or parts of the vehicle or greater damage to
the defective part, resulting from a non-remedied defect or continued driving.
•
•
•
•
•
•
•
•
Damage as a result of the use of unapproved lubricants and/or
cooling mixture (antifreeze and anti corrosion additives) or the
release of lubricants.
A repeated repair job as a consequence of wrong diagnosis or poor
workmanship.
Any indirect costs and expenses such as, but not limited to, towing,
overtime premium, call-out and hire-in, mileage, downtime
expenses, replacement vehicles, diagnosis, test rides, cleaning
material, travel expenses, bills for hotels, meals, fax and phone,
delivery of the defective part or coach to the repair facility, loss of
time, inconvenience, loss of use of the coach, or lost profits or revenues.
Any coach on which odometer mileage has been changed.
Damage from the environment, including airborne fallout (chemicals, tree sap, etc.) salt, hail, windstorm, lightening, etc.
Normal deterioration of soft trim and appearance items due to wear
and exposure.
Paint deterioration or damage due to the use of aggressive cleaning detergents, chemicals, and agents derived from petroleum
products not released for motor vehicles.
Any coach registered and normally operated outside the United
States of America or Canada.
Limited Warranty is offered in accordance with the applicable manufacturer's standard engine and transmission procedures in the USA and
Canada.
Contact your nearest engine and transmission dealer for additional
detailed information on their Limited Warranty.
105
WARRANTY/CUSTOMER ASSISTANCE
Customer's Responsibility
•
•
•
•
•
•
•
106
Maintain the coach properly (observing maintenance schedules/
intervals) using all appropriate manuals and bulletins, such as
engine, transmission, A/C, and accessory operating, service and
maintenance manuals (and any other pertinent manuals or manufacturer communications).
Carry out normal service tasks such as (but not limited to) headlight
adjustment, wheel balance and alignment, brake adjustment, door
adjustment/alignment, and all normal fitting, bolt and nut tightening
and securing.
Furnish all normal consumable and service items such as (but not
limited to) filters, hoses, belts, seals, fluids, fuses, bulbs, wipers and
blades, brake and clutch linings, diaphragms, shocks and other normal wear items.
Insure that all wiring, lines and hoses are properly maintained and
routed.
Pay all costs required for tasks such as (but not limited to) temporary or minor repairs, repairs required by poor installation or lack of
proper care, misdiagnosis, consequent damage to other parts,
increased damage because of repair delay, use of improper or
unapproved fluids, or improper repair and diagnosis.
Pay all costs required for normal maintenance and service such as
(but not limited to) meals/lodging/travel time, towing, vehicle rental,
lost operating time and profit/revenue, and any other such costs
incurred.
Record and preserve repair, service and maintenance records to be
able to provide documentation of any submitted warranty claim.
Return all parts to
LZ Busline, LLC
167 Lamp and Lantern Village,
No. 125, St. Louis,MO 63017
or as instructed by LZ. No warranty claim will be approved unless
failed parts are received by LZ within thirty (30) days from the claim
date. If a failed part is not returned, customer will be billed for the new
part and no repair labor cost will be reimbursed.
This list is not intended to be complete nor to represent all customer
responsibilities. Customers should use good judgement in all warranty
matters.
WARRANTY/CUSTOMER ASSISTANCE
Obtaining Warranty Service
Shipping Charges For Warranty Parts
Any time you may think you have a warranty issue with a LZ motor
coach,
All warranty replacement parts will be shipped by prepaid ground
freight. If requested from the customer and authorized by LZ Customer
Care Representative, the part(s) may be expedited with special delivery
from a LZ location to a repair facility if the coach is in an Emergency
Coach Down situation, as determined by LZ in its sole discretion, and
in need of emergency warranty parts to make it drivable. This is covered by warranty only when authorized by a LZ Customer Care Representative.
1.Have your coach's VIN, in-service date, actual mileage and customer
name handy.
2.Go online to "lzbusline.com" using your customer log-in and fill out a
warranty claim form, OR
3.Call 314-45BYLZ (314-579-9649) during business hours, ask for
"warranty," and speak directly to a qualified LZ warranty specialist.
4.If parts are shipped to you, a warranty claim form tag and return shipping label will accompany each part. You must complete this warranty
claim form tag for each part and return it with each warranted part to
LZ within 30 days.
Warranty Parts Handling
LZ shall provide the replacement parts at "No Charge" to the OWNER
PENDING THE SETTLEMENT OF THE CLAIM. Accompanying each
part will be a (1) warranty claim form tag and a (2) return shipping label.
Any and all parts replaced in warranty must be tagged with a completed
warranty claim form tag and returned within 30 days after filing a claim
with LZ, using that shipping label. In the event the failed part is not
returned within 30 days, the Buyer will be billed for the new part that
was originally supplied at "No Charge." Parts that are replaced at "No
Charge" in warranty that prove not to be defective will be returned and
CHARGED BACK TO THE OWNER.
107
WARRANTY/CUSTOMER ASSISTANCE
Product Improvement, Service Information, Field
Change Or Campaign Programs
LZ publishes Product Improvement, Service Information Bulletins, and
Field Change Programs. When published, these bulletins and programs
will be posted online at www.lzbusline.com and also distributed to the
Buyer on file with LZ.
Product Improvement Bulletins go to the registered Owner and will
detail the new improvements made to coaches in production. Should
the Owner wish to update its coaches, sufficient information will be
available to accomplish the improvement. Product improvements are to
be applied to the coach at the Owner's option and expense.
Service Information Bulletins go to the registered Owner. They will
cover a variety of topics that will help the Owner better maintain the
coach with the most up-to-date information available.
Field Change or Campaign Programs. These may be necessary to
make corrections or improvements to the coaches to ensure maintenance of satisfactory standards and compliance with applicable laws.
When this occurs, the LZ Service Department will notify the Owner.
The Field Changes should be made as soon as possible after receiving
this notice. Instructions for claiming repair expenses shall be set forth
in the applicable bulletins of the Field Change or Campaign Programs.
108
FALCON 45 MOTOR COACH
167 Lamp and Lantern Village,
No. 125, St. Louis, MO 63017
Tel.: 314-579-9649
Fax: 314-878-6668
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement