Service Manual - Grande West Transportation Group · vicinity service manual part i version 1.0 1.0 author: a. kedans return to main index table of contents table of contents .....1.0

Service Manual

Part I

VICINITY SERVICE MANUAL PART I

VERSION 1.0

1.0 AUTHOR: A. KEDANS

RETURN TO MAIN INDEX

TABLE OF CONTENTS

Table of Contents ....................................................................................................................................................... 1.0

Chapter 1 GENERAL INFORMATION ........................................................................................................................... 1.1

INTRODUCTION ...................................................................................................................................................... 1.1

Overview ............................................................................................................................................................. 1.1

Service Assistance ............................................................................................................................................... 1.1

Units and Conversions ........................................................................................................................................ 1.1

HEALTH AND SAFETY .............................................................................................................................................. 1.2

Warning Symbols ................................................................................................................................................ 1.2

Personal Safety ................................................................................................................................................... 1.2

Hazardous Materials ........................................................................................................................................... 1.2

Battery Acid .................................................................................................................................... 1.2

Coolant ........................................................................................................................................... 1.2

Oil and Hydraulic Fluid ................................................................................................................... 1.2

Friction Material Dust .................................................................................................................... 1.3

Insulation Material ......................................................................................................................... 1.3

Diesel Fuel ...................................................................................................................................... 1.3

DPF Exhaust System ....................................................................................................................... 1.3

Exhaust Emissions .......................................................................................................................... 1.3

Environmental Warnings .................................................................................................................................... 1.3

Working On the Vehicle ...................................................................................................................................... 1.3

VEHICLE IDENTIFICATION ....................................................................................................................................... 1.4

TORQUE CHARTS .................................................................................................................................................... 1.5

Chapter 2 MAINTENANCE ........................................................................................................................................... 2.1

DAILY MAINTENANCE CHECKS ................................................................................................................................ 2.1

Checking Engine Oil Level ................................................................................................................................... 2.1

Checking Coolant Level ....................................................................................................................................... 2.1

Checking Transmission Oil Level ......................................................................................................................... 2.2

Checking Power Steering Fluid ........................................................................................................................... 2.2

Air Filter Minder ................................................................................................................................................. 2.3

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Fuel Filter and Water Trap .................................................................................................................................. 2.3

A/C Drive Belts .................................................................................................................................................... 2.3

A/C Compressor .................................................................................................................................................. 2.4

Alternator ........................................................................................................................................................... 2.4

TOWING AND LIFTING ............................................................................................................................................ 2.5

Towing ................................................................................................................................................................ 2.5

Lifting .................................................................................................................................................................. 2.6

LUBRICATION POINTS ............................................................................................................................................. 2.7

List of Lubricants ................................................................................................................................................. 2.8

Chapter 3 SERVICE SCHEDULES .................................................................................................................................. 3.1

ENGINE SCHEDULE .................................................................................................................................................. 3.1

TRANSMISSION SCHEDULE ..................................................................................................................................... 3.2

DRIVE SHAFT SCHEDULE ......................................................................................................................................... 3.2

REAR AXLE SCHEDULE ............................................................................................................................................. 3.2

FRONT AXLE & SUSPENSION SCHEDULE ................................................................................................................. 3.3

PNEUMATIC/BRAKE SYSTEM SCHEDULE ................................................................................................................ 3.3

ENGINE COOLING SYSTEM SCHEDULE .................................................................................................................... 3.4

ELECTRICAL SYSTEM SCHEDULE .............................................................................................................................. 3.4

AFTERTREATMENT/EXHAUST SYSTEM SCHEDULE .................................................................................................. 3.5

HVAC SCHEDULE ..................................................................................................................................................... 3.5

STEERING/HYDRAULIC SYSTEM SCHEDULE ............................................................................................................ 3.6

AIR SUSPENSION SYSTEM SCHEDULE ..................................................................................................................... 3.6

TIRE & WHEEL SCHEDULE ....................................................................................................................................... 3.7

Chapter 4 ENGINE ....................................................................................................................................................... 4.1

OVERVIEW .............................................................................................................................................................. 4.1

Description .......................................................................................................................................................... 4.1

Specifications ...................................................................................................................................................... 4.1

Maintenance ....................................................................................................................................................... 4.1

Mounting ............................................................................................................................................................ 4.1

Torque Specifications ..................................................................................................................... 4.2

STARTING SYSTEM .................................................................................................................................................. 4.4


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Overview ............................................................................................................................................................. 4.4

Rotation Check .................................................................................................................................................... 4.4

Maintenance ....................................................................................................................................................... 4.4

COOLING SYSTEM ................................................................................................................................................... 4.5

Description .......................................................................................................................................................... 4.5

Specifications ................................................................................................................................. 4.5

Schematic ........................................................................................................................................................... 4.6

Radiator .............................................................................................................................................................. 4.7

Mounting ........................................................................................................................................ 4.7

Maintenance .................................................................................................................................. 4.7

Cleaning .......................................................................................................................................... 4.7

Mounting Diagram ......................................................................................................................... 4.8

Cooling Fans ........................................................................................................................................................ 4.9

Diagnosing for Repairs ................................................................................................................... 4.9

Replacing diagnostic LED bulb ....................................................................................................... 4.9

Coolant ............................................................................................................................................................... 4.9

Coolant Low Level Indicator ......................................................................................................... 4.10

Coolant Hoses .............................................................................................................................. 4.10

Pressure Testing ........................................................................................................................... 4.10

Filling ............................................................................................................................................ 4.10

Draining ........................................................................................................................................ 4.11

Flushing ........................................................................................................................................ 4.11

AIR INTAKE SYSTEM .............................................................................................................................................. 4.12

Description ........................................................................................................................................................ 4.12

Air Filter ............................................................................................................................................................ 4.12

Charge Air Cooler .............................................................................................................................................. 4.13

Maintenance ................................................................................................................................ 4.13

Mounting ...................................................................................................................................... 4.13

Diagram ........................................................................................................................................ 4.13

Alternator Mounting ......................................................................................................................................... 4.14

FUEL SYSTEM ........................................................................................................................................................ 4.15


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Description ........................................................................................................................................................ 4.15

Diagram ............................................................................................................................................................ 4.16

Fuel Requirements ............................................................................................................................................ 4.17

Primary Fuel Filter ............................................................................................................................................ 4.17

Water Separator .......................................................................................................................... 4.17

Replacing Primary Fuel Filter ....................................................................................................... 4.17

Secondary Fuel Filter ........................................................................................................................................ 4.17

Fuel Tank Maintenance .................................................................................................................................... 4.18

Priming the fuel system ............................................................................................................... 4.18

Fuel Drain ..................................................................................................................................... 4.18

EXHAUST SYSTEM ................................................................................................................................................. 4.19

Description ........................................................................................................................................................ 4.19

Mounting .......................................................................................................................................................... 4.19

SCR System ....................................................................................................................................................... 4.21

Description ................................................................................................................................... 4.21

Diesel Exhaust Fluid ..................................................................................................................... 4.21

Testing ...................................................................................................................................... 4.21

DEF Dosing Module ...................................................................................................................... 4.22

Maintenance ............................................................................................................................ 4.22

Aftertreatment ............................................................................................................................. 4.22

Diesel Particulate Filter ................................................................................................................ 4.24

Maintenance ............................................................................................................................ 4.25

Regeneration ................................................................................................................................ 4.25

Passive Regeneration ............................................................................................................... 4.25

Active Regeneration ................................................................................................................. 4.25

Stationary Regeneration .......................................................................................................... 4.26

Warning Lamps ................................................................................................................................................. 4.26

Malfunction Indicator .................................................................................................................. 4.26

Aftertreatment Diesel Particulate Filter ...................................................................................... 4.27

High Exhaust System Temperature .............................................................................................. 4.27

Aftertreatment Diesel Exhaust Fluid ............................................................................................ 4.27


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DEF Tank ........................................................................................................................................................... 4.28

Filling ............................................................................................................................................ 4.28

Maintenance ................................................................................................................................ 4.28

Exterior Cleaning ...................................................................................................................... 4.28

Interior Cleaning ...................................................................................................................... 4.29

DEF Cap Cleaning ..................................................................................................................... 4.29

Draining .................................................................................................................................... 4.30

Chapter 5 TRANSMISSION .......................................................................................................................................... 5.1

ZF-ECOLIFE .............................................................................................................................................................. 5.1

Overview ............................................................................................................................................................. 5.1

Specifications ...................................................................................................................................................... 5.1

Towing ................................................................................................................................................................ 5.1

Oil Level .............................................................................................................................................................. 5.2

Recommended Lubricants ............................................................................................................. 5.2

Checking oil level ............................................................................................................................ 5.2

Changing oil .................................................................................................................................... 5.3

Maintenance ....................................................................................................................................................... 5.3

Mounting ............................................................................................................................................................ 5.4


Transmission to Engine Connection ............................................................................................... 5.5

Gear Selector ...................................................................................................................................................... 5.6

Diagnostics ..................................................................................................................................... 5.6

Retarder .............................................................................................................................................................. 5.6

Operation ....................................................................................................................................... 5.6

Deactivation ................................................................................................................................... 5.7

Activation ....................................................................................................................................... 5.7

ZF-ECOMAT 4 .......................................................................................................................................................... 5.9

Overview ............................................................................................................................................................. 5.9

Specifications ...................................................................................................................................................... 5.9

Towing ................................................................................................................................................................ 5.9

Oil Level ............................................................................................................................................................ 5.10


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RECOMMENDED LUBRICANTS ..................................................................................................... 5.10

Checking oil level .......................................................................................................................... 5.10

Changing oil .................................................................................................................................. 5.11

Maintenance ..................................................................................................................................................... 5.12

Mounting .......................................................................................................................................................... 5.12

Transmission to Engine Connection ............................................................................................. 5.12

Diagram ........................................................................................................................................ 5.13

Torque Specifications ................................................................................................................... 5.14

Gear Selector .................................................................................................................................................... 5.14

Diagnostics ................................................................................................................................... 5.14

Retarder Activation ........................................................................................................................................... 5.15

10-Pin Plug ................................................................................................................................... 5.15

22-Pin Plug ................................................................................................................................... 5.16

Retarder Diagram ......................................................................................................................... 5.17

DRIVE SHAFT ......................................................................................................................................................... 5.18

Description ........................................................................................................................................................ 5.18

Inspection ......................................................................................................................................................... 5.18

Lubrication ........................................................................................................................................................ 5.18

Removal ............................................................................................................................................................ 5.18

Chapter 6 FRONT SUSPENSION AND STEERING .......................................................................................................... 6.1

FRONT SUSPENSION ............................................................................................................................................... 6.1

Description .......................................................................................................................................................... 6.1

Maintenance ....................................................................................................................................................... 6.1

Checking Height .................................................................................................................................................. 6.2

Complete Assembly Diagram .............................................................................................................................. 6.3

Upper Control Arm Diagram ............................................................................................................................... 6.4

Lower Control Arm Diagram ............................................................................................................................... 6.5

STEERING ................................................................................................................................................................ 6.6

Overview ............................................................................................................................................................. 6.6

Inspection ........................................................................................................................................................... 6.6

Checking Ball Joints ........................................................................................................................ 6.6


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Axial End Float ............................................................................................................................ 6.7

Radial End Float.......................................................................................................................... 6.7

Maintenance ....................................................................................................................................................... 6.7

Changing Steering Fluid ................................................................................................................. 6.7

Changing Filter Element ................................................................................................................. 6.8

Bleeding Steering Gear .................................................................................................................. 6.9

Diagram ............................................................................................................................................................ 6.10

Torque Specifications ....................................................................................................................................... 6.11

Hydraulic System .............................................................................................................................................. 6.11

Maintenance ................................................................................................................................ 6.11

Diagram ............................................................................................................................................................ 6.12

Chapter 7 REAR SUSPENSION/AXLE ............................................................................................................................ 7.1

REAR SUSPENSION .................................................................................................................................................. 7.1

Description .......................................................................................................................................................... 7.1

Torque Specifications ......................................................................................................................................... 7.1

Maintenance ....................................................................................................................................................... 7.1

Checking Shock Absorbers .................................................................................................................................. 7.2

Checking Height .................................................................................................................................................. 7.2

Diagram .............................................................................................................................................................. 7.3

ECAS ........................................................................................................................................................................ 7.4

Overview ............................................................................................................................................................. 7.4

Electronic Control Unit ....................................................................................................................................... 7.4

Indicator Lamp .................................................................................................................................................... 7.4

Maintenance ....................................................................................................................................................... 7.5

Height Measurement .......................................................................................................................................... 7.5

Air Diagram ......................................................................................................................................................... 7.6

REAR AXLE ............................................................................................................................................................... 7.7

Description .......................................................................................................................................................... 7.7

Specifications ...................................................................................................................................................... 7.7

Maintenance ....................................................................................................................................................... 7.7

Checking Oil.................................................................................................................................... 7.7


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Draining Oil .................................................................................................................................... 7.8

Filling Oil ......................................................................................................................................... 7.8

Chapter 8 PNEUMATIC SYSTEM .................................................................................................................................. 8.1

AIR SUPPLY .............................................................................................................................................................. 8.1

Description .......................................................................................................................................................... 8.1

Condenser ........................................................................................................................................................... 8.1

Maintenance .................................................................................................................................. 8.1

Cleaning .......................................................................................................................................... 8.2

Air Dryer and Reservoirs ..................................................................................................................................... 8.2

Charge Cycle ................................................................................................................................... 8.3

Diagram .......................................................................................................................................... 8.4

Maintenance .................................................................................................................................. 8.5

Testing ............................................................................................................................................ 8.6

Leak Testing ........................................................................................................................................................ 8.6

Air System Diagram ............................................................................................................................................ 8.7

BRAKING SYSTEM.................................................................................................................................................... 8.8

Description .......................................................................................................................................................... 8.8

Disc Brakes .......................................................................................................................................................... 8.8

Brake Actuation.............................................................................................................................. 8.8

Brake Release ................................................................................................................................. 8.8

Brake Adjustment (Automatic) ...................................................................................................... 8.8

Front/Rear Disc Brake Sectioned View ............................................................................................................... 8.9

Brake Pads .................................................................................................................................... 8.10

Inspection ................................................................................................................................. 8.10

Replacing .................................................................................................................................. 8.10

Brake Discs ........................................................................................................................................................ 8.10

Inspection ..................................................................................................................................... 8.10

Removal ....................................................................................................................................... 8.11

Assembly ...................................................................................................................................... 8.12

Rear Brakes ....................................................................................................................................................... 8.12

Brake Pads .................................................................................................................................... 8.12


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Inspection ................................................................................................................................. 8.12

Replacing .................................................................................................................................. 8.12

Setting Clearance ..................................................................................................................... 8.13

Wear Sensor ............................................................................................................................. 8.13

Spring Brakes .................................................................................................................................................... 8.13

Replacing Brake Chambers .......................................................................................................... 8.13

Maintenance ................................................................................................................................ 8.14

Brake Testing ................................................................................................................................ 8.14

Parking/Emergency Brake ................................................................................................................................ 8.14

Emergency Brake Application ...................................................................................................... 8.14

ABS/ATC ............................................................................................................................................................ 8.15

Diagnostics ................................................................................................................................... 8.15

Pressure Modulator Valves .......................................................................................................... 8.15

Traction Control Valve ................................................................................................................. 8.16

Wheel Speed Sensor .................................................................................................................... 8.16

System Diagram ................................................................................................................................................ 8.17

Chapter 9 ELECTRICAL SYSTEM ................................................................................................................................... 9.1

SYSTEM AND COMPONENTS .................................................................................................................................. 9.1

Description .......................................................................................................................................................... 9.1

Precautions ......................................................................................................................................................... 9.1

Electrical Compartment ...................................................................................................................................... 9.1

Diagnostic Switches ....................................................................................................................... 9.2

Alternator ........................................................................................................................................................... 9.2

Regulator ........................................................................................................................................ 9.2


Alternator Drive Belt ...................................................................................................................... 9.2

Starter ................................................................................................................................................................. 9.3

Maintenance .................................................................................................................................. 9.3

Replacing ........................................................................................................................................ 9.3

BATTERIES ............................................................................................................................................................... 9.5

Overview ............................................................................................................................................................. 9.5


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Safety Precautions .............................................................................................................................................. 9.5

Inspection ........................................................................................................................................................... 9.5

Battery Disconnect Switch .................................................................................................................................. 9.5

Rapid Check ........................................................................................................................................................ 9.6

Discharge Testing ................................................................................................................................................ 9.6

Corrosion ............................................................................................................................................................ 9.6

Charging .............................................................................................................................................................. 9.6

Deep Cycling ................................................................................................................................... 9.7

MULTIPLEX SYSTEM ................................................................................................................................................ 9.8

Overview ............................................................................................................................................................. 9.8

Multiplex Nodes.................................................................................................................................................. 9.8

Multiplex Module ........................................................................................................................... 9.8

CAN Diagram ....................................................................................................................................................... 9.9

Display Panel Standard Symbols ....................................................................................................................... 9.10

LCD Display Icons .............................................................................................................................................. 9.11

Driver’s Station General Layout ........................................................................................................................ 9.12

Left Front Dash ................................................................................................................................................. 9.13

Auxiliary Heater Switch ................................................................................................................ 9.13

Driver’s Floor Heater Switch ........................................................................................................ 9.13

Instrument Dimmer Switch .......................................................................................................... 9.13

Right Front Dash ............................................................................................................................................... 9.14

Defroster Dials ............................................................................................................................. 9.14

Transmission Gear Selector ......................................................................................................... 9.14

Ramp Buttons............................................................................................................................... 9.14

Level Switch.................................................................................................................................. 9.14

Upper Side Console........................................................................................................................................... 9.15

Reading Light Switch .................................................................................................................... 9.15

Parking Brake Lever...................................................................................................................... 9.15

Master Switch .............................................................................................................................. 9.15

Passenger Overhead Lights Switch .............................................................................................. 9.15

Hazard Lights Switch .................................................................................................................... 9.15


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Door Handle ................................................................................................................................. 9.16

Windshield Wiper Control Switch ................................................................................................ 9.16

Diagram ........................................................................................................................................ 9.17

Lower Side Console ........................................................................................................................................... 9.18

Light/Buzzer Test Switch .............................................................................................................. 9.18

ECAS Level II Switch ..................................................................................................................... 9.18

Passenger Floor Heater Fan Switch ............................................................................................. 9.18

Stop Request Buzzer Prohibit Switch ........................................................................................... 9.18

Windshield Washer Switch .......................................................................................................... 9.18

HVAC Control Switch .................................................................................................................... 9.18

Regeneration Switches ................................................................................................................ 9.18

Engine Fast Idle Switch................................................................................................................. 9.18

Interlock Bypass Toggle ................................................................................................................ 9.18

SOS Emergency Toggle ................................................................................................................. 9.18

Diagram ........................................................................................................................................ 9.19

DESTINATION SIGNS ............................................................................................................................................. 9.20

Overview ........................................................................................................................................................... 9.20

Front Destination Sign ...................................................................................................................................... 9.20

Side Destination Sign ........................................................................................................................................ 9.20

Rear Destination Sign ....................................................................................................................................... 9.20

Control Console ................................................................................................................................................ 9.20

Maintenance ..................................................................................................................................................... 9.21

Cleaning ........................................................................................................................................ 9.21

Fuse Replacement ........................................................................................................................ 9.21

Required Fuses ......................................................................................................................... 9.22

Chapter 10 WHEELS AND TIRES ................................................................................................................................ 10.1

WHEELS ................................................................................................................................................................. 10.1

Inspection ......................................................................................................................................................... 10.1

Safety Precautions ............................................................................................................................................ 10.1

Cleaning ............................................................................................................................................................ 10.1

Fitting ................................................................................................................................................................ 10.1


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TIRES ..................................................................................................................................................................... 10.2

Safety Precautions ............................................................................................................................................ 10.2

Tire Pressure ..................................................................................................................................................... 10.2

Tire Replacement .............................................................................................................................................. 10.2

Chapter 11 HVAC ...................................................................................................................................................... 11.1

HEATING SYSTEM .................................................................................................................................................. 11.1

Auxiliary Heater ................................................................................................................................................ 11.1

Servicing ....................................................................................................................................... 11.1

Maintenance ................................................................................................................................ 11.1

Heater/Defroster .............................................................................................................................................. 11.2

Components ................................................................................................................................. 11.3

Diagram ............................................................................................................................................................ 11.4

AIR CONDITIONING SYSTEM ................................................................................................................................. 11.5

Description ........................................................................................................................................................ 11.5

Components ..................................................................................................................................................... 11.5

Control Panel .................................................................................................................................................... 11.5

Maintenance ..................................................................................................................................................... 11.5

HVAC Activation ................................................................................................................................................ 11.6

A/C Compressor ................................................................................................................................................ 11.6

Chapter 12 WINDSHIELD .......................................................................................................................................... 12.1

WIPER SYSTEM ...................................................................................................................................................... 12.1

Description ........................................................................................................................................................ 12.1

Maintenance ..................................................................................................................................................... 12.1

Preventative Maintenance ........................................................................................................... 12.1

Wiper Arm Replacement .................................................................................................................................. 12.1

Alignment ......................................................................................................................................................... 12.2

Road Side ..................................................................................................................................... 12.2

Curb Side ...................................................................................................................................... 12.2

Adjustment ....................................................................................................................................................... 12.2

Alignment Diagram ........................................................................................................................................... 12.3

Adjustment Diagram ......................................................................................................................................... 12.4


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WASHER SYSTEM .................................................................................................................................................. 12.5

Description ........................................................................................................................................................ 12.5

Washer Fluid ..................................................................................................................................................... 12.5

Washer Fluid Reservoir ..................................................................................................................................... 12.5

Filling ............................................................................................................................................ 12.6


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CHAPTER 1 GENERAL INFORMATION

INTRODUCTION

OVERVIEW

This manual contains information on the maintenance of vehicles manufactured by Grande West Transportation

International Ltd. This information applies to original equipment and recommended optional equipment.

Regular preventive maintenance and repairs are essential to the safe and reliable operation of the Vicinity bus. The

recommended procedures described in this manual are the most efficient way to carry out maintenance of the bus.

These methods may involve the use of special purpose tools, which should be used according to the

recommendations provided.

All of the information contained in this manual is based on the most up-to-date data available at the time of

publishing. Grande West Transportation International Ltd. reserves the right to change the procedures, materials,

specifications, dimensions or design of the vehicle shown, described or referred to herein at any time and without

prior notice in accordance with the Company's policy of constant product improvement.

SERVICE ASSISTANCE

Grande West Transportation International Ltd.

3168 262 St. Aldergrove, BC

Canada V4W 2Z6

For technician support, call 1-855-381-3303 or visit www.grandewest.com

UNITS AND CONVERSIONS

Measurements are given using the Metric system. A conversion to the Imperial system is offered in most cases.

Below is a table of the most commonly used Metric units, their abbreviations, and their Imperial equivalents.

Metric Imperial

Kilometre (km) Mile (mi)

Metre (m) Foot (ft)

Millimetre (mm) Inch (in)

Kilogram (kg) Pound (lb)

Gram (g) Ounce (oz)

Litre (l) Gallon (gal)

Newton metre (Nm) Pound-foot (lb-ft)

Kilopascal (kPa) Pound per square inch (psi)

Degrees Celsius (°C) Degrees Fahrenheit (°F)

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HEALTH AND SAFETY

WARNING SYMBOLS

Please take note of the following symbols, which are

used throughout this manual to identify potential

health hazards or to provide instructions to prevent

any personal injuries or damage to the vehicle and its

components.

CAUTION: Information with this heading serves as a

reminder of an operation that could result in vehicle

damage if not followed properly.

Note: This heading contains a tip and/or unique

procedure for servicing the vehicle.

PERSONAL SAFETY

Remove rings, watches, and all other jewelry before

working on the vehicle.

Always wear head and eye protection when working

underneath the vehicle.

Wear gloves or use barrier cream to protect hands.

Tie long hair back and keep loose clothing away from

moving parts.

HAZARDOUS MATERIALS

BATTERY ACID

Diluted sulphuric acid can cause skin burns, eye

damage, and internal damage if ingested. Vapour

from the solution can also irritate the respiratory

system and eyes. Take care when topping up or

carrying the battery. Since hydrogen gas is given off

by the battery, it is highly explosive and a naked flame

should never come within close proximity.

COOLANT

Cooling system antifreeze contains ethylene glycol

and therefore is highly toxic if ingested. Do not allow

coolant to come into contact with the skin or eyes as

it can be absorbed through the skin and causes

irritation.

OIL AND HYDRAULIC FLUID

Oil contains small amounts of polycyclic aromatic

hydrocarbons, which can cause irritation, dermatitis,

and acne if it comes into repeated contact with the

skin. Toxicity through ingestion of oil or hydraulic fluid

is of a low order, however this should be avoided. If it

is swallowed or comes into contact with the eyes,

seek medical advice immediately.

WARNING

Information in this box contains safety

instructions that, if not strictly adhered to, could

result in environmental damage, personal injury,

or death.

WARNING

Certain components on the vehicle contain or

may produce material that must be handled with

caution. The below listed materials must NOT be

ingested or come into contact with the eyes, skin,

or mouth.

WARNING

The following are general instructions for your

own safety and are by no means comprehensive.

Assess each situation according to its various

health, safety, and environmental risks.


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FRICTION MATERIAL DUST

Friction material dust may contain a high percentage

of white asbestos bonded in a resin. Handling and

fitting lined brake shoes or clutch plates is not

regarded as a health risk. When working around dust

produced by worn linings dust masks should be worn.

However, it is necessary to avoid generating airborne

dust concentration, therefore an approved vacuum

cleaner or damp cloth should be used for dust

removal.

INSULATION MATERIAL

Insulation materials include man-made fibres, such as

glass, rock, slag, and metal oxides. Contact with these

may cause skin irritation. Inhalation of dust from the

fibres should be avoided and proper mask and gloves

should be worn when working in direct exposure.

DIESEL FUEL

Skin contact with diesel fuel may cause irritation and

dermatitis. Inhalation and ingestion are major risks

and can cause serious medical problems. If swallowed

or contact is made with the eyes, seek medical

attention immediately.

DPF EXHAUST SYSTEM

During regeneration, exhaust gas temperatures can

reach 800°C (1500°F), and exhaust system surface

temperature could exceed 700°C (1300°F). These

temperatures are hot enough to ignite or melt

common materials, and to cause serious burns.

EXHAUST EMISSIONS

Exhaust emissions can be highly toxic if inhaled in

sufficient quantity. Avoid exposure to emissions in

enclosed spaces and use adequate extraction devices.

ENVIRONMENTAL WARNINGS

Used engine oil, hydraulic fluid, transmission fluid,

coolant/antifreeze, batteries, and tires can pose a

serious threat to personal health and the

environment. These materials must be disposed of in

a safe and environmentally responsible manner.

These items must never be disposed of using

household refuse bins or by pouring down drains.

Observe local regulations and laws pertaining to

environmental protection and disposal of hazardous

materials.

Contact local authorities for information on safe

disposal facilities in your area.

WORKING ON THE VEHICLE

Normal hazards are associated with all forms of

powered transport. Before beginning work on the

vehicle, make note of all instructions pertaining to

safety and hazardous items. Ensure that all personnel

are using appropriate safety equipment.

When working on the vehicle and its components,

particularly the parts removed from the chassis, the

following areas may present hazards in addition to

those normally encountered on a motor vehicle:

Projections – chassis cross members,

exhaust tail pipe, etc.

Moving parts – cooling fan, drive shaft, brake

levers, steering linkage, etc.

Temporary components – driver’s seat, etc.

Noise – engine, exhaust, etc.

Projectiles – screws under high air pressure,

etc.

Stored energy – tire air pressure, braking

system air pressure, parking/emergency

spring brake compression, diesel injection

pump, etc.


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VEHICLE IDENTIFICATION

The exact vehicle specification is identified by the Vehicle Identification Number (VIN) stamped on the

manufacturer’s identification plate, located at floor level beneath the defroster access panel. Please quote the VIN

in any enquiries concerning your vehicle. An example VIN plate is shown below:

1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th 13th 14th 15th 16th 17th

WMI Number Vehicle Descriptor Section CVMA Serial Number


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TORQUE CHARTS

Unless otherwise specified, the tables below can be used as a reference for torque settings for all fasteners.


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CHAPTER 2 MAINTENANCE

DAILY MAINTENANCE CHECKS

CHECKING ENGINE OIL LEVEL

The engine oil dipstick can be accessed from the curb

side rear engine door.

In order to check the oil level:

1. Shut off the engine for an accurate reading.

2. Wait at least 15 minutes after shutting off

the engine to check the oil level. This allows

time for the oil to drain into the oil pan.

Use oil grade API CG-4/SL ACEA E5 15W/40

CES 20077.

CAUTION: Never operate the engine if the oil level is

below the low (L) mark or above the high (H) mark as

this can result in engine damage or poor engine

performance.

CHECKING COOLANT LEVEL

The coolant level is displayed on the expansion tank,

which can be accessed from behind the rear engine

door.

CAUTION: Never use a sealing additive to stop leaks

in the cooling system. This can result in cooling

system plugging and inadequate coolant flow, causing

the engine to overheat.

Cummins Inc. recommends the use of fully

formulated antifreeze/coolant meeting Cummins

Engineering Standards (C.E.S.) 14603.

WARNING

Do not remove a pressure cap from a hot engine.

Wait until the coolant temperature is below 50°C

(120°F) before removing the pressure cap.


VERSION 1.0


CHECKING TRANSMISSION OIL LEVEL

Transmission oil level should be checked once every

10,000 km. The transmission oil dipstick can be

accessed from the rear engine compartment door.

CAUTION: Always maintain the correct oil level as

insufficient oil can lead to transmission malfunction

and damage. Too much oil will cause the transmission

to overheat.

Steps for checking the transmission oil level are listed

as follows:

1. Confirm that the oil level is at operating

temperature (between 80°C and 90°C) in

order to obtain a definitive reading.

2. Ensure vehicle is stationary and on level

ground.

3. Shift range selector (pushbutton) to Neutral

position.

4. Run engine for 15 to 20 seconds at 1200 –

1500 rpm (not required with directly

mounted heat exchanger).

5. Let engine run at idle speed (500 – 700 rpm).

The speed must never drop below 450 rpm.

CAUTION: Idle speed should be set between 500 and

700 rpm. It must never drop below 400 rpm as this

will cause the engine to stall.

Follow up with regular visual inspection of the

transmission for signs of leakage. In exceptional cases

the oil level may need to be checked while the

transmission oil is cold, then checked again at normal

operating temperature.

For further instructions, refer to the ZF-EcoLife or ZF-

Ecomat 4 manual.

CHECKING POWER STEERING FLUID

The power steering fluid reservoir is located in the

engine compartment and can be accessed from the

rear engine door.

The fluid level should be checked with the engine at

idle and maintained at the max level indicator.

Recommended fluid: Automatic Transmission Fluid

Dexron III.

WARNING

Insufficient oil in the system can lead to partial or

complete failure of the retarder, rendering

braking action impaired or unavailable.

Vendor%20Manual%20Links/ZF/EcoLife/EcoLife%20Operating%20Instructions.pdf

Vendor%20Manual%20Links/ZF/Ecomat%204/Ecomat%204%20Operating%20Instructions.pdf



VERSION 1.0


AIR FILTER MINDER

The air filter minder is located in the pipe below the

air cleaner, and is accessible from the rear engine

door.

When the yellow band turns red, as shown in the

picture, the air filter needs to be replaced. The minder

can be removed by pressing the rubber diaphragm on

the end of the unit.

FUEL FILTER AND WATER TRAP

The primary fuel filter is a combination of filter and

sediment/water trap. This unit can be accessed from

the rear curb side engine door.

To drain water and sediment from the filter, a hose of

suitable diameter can be attached to the spigot of the

fuel filter. The drain valve can then be loosened to

allow the collected water and sediment to drain into

a suitable container for disposal.

CAUTION: After allowing fluid to enter storm or

catchment basins, dispose of it in accordance with

local and federal bylaws and statutes.

A/C DRIVE BELTS

The A/C drive belts can be accessed from the rear

curb side engine access door.

CAUTION: Ensure that the master switch and the rear

start switch are secure to prevent engine start.

Inspect the belts daily, checking for intersecting

cracks. Small cracks and transverse (across the belt

width) cracks are acceptable. Longitudinal (direction

of belt length) cracks that intersect with transverse

cracks are not acceptable.


VERSION 1.0


Belts must be replaced if they have intersecting cracks,

are frayed, or have chunks of material missing.

A/C COMPRESSOR

After checking the drive belts, inspect the A/C

compressor mounts for damage and correct

mounting.

ALTERNATOR

CAUTION: Keep the alternator clean and ensure that

the ventilation slots or air spaces are clear and free

from obstruction at all times.

The alternator should be checked every day to ensure

that it is charging at the correct voltage. Perform a

daily visual inspection of the condition of the

alternator drive belt, ensuring that it is set to the

correct tension without slippage.


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TOWING AND LIFTING

TOWING

CAUTION: Before towing the vehicle, the

transmission must be shifted into Neutral. Failure to

do so will cause damage to the drive shaft or rear axle.

Care must be taken to ensure that the vehicle will not

suffer structural or drivetrain damage as a result of

towing.

Without a means of supplying air to the vehicle being

towed, the parking brake (spring brake) must be

released. Please refer to the rear braking section for

information on this process.

An air coupling to supply air to the vehicle is available

within the front road side access panel.

It is recommended that a ramp truck only be used

when towing the Vicinity Bus. If a ramp style truck is

not available, then the Vicinity bus must be towed

using the tow eyes on the front of the bus.

WARNING

Failure to comply with the safety precautions in

this section could result in personal injury or

vehicle damage. Always follow the recommended

procedures. The operator of the towing vehicle is

ultimately responsible for safely securing and

towing the vehicle. Ensure that the operator of

the towing vehicle is aware of the safety

requirements and towing procedures contained

in this section.

WARNING

Follow all government safety regulations. A

vehicle safety restraint system must be used that

is independent of the primary lifting and towing

attachments.

WARNING

The driveshaft or both rear axle shafts must be

removed when towing, regardless of distance or

speed traveled. Damage to the

transmission/drive unit may occur if the vehicle is

towed without first removing the driveshaft or

rear axle.


VERSION 1.0


LIFTING

When lifting the vehicle for maintenance, always

hoist at the front wheel and drive wheel or designated

chassis locations. Chassis distortion and/or body

damage can occur if lifting is attempted at points not

designated. We strongly recommend that wheel lifts

are used and remain in place for support.

After hoisting the bus to working height, place

additional jack stands under the axles for support.

Position lift equipment and jack stands on a firm and

level surface. Do not lift with passengers and/or cargo

onboard.

WARNING

The axles must not hang unsupported on the

shock absorbers as this could result in serious

injury or death. Always follow the proper lifting

procedures provided by the Hoist or Lift

manufacturer’s operating instructions.

WARNING

Do not walk under a vehicle being lifted until the

lifts are stopped and in a “locked” position and/or

jack stands are positioned under the chassis.


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LUBRICATION POINTS


VERSION 1.0


LIST OF LUBRICANTS

Vehicle Component Volume General Specification

Cummins ISB 220

16.7 (new) 14.2 litres

API CG-4/SL ACEA E5 15W/40 CES 20077

Engine cooling system 70 litres Cummins Standard 14603

HVAC coolant system 60 litres Cummins Standard 14603

Transmission – ZF EcoLife oil change

38 litres (new) 24 litres

TE-ML 20 ZF website

Transmission – ZF Ecomat oil change

28 litres (new) 18 litres

TE-ML 14 ZF website

Graziano rear differential 20 litres GL-5 SAE 80W-90/ SAE 90W (see page 10)

Power steering fluid 10.0 litres ATF Dexron III

Grease: Steering drag link, Steering relay shaft

As required Lithium-based

Grease: Prop shaft As required Lithium-based

Exhaust aftertreatment system 20.0 litres DEF meeting ISO 22241-1 (or DIN 70070) standard

Windshield washer fluid 8.7 litres

Pre-mixed fluid with a recommended -40°C rating

http://www.zf.com/

http://www.zf.com/

Vendor%20Manual%20Links/Oerlikon%20Graziano/Rear%20Axle%20Service%20Manual.pdf


VERSION 1.0


CHAPTER 3 SERVICE SCHEDULES

This vehicle’s service schedule is cumulative. Perform maintenance at the interval that occurs first. At each scheduled maintenance interval, perform all previous maintenance checks that are due for scheduled maintenance.

ENGINE SCHEDULE

DAILY 10,000K 20,000K YEARLY 2 YEARS

COOLANT LEVEL - CHECK X

FUEL-WATER SEPARATOR - DRAIN X

PRIMARY FUEL FILTER - CHANGE X

LUBRICATING OIL LEVEL - CHECK X

CHECK DIESEL EXHAUST FLUID (DEF) LEVEL X

AIR CLEANER RESTRICTION - CHECK X

CHECK CHARGE AIR PIPING FOR LEAKS, CRACKS, AND LOOSE CONNECTION.

X

CHARGE-AIR COOLER - CHECK X

FUEL FILTER (SECONDARY) - CHANGE X

LUBRICATING OIL AND FILTERS - CHANGE X

ENGINE COOLANT ANTIFREEZE - CHECK X

BATTERY CABLES AND CONNECTIONS - CHECK X

RADIATOR PRESSURE CAP - CHECK X

DRIVE BELT, COOLING FAN - CHECK X X

BELT TENSIONER - INSPECT FOR REUSE X

AIR COMPRESSOR DISCHARGE LINES - CHECK X

COOLING SYSTEM - FLUSH X

ENGINE STEAM CLEANING - CLEAN X

RADIATOR HOSES - CHECK X X

CRANKCASE VENTILATION FILTER - CHANGE 120,000 Kilometres or 2,500 Hours

OVERHEAD SET - ADJUST 240,000 Kilometres or 5,000 Hours or 4 years

DIESEL PARTICULATE FILTER - CLEAN 321,500 Kilometres or 6,500 hours

DIESEL EXHAUST FLUID DOSING UNIT FILTER - CHANGE 321,500 Kilometres or 6,500 hours


VERSION 1.0


TRANSMISSION SCHEDULE

ECOLIFE DAILY 10,000K 20,000K YEARLY 2 YEARS

INSPECT THE TRANSMISSION FOR SIGNS OF LEAKAGE X

OIL LEVEL CHECK X

CLEAN TRANSMISSION BREATHER CAP X

ECOMAT 4 DAILY 10,000K 20,000K YEARLY 2 YEARS

INSPECT THE TRANSMISSION FOR SIGNS OF LEAKAGE X

OIL LEVEL CHECK X

CLEAN TRANSMISSION BREATHER CAP X

First oil and filter change must be done at a maximum of 150,000 km or 3 years. Further intervals are dependent

upon used lubricant class for service.

The oil change intervals defined in the ZF list of lubricants TE-ML 20* are binding. The latest list of lubricants can be

obtained from all ZF Sales & Service Centres or downloaded online.

*TE-ML 20 is used in vehicles equipped with a ZF-EcoLife transmission, whereas TE-ML 14 is used for ZF-Ecomat 4

transmissions.

DRIVE SHAFT SCHEDULE


CHECK TIGHTNESS OF ALL FASTENERS X

CHECK UNIVERSAL AND SLIDING JOINTS FOR WEAR X

GREASE UNIVERSAL AND SLIDING JOINTS X

REAR AXLE SCHEDULE


CHECK OIL LEVEL X

REPLACE OIL 120,000 km* or 2 years

*initial oil change within first 8,000 km

CHECK FOR VENT BREATHER CLOGGING X

The oil used for the rear axle must be corresponding to the specifications MIL-L-2105 D and API GL5 with the

following viscosity: SAE 85W 140 – SAE 80W 140.

http://www.zf.com/corporate/en_de/products/spare_parts/technical_information/lubricants/lists_of_lubricants/lists_of_lubricants.jsp


VERSION 1.0


FRONT AXLE & SUSPENSION SCHEDULE


VISUAL INSPECTION OF THE JOINTS CONNECTING THE SUSPENSION TO THE CHASSIS

X

VISUAL INSPECTION OF THE T-JOINT SEALS STATUS X

VISUAL INSPECTION OF ALL SUSPENSION COMPONENTS

X

PNEUMATIC/BRAKE SYSTEM SCHEDULE


CHECK COMPRESSOR OPERATING PRESSURES CUT IN/CUT OUT

X

CHECK LOW AIR PRESSURE ALARM/LIGHT ARE OPERATING CORRECTLY

X

CHECK THE OPERATION OF PARKING BRAKE X

CHECK ALL AIR LINE CONNECTIONS AND MOUNTINGS FOR LEAKAGE AND SECURITY

X

CHECK FUNCTION AND CLEANLINESS OF AIR DRYER X

REPLACE AIR DRYER CARTRIDGE X

CHECK DISC BRAKE PAD THICKNESS X

CHECK DISC BRAKE ROTOR FOR DEFECTS X

CHECK BRAKE PAD RUNNING CLEARANCE X

DRAIN AIR RESERVOIRS X

Since no two vehicles operate under identical conditions, maintenance intervals will vary. Experience is a valuable

guide in determining the best maintenance interval for any one particular vehicle.

The tests outlined in the brake service section check both leakage and device function. Performing these tests on a

quarterly basis and recording the results of the tests in the vehicle maintenance records will provide a valuable basis

for performance comparisons/trends and assist in deciding maintenance intervals.


VERSION 1.0


ENGINE COOLING SYSTEM SCHEDULE


CHECK COOLING SYSTEM LEVEL X

CHECK HOSES FOR LEAKS AND SIGNS OF DETERIORATION

X

CHECK PRESSURE CAP SPRING AND SEAL X

DRAIN AND FLUSH OUT. REFILL WITH THE CORRECT ENGINE COOLANT

X

CHECK STRENGTH OF ANTI-FREEZE X

CHECK RADIATOR AND CHARGE AIR COOLER CORE - CLEAR ALL DEBRIS

X

CHECK ELECTRIC COOLING FANS FOR FAULTS AND OPERATION

X

CHECK CONDITION OF THE RADIATOR SURROUND AND CASSETTE ASSEMBLY AND SEALS

X

ELECTRICAL SYSTEM SCHEDULE


CHECK OPERATION OF ALL LIGHTS, SWITCHES, WARNING LIGHTS, DIRECTION INDICATORS, STOP LIGHTS, HORNS

X

CHECK THAT INSTRUMENTS ARE WORKING CORRECTLY X

CHECK HEADLIGHT BEAMS ARE CORRECTLY SET X

REMOVE BATTERY(IES), CLEAN AND TEST, CLEAN AND REPAINT THE CARRIER IF REQUIRED

X

CHECK THAT ALTERNATOR IS CHARGING CORRECTLY X

CHECK ALL CONNECTIONS THROUGHOUT THE SYSTEM FOR CLEANLINESS, SECURITY AND INSTALLATION

X


VERSION 1.0


AFTERTREATMENT/EXHAUST SYSTEM SCHEDULE


CHECK DIESEL EXHAUST FLUID (DEF) LEVEL X

CHECK EXHAUST WRAP FOR DAMAGE OR OIL CONTAMINATION

X

CHECK SECURITY OF ALL PIPE CLAMPS X

CHECK THE RUBBER MOUNTS FOR SIGN OF DAMAGE OR SEPARATION

X

CHECK ALL PIPE JOINTS TO ENSURE NO EXHAUST LEAKS

X

CHECK FOR SECURITY AND CONDITION OF EXHAUST SYSTEM INSULATION MATERIAL

X

ENSURE THAT THE DOSER UNIT AIR VENT AND AIR REGULATOR ARE FREE FROM DEBRIS AND ARE NOT RESTRICTED IN ANY WAY

X

CHANGE AFTERTREATMENT DIESEL PARTICULATE FILTER EVERY 321,500KM OR 6,500 HRS

HVAC SCHEDULE


CHANGE INTERNAL AIR FILTERS X

CHECK A/C DRIVE BELTS FOR TENSION AND CRACKS X

CHECK GENERAL CONDITION OF EQUIPMENT X

CHECK A/C COMPRESSOR MOUNTS FOR DAMAGE X

CHANGE CONDENSER FAN BRUSHES X

CHECK EVAPORATOR BLOWER BRUSHES X

CHECK FUSES AND RELAYS AT THE RELAY BOARD X

REPLACE EVAPORATOR BLOWER BRUSHES X

CLEAN AIR RETURN FILTER X

CHECK THE CABLE TIGHTNESS AT THE RELAY BOARD X

CHECK FOR OIL ON HOSE CONNECTIONS (I.E. GAS LEAKAGE)

X

Note: HVAC system service must be carried out by an expert or an authorized service station.


VERSION 1.0


STEERING/HYDRAULIC SYSTEM SCHEDULE


CHECK POWER STEERING FLUID LEVEL X

CHECK ALL PIPEWORK/HOSES AND CONNECTIONS FOR LEAKS/SECURITY AND INTEGRITY

X

CHANGE HYDRAULIC OIL ANNUALLY OR EVERY 160,000 KM

CHANGE RESERVOIR FILTER ANNUALLY OR EVERY 160,000 KM

CHECK ALL COMPONENTS FOR SECURITY X

CHECK THE STEERING AND BEVEL BOXES FOR LEAKS X

CHECK ALL BALL JOINTS AND LINKAGES FOR PLAY X

LUBRICATE STEERING RELAY SHAFT X

CHECK FOR PLAY IN STEERING COLUMN X

CHECK HYDRAULIC STEERING LIMITER X

AIR SUSPENSION SYSTEM SCHEDULE


CHECK SUSPENSION COMPONENT MOUNTINGS AND TIGHTEN IF NECESSARY

X

CHECK SHOCK ABSORBER AND MOUNTINGS X

CHECK THE RIDE HEIGHT X

REMOVE ALL ROAD DIRT AND OIL/GREASE BUILD UP FROM AIR SPRINGS AND SUPPORTS

X

CHECK SUSPENSION AIR SYSTEM FOR LEAKS X

INSPECT CLEAN/CHANGE AIR SUSPENSION LINE FILTER

X


VERSION 1.0


TIRE & WHEEL SCHEDULE


VISUALLY CHECK ALL WHEEL NUTS X

CHECK TIRES ARE FREE FROM DAMAGE, CUTS, AND DEBRIS

X

CHECK TIRE PRESSURES ARE CORRECT INCLUDING SPARE IF FITTED

X

CHECK TREAD DEPTH IS WITHIN LEGAL LIMIT X

Note: The above listed annual checks should be performed after the first 4,800 km of service use, and then

conducted annually.


VERSION 1.0


CHAPTER 4 ENGINE

OVERVIEW

DESCRIPTION

This vehicle is powered by a Cummins ISB 6.7 EPA 220

electronically controlled turbo-charged 6-cylinder

diesel engine.

SPECIFICATIONS

Type . . . . . . . . . . 6-cylinder Cummins ISB 6.7 EPA 220

Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 litres

Valve clearance – inlet . . . . . . . . .0.254 mm (0.010 in)

Valve clearance – exhaust . . . . . .0.660 mm (0.026 in)

Firing order . . . . . . . . . . . . . . . . 6-cylinder 1-5-3-6-2-4

Idle speed . . . . . . . . . . . Min. 650 rpm - Max. 850 rpm

Oil pressure at idle (min.) . . . . . . . . . . .69 kPa (10 psi)

Oil pressure at rated (min.) . . . . . . . . 207 kPa (30 psi)

MAINTENANCE

Engine maintenance is based on the information on

the engine data plate, located on the engine valve

cover.

Using the information found on the engine data plate,

log on to the Cummins website to create an account

and access all of the maintenance/service

information for this vehicle’s Cummins engine.

MOUNTING

The engine and transmission are mounted to the

frame at four points: two on the front of the engine

and two on the transmission. The engine torque is

controlled from the torque arm at the mid-point of

the power unit.

https://quickserve.cummins.com/info/index.html


VERSION 1.0


TORQUE SPECIFICATIONS


VERSION 1.0



VERSION 1.0


STARTING SYSTEM

OVERVIEW

The 24V starting system is comprised of a starting

motor, starter solenoid, integral magnetic switch

relay, starter switches, circuit breakers, and electrical

connections. The integral magnetic switch relay

minimizes voltage drops and allows the solenoid to

receive the maximum voltage available in any starting

condition.

ROTATION CHECK

If the starter solenoid is making noise, but the engine

is not rotating, the starting motor may need to be

replaced. To determine this, perform a rotation check:

1. Make note of the starting motor voltage

before beginning cranking.

2. Turn the ignition to the OFF position and

attempt to bar the crankshaft in both

directions.

3. Use a Cummins-approved barring tool to bar

the engine.

If the crankshaft bars over, attempt

to start the engine. If the starter

motor cranks the engine, the issue

may be damage to the starter

motor pinion gear and flywheel ring

gear.

If the crankshaft does not rotate or

requires more than the normal

effort to bar, there may be either an

internal malfunction or a problem

with the drive unit and/or

accessories.

4. If the engine cranking speed is slower than

usual or does not crank and the engine

rotates freely:

Ensure that the wiring connections

are clean, tight, and undamaged.

Check the battery voltage.

5. If the voltage drops more than 4.8-VDC

during the rotation check, ensure that all

electrical connections are clean and tight. If

the cables are correct and the voltage

continues to drop below the limit, replace

the starting motor.

MAINTENANCE

If a rotation check determined that the starting motor

requires replacement, follow these steps:

1. Disconnect the batteries.

2. Remove the electrical connections from the

starting motor. Tag each wire according to its

location on the starting motor.

WARNING

Batteries can emit explosive gases. To reduce the

possibility of personal injury, always ventilate the

compartment before servicing the batteries.

Remove the negative (-) battery cable first and

attach the negative (-) battery cable last.

WARNING

Hot steam can cause serious bodily harm. Wear

safety glasses or a face shield and protective

clothing when using a steam cleaner.

WARNING

Always wear protective eye and face gear when

using compressed air as flying debris and dirt can

cause bodily injury.


VERSION 1.0


3. Remove the three cap screws and starting

motor.

If equipped with a starting motor

spacer, remove the spacer and

clean all surfaces between the

starting motor, starting motor

spacer, and flywheel housing with a

wire brush.

4. Clean any leftover sealant from the starting

motor mounting flange on both the wet

flywheel housing (if applicable) and starting

motor. Ensure that these components are

clean of oil and debris.

5. Re-install all removed parts and the new

starting motor per Cummins installation

instructions.

6. Connect the electrical connection to the

starting motor.

7. Connect the batteries. Operate the starting

motor to ensure proper function.

CAUTION: Do not overtighten the electrical

connections as starter damage can result.

COOLING SYSTEM

DESCRIPTION

The cooling system is comprised of an engine driven

water pump, thermostat, radiator, and electric

cooling fans.

When the engine starts, the engine belt turns a water

pump that pushes coolant through the engine block.

A thermostat is used to control the flow of coolant,

providing efficient engine warm-up and regulating

coolant temperature. When the coolant temperature

falls below the operating range, engine coolant is

bypassed back to the inlet of the water pump. When

the engine coolant temperature reaches the

operating range (86°C), the thermostat opens, seals

off the bypass, thus forcing the coolant to flow to the

radiator. Warm coolant enters the top of the radiator,

flows out the bottom, and enters the transmission oil

cooler. It then flows through the heat exchanger and

returns back to the engine where the temperature is

regulated and the process repeats once it heats up

again.

The six cooling fans are controlled by sensors placed

in the radiator coolant flow. The variable speed fans

are controlled by the TMC control unit.

SPECIFICATIONS

Coolant type . . . . . . . . . . . . Cummins Standard 14603

Capacity . . . . . . . . . . . . . . . . . . 70 litres (18.5 gallons)

Min. coolant strength . . . .50% water/50% antifreeze

Operating range . . . . . . . . . .86 to 97°C (187 to 207°F)

Min. pressure cap . . . . . . . . . . . . . . 100 kPa (14.5 psi)

Testing coolant . . . . . . . . . . . . . . . Fleetguard Test Kits



VERSION 1.0


SCHEMATIC


VERSION 1.0


RADIATOR

This vehicle comes equipped with a Dura-Lite radiator.

The radiator is mounted on flexible supports and is

located under the rear road side access door.

MOUNTING

CAUTION: The proper mounting and handling of a

radiator is vitally important. Mounting brackets

should routinely be checked for looseness, which can

result in excessive vibration and shock loads. Over

time, rubber mounting isolators can deteriorate,

weaken, and break, and should therefore be replaced

if ever in an unsuitable condition.

MAINTENANCE

The fan side of the radiator should be checked at

regular intervals for build-up of dirt, mud, insects, and

dust. Obstructions such as these can cause blockages

that may reduce the cooling efficiency of the system.

The radiator components can be cleaned using an

approved chemical cleaner and rinsed off using a hose

in the reverse direction of regular air flow.

For information on power and ground stud

maintenance, refer to the electrical system chapter.

CLEANING

CAUTION: Use extreme care when using a pressure

washer to clean the radiator as the water pressure or

proximity of the nozzle may damage radiator fins and

affect the cooling efficiency of the system.

If it is not possible to remove the radiator from the

vehicle for cleaning, an effective alternative method

is using shop air and hot water. This is done by

reversing the direction of normal air flow through the

back of the core. Using a Fin Comb or similar tool to

loosen debris from the fins, taking care to ensure that

the fins and tubes on the cores do not sustain damage,

can be helpful in this case.

The fan reversal push button is located in the rear

engine compartment. Ensure that the engine is

turned on, then press the “Fan Reverse” button.

The LED light will illuminate and the fans will reverse

for 20 seconds at 5000 rpm. The fans will then restart

in forward direction for 10 seconds at 750 rpm in

order to either verify operation and/or assist in

cleaning out the charge air cooler and radiator cores.

WARNING

Before starting any work on the radiator, ensure

that the vehicle is completely stationary and the

engine is turned off.

WARNING

This vehicle comes with a Dura-Lite radiator that

may have specific installation instructions.

Following these instructions is critical to avoiding

mounting issues and premature failure. For

further information on installation and mounting,

contact Dura-Lite Customer Support.

WARNING

External air/water pressure must not exceed 138

kPa (20 psi) for the radiator core.


VERSION 1.0


MOUNTING DIAGRAM


VERSION 1.0


COOLING FANS

This vehicle comes equipped with eight EMP cooling

fans – six for the radiator and two for the charge air

cooler. The radiator cooling fans can be accessed by

opening the rear road side radiator door.

For detailed information on these fans, refer to the

EMP manual.

DIAGNOSING FOR REPAIRS

A diagnostic LED light is located in the rear engine

compartment. When the vehicle is running, the LED

light will blink out codes to the repair technician when

a system problem is detected.

For a table containing blink code meanings, refer to

the “Error! Reference source not found” section of

the EMP manual.

REPLACING DIAGNOSTIC LED BULB

The diagnostic LED light is easily replaceable should

the bulb burn out. To replace the bulb:

1. Grasp the glass bulb and pull straight out.

2. Insert the new bulb by aligning the terminals

on the bulb with those on the socket and

push straight in. The positive red side of the

LED light body must align with the red wire

on the holder.

COOLANT

CAUTION: Never use water by itself for coolant as this

can result in damage from corrosion.

CAUTION: Allow the engine to cool below 50°C (120°F)

before adding coolant. Do not add cold coolant to a

hot engine as engine castings may become damaged.

Ensuring that the recommended coolant for current

weather conditions is correctly used provides

protection against frost, corrosion, and overheating.

Only use a coolant mixture that is suitable for the

climate in which the vehicle will be operating:

For outside temperatures of 0 to -32°C (32 to

-25°F), use 50-percent ethylene glycol

antifreeze and 50-percent water for the

engine coolant mixture.

For cold weather conditions in the -32 to -

54°C (-25 to -65°F) range, use 60-percent

ethylene glycol antifreeze and 40-percent

water for the engine coolant mixture.

Note: In both temperature ranges, the diesel fuel

must have maximum cloud and pour points 6°C (10°F)

lower than the ambient temperature in which the

engine operates.

Vendor%20Manual%20Links/EMP/Cooling%20Fans%20Service%20Manual.pdf

Vendor%20Manual%20Links/EMP/Cooling%20Fans%20Service%20Manual.pdf


VERSION 1.0


COOLANT LOW LEVEL INDICATOR

When the coolant level falls below a certain level, the

CHECK ENGINE lamp will flash for 30 seconds. This

lamp is controlled by the engine control module.

CAUTION: Low coolant level is not always indicative

of a leak in the cooling system. However, the cooling

system should be checked for leaks and repaired, if

necessary, as soon as the lamp comes on.

COOLANT HOSES

Radiator hoses are used to direct coolant between

the engine and the radiator. The upper radiator hose

connects the thermostat housing to the radiator inlet.

The lower radiator hose connects the radiator to the

water pump inlet.

Coolant hoses should be regularly checked for signs of

deterioration. Hardened, cracked, swollen, or

restricted hoses should be replaced. If a hose shows

any signs of chafing, the cause should be fixed

immediately.

Note: The silicone engine coolant hose will exhibit

swelling due to the elasticity of the hose. This is

normal behaviour and does not require replacing.

PRESSURE TESTING

Coolant leaks are often the result of damage and not

corrosion. Leaks can be located by conducting a

pressure test:

1. Pressurize system using proper tool, taking

care to only pressurize to cap rating.

2. Check for leaks.

FILLING

Engine coolant levels must be checked daily. Before

filling or topping up the cooling system, the following

precautionary conditions must be met in order to

ensure environmental safety and proper system

functionality:

The engine must be turned off and cold.

The manual bleed valve (if applicable) must

be open.

CAUTION: If filling an empty system, purge the

heating system first before continuing.

Fill with coolant to the bottom of the cooling system

fill neck on top of the expansion tank

Note: This system has a maximum fill rate of 19 litres

(5 gallons) per minute.

CAUTION: Air pockets can cause serious engine

damage. During filling, air must be vented from the

engine coolant passages. Wait 2 to 3 minutes to allow

air to be vented, then add coolant to top up the level.

At least the same amount of coolant that was drained

from the system must go back into it during filling.

Any drained coolant that remains after filling is an

indication of an air pocket, which must be purged

before returning the vehicle to service.

WARNING

Skin contact with antifreeze or coolant solution

can cause skin disorders or other injuries. Wash

area immediately after contact and avoid

prolonged exposure.

WARNING

Never use a sealing additive to seal leaks in the

coolant system as this can result in clogging and

insufficient coolant flow.

WARNING

Heated coolant spray or steam can cause

personal injury. Do not remove pressure caps

from a hot engine. Wait until the coolant

temperature falls below 50°C (120°F) before

removal.


VERSION 1.0


DRAINING

The drain plug is located at the bottom of the radiator.

Drain the coolant into a clean, suitably sized container.

If the coolant is going to be re-used, cover the

container in order to prevent contamination.

FLUSHING

The cooling system should be drained and flushed out

every two years or 96,000 km (60,000 miles),

whichever occurs first. To drain and flush the system:

1. Remove the radiator caps and fill the cooling

system with a mixture of sodium carbonate

and water (or a commercially available

equivalent). Note that this system has a

maximum fill rate of 19 litres (5 gallons) per

minute.

2. Wait 2 to 3 minutes with the engine OFF to

allow the system to release trapped air and

the coolant level to stabilize.

3. Add plain, good quality water to bring the

level back to FULL.

4. Turn the blower ON. Turn all cab heater

switches to HIGH in order to allow maximum

coolant flow through heater core(s).

5. Switch the engine on to LOW IDLE for 2

minutes.

6. Switch off the engine and add plain water to

bring the level back to FULL.

7. Start the engine on HIGH IDLE and let run

until the thermostat opens.

8. Allow cool down of system components by

turning the engine down to LOW IDLE for 2

minutes.

9. Shut the engine OFF. Allow the system to

cool to 50°C (122°F).

10. Drain the cooling system. If the water being

drained is still dirty, repeat flushing process

until the water runs clean.

WARNING

Heated coolant spray or steam can cause

personal injury. Do not attempt to drain the

coolant while the engine is hot. Wait until the

coolant temperature falls below 50°C (122°F)

before draining.

WARNING

The handling and disposal of used antifreeze can

be subject to government regulations. Only used

authorized waste disposal facilities.

WARNING

Used coolant must be disposed of in accordance

with local environmental regulations.


VERSION 1.0


AIR INTAKE SYSTEM

DESCRIPTION

The air intake system can be accessed from the rear

engine compartment door. It is comprised of the

following components:

Roof intake

Air cleaner

Charge air cooler (CAC)

AIR FILTER

To service the air filter, complete the following steps:

1. Remove the three fasteners as indicated.

2. There will be some initial resistance, similar

to breaking the seal on a jar. Gently move the

end of the filter back and forth to break the

seal and rotate while pulling the filter

straight out. Avoid knocking the filter against

the housing.

3. If there is a safety filter, do a visual

inspection for damage. Verify that the safety

filter is properly seated in the housing. Do

not remove the safety filter unless it is

damaged or due for replacement. The safety

filter should be replaced every three primary

filter changes. After removal, replace

immediately or ensure that the air cleaner

outlet tube is sufficiently covered to avoid

admitting any contaminant.

4. Squeeze while examining the Vacuator™

Valve (if equipped). Remove the Vacuator™

Valve and clean out any dust found in the

drop tube. Reinstall or replace if found worn

or damaged.

5. Use a clean damp cloth to wipe the filter

sealing surface and the inside of the outlet

tube. Contaminant on the sealing surface

could prevent an effective seal and cause

leakage.

6. If servicing the safety filter, carefully seal it

into position before installing the primary

filter. Seal the filter by hand, ensuring that it

is completely inserted into the air cleaner

housing before securing the cover in place.

7. Install the cover and three fasteners.


VERSION 1.0


CAUTION: Never use the service cover to push

the filter into place as doing so could damage the

housing and cover fasteners and will void the

warranty.

CHARGE AIR COOLER

The Charge Air Cooler (CAC) is mounted in the engine

compartment in the upper curb side corner and can

be accessed from the upper rear engine door.

The temperature of the CAC cooler is controlled with

two electric fans that form part of the total cooling

package. For a description and operating instructions,

see Cooling Fans.

MAINTENANCE

If the intake system is opened up for maintenance or

repairs, the system must be checked for integrity and

correct fitting of all clamps and hoses.

Ensure that restriction indicators are reset and in

proper working order.

Verify that all mounting bands, clamps, bolts, and

connections in the entire air cleaner system are tight.

Check for holes in piping and repair/replace as

needed. Any leaks in the intake piping will admit dust

directly to the engine.

MOUNTING

CAUTION: The proper mounting of a charge air cooler

is vitally important. Mounting brackets should

routinely be checked for looseness, which can result

in excessive vibration and shock loads. Over time,

rubber mounting isolators can deteriorate, weaken,

and break, and should therefore be replaced if ever in

an unsuitable condition

Depending on the size of the clamp, the torque required to mount the CAC will be within the range of 5.6 to 8.5 Nm (4.1 to 6.3 lb-ft).

DIAGRAM

WARNING

This vehicle comes with a Dura-Lite charge air

cooler that may have specific installation

instructions. Following these instructions is

critical to avoiding mounting issues and

premature failure. For information on installation

and mounting, contact Dura-Lite directly.


VERSION 1.0


ALTERNATOR MOUNTING


VERSION 1.0


CAUTION: Slip bushing located in rear mounting foot

must be securely tightened against alternator

mounting bracket on engine. Failure to do so can

result in broken mounting feet or broken upper

mounting bracket.

FUEL SYSTEM

DESCRIPTION

Diesel fuel is held in a 250-litre (66-gallon) tank

located at the front curb side of the vehicle. The feed

line carries fuel to the engine, where it feeds into a

steel braided hose and passes through the primary

fuel filter. Once fuel has cycled through the engine,

the return line directs any excess amounts from the

engine pump back into the fuel tank.

A. Return fuel line

B. Vent

C. Vent

D. Auxiliary heater

E. Auxiliary heater return

F. Engine feed fuel line

Feed and return fuel line fittings can be found by

removing the access panel located on the front curb

side wheel tub of the vehicle. The feed line is colour-

coded red, whereas the return line is black.

WARNING

Fuel lines contain very high pressure fuel. Shut off

the engine and wait at least 10 minutes to allow

fuel pressure to decrease before loosening any

fittings.


VERSION 1.0


DIAGRAM

For part descriptions, refer to the Vicinity Parts

Manual 2015.


VERSION 1.0


FUEL REQUIREMENTS

This vehicle is fitted with a Cummins engine with a

Diesel Particulate Filter (DPF) and a Selective Catalytic

Reduction (SCR) exhaust system. This installation

requires the use of an ultra-low sulphur diesel fuel

containing no more than 15 ppm of sulphur.

CAUTION: Failure to use the specified fuel may cause

damage to the engine or exhaust system.

PRIMARY FUEL FILTER

The function of the primary fuel filter is to filter fuel

and separate water that has entered the fuel due to

condensation. It can be accessed by opening the rear

curb side engine door of the vehicle.

WATER SEPARATOR

The water separator is located at the base of the

primary fuel filter. It collects water that has been

separated by the primary fuel filter. Simply open the

white drain located underneath the water separator

in order to drain any accumulated water.

REPLACING PRIMARY FUEL FILTER

In order to safely change the primary fuel filter, first

shut off the fuel tap by turning the valve to the left.

Then, complete the following steps:

1. Drain any water that has accumulated in the

water separator.

2. Unscrew fuel filter from head and safely discard.

3. Lubricate the rubber gasket (O-ring) of water

separator bowl.

4. Tighten water separator onto filter.

5. Fill new filter with clean diesel fuel and lubricate

the filter seal.

6. Tighten the primary fuel filter until the rubber

gasket (O-ring) adheres to the filter base, then

tighten an additional half-turn. Do not

overtighten.

7. Start engine and inspect for any leakage.

CAUTION: Do not use a wrench to tighten the fuel

filter as this may cause damage.

SECONDARY FUEL FILTER

The fuel hose connects the primary fuel filter to the

engine, where the secondary fuel filter is attached. It

can be accessed from beneath the engine or by

opening the curb side engine door.


VERSION 1.0


For information on how to replace the secondary fuel

filter, refer to Replacing the primary fuel filter or the

Cummins website.

FUEL TANK MAINTENANCE

Maintenance should be performed on an annual basis.

This may include the following:

Check for leaks.

Fuel contamination check.

Internal cleaning.

Possible fuel leakage can easily be checked by

examining the fuel tank access panels for any fuel

running down the sides.

PRIMING THE FUEL SYSTEM

Changing the fuel filter or opening the fuel system

requires the fuel system to be primed after. To do this,

simply open the fuel shut off valve and pump the

black priming pump until you feel it harden.

FUEL DRAIN

Should the fuel tank require any repairs, there is a

drain line located underneath the vehicle behind the

curb side front wheel. Drain fuel before replacing or

repairing the fuel tank.

Contaminated fuel can cause significant damage to

the engine and should be handled as follows:

1. Drain the fuel tank and detach it from chassis.

2. Pour approximately 2 litres (0.5 gallons) of fuel

into the tank and use a swirling motion to coat

the interior. This cleans the fuel tank by flushing

out any build-up or debris.

3. Blow out the fuel tank using compressed air.

WARNING

Fuel lines contain very high pressure fuel. Shut off

the engine and wait at least 10 minutes to allow

fuel pressure to decrease before loosening any

fittings.

WARNING

Used oil must be disposed of in accordance with

local environmental regulations.



VERSION 1.0


EXHAUST SYSTEM

DESCRIPTION

This vehicle is fitted with a Selective Catalyst

Reduction (SCR) exhaust system and a Diesel

Particulate Filter (DPF), located on the rear road side

of the vehicle. The exhaust system begins with the

turbocharger outlet, which connects to the catalytic

device system. The decomposition reactor injects

diesel exhaust fluid (DEF) into the catalytic device

system in order to aid with the nitrogen oxide (NOx)

emission burning process. The catalytic device system

is connected to the DPF module via the

decomposition reactor. After passing through this

filtration system, exhaust then flows out of the

exhaust pipe located at the upper rear road side of

the vehicle.

MOUNTING

The exhaust system is located in the upper road side

corner of the engine compartment. The complete unit

of the exhaust system is attached to brackets

connected to the body of the vehicle and is

suspended by rubber mounts.

CAUTION: The proper mounting of the exhaust

system is vitally important. Mounting brackets should


from excessive vibration and shock loads. Over time,



an unsuitable condition.

WARNING

Nitrogen oxide can be highly toxic if inhaled.

Minimize exposure to emissions in enclosed

spaces unless adequate ventilation facilities are

available.

WARNING

Exhaust gas temperature can reach 816°C

(1500°F), and exhaust system surface

temperature could exceed 740°C (1300°F) during

regeneration, even after the vehicle has stopped

moving. To avoid the risk of fire, property

damage, burns or personal injury, allow the

exhaust system to cool before beginning service

or repair. Ensure that no combustible materials

are located near hot exhaust or exhaust

components.


VERSION 1.0



VERSION 1.0


SCR SYSTEM

DESCRIPTION

This engine comes equipped with a selective catalytic

reduction (SCR) system, which is used to decrease the

nitrogen oxide emissions (NOx) from the vehicle

tailpipe. This system is composed of the following

main components:

Aftertreatment diesel exhaust fluid (DEF)

dosing unit

Aftertreatment DEF dosing valve

Aftertreatment SCR catalyst

DIESEL EXHAUST FLUID

Diesel exhaust fluid (DEF) is sprayed into the exhaust

fuel prior to the aftertreatment SCR catalyst. The DEF

then vaporizes and decomposes to form carbon

dioxide and ammonia. The ammonia reacts with the

NOx emissions over the aftertreatment SCR catalyst,

forming nitrogen and water.

DEF is required for an engine equipped with an SCR

system. Cummins Inc. requires the use of DEF meeting

ISO 22241-1 (or DIN 70070 standard). There are no

substitutes for DEF that meet this criteria.

CAUTION: Agricultural grade urea does not meet the

necessary specifications required. Never attempt to

create DEF by mixing agricultural grade urea with

water as this could result in aftertreatment system

damage.

TESTING

Usage of the correct concentration of diesel exhaust

fluid is critical to the proper performance of the

engine and aftertreatment systems.

Concentration of DEF should be checked when:

The vehicle has been in storage for an

extended amount of time.

Water may have entered the diesel exhaust

fluid tank.

To test the concentration of diesel exhaust fluid, use

a DEF specified refractometer and follow the

instructions provided.

WARNING

It is unlawful to tamper with, modify, or remove

any component of the SCR system.

WARNING

Diesel exhaust fluid contains urea. Keep away

from children and pets. Avoid contact with eyes.

In case of contact, immediately flush with water

for at least 15 minutes. Do not swallow. If

ingested, contact a physician immediately.

WARNING

It is unlawful to operate the vehicle/equipment

without diesel exhaust fluid, or to use a diesel

exhaust fluid that does not meet the

specifications provided by Cummins Inc.

WARNING

DEF can be harmful to the environment. Consult

with local regulatory authorities for proper

disposal process of DEF.


VERSION 1.0


The percent Urea Concentration needs to be 32.5 +/-

1.5%. If the DEF concentration is outside of this range:

1. Drain the diesel exhaust fluid tank and flush

with distilled water.

2. Fill with good quality DEF.

3. Reassess the DEF concentration.

DEF DOSING MODULE

The DEF dosing module is mounted in the rear road

side of the engine compartment.

It is fitted with a filter that can be accessed for service

maintenance purposes through a hole in the bottom

of the compartment. The DEF dosing module filter is

a 10-micron filter designed to prevent foreign objects

that may be suspended in the DEF from entering the

dosing system. Debris can cause permanent damage

and premature failure to either the aftertreatment

DEF dosing module or the aftertreatment DEF dosing

valve.

MAINTENANCE

The aftertreatment DEF dosing module filter should

be changed every 321,500 km (200,000 miles) or

6,500 hours.

For a full maintenance schedule, refer to SECTION IX.

AFTERTREATMENT/EXHAUST SYSTEM SCHEDULE.

To remove the DEF dosing module filter:

1. Unscrew the DEF filter cap using a 27 mm

(1.06 in) socket.

2. Remove the aftertreatment DEF filter

equalizing element.

3. Remove the old aftertreatment DEF dosing

module filter element.

Note: If the DEF dosing module filter is being changed

as part of a maintenance interval, it cannot be reused

and should be discarded.

AFTERTREATMENT

The aftertreatment diesel exhaust fluid dosing unit

pumps DEF from the DEF fluid tank to the

aftertreatment DEF dosing valve. The aftertreatment

DEF dosing unit is electrically heated and contains a

filter. The SCR system is specifically designed to freeze

and thaw out, as DEF has a freezing point of

approximately -12°C (11°F).

Once the aftertreatment diesel exhaust fluid dosing

valve is cooled to a temperature of 250°C (482°F), it

sprays diesel exhaust fluid (DEF) into the exhaust. The

amount of DEF sprayed into the exhaust is regulated


VERSION 1.0


by the aftertreatment diesel exhaust fluid controller.

This also controls the diesel exhaust fluid tank heater,

diesel exhaust fluid line heaters, and reports the

diesel exhaust fluid tank temperature and level back

to the engine ECM.


VERSION 1.0


DIESEL PARTICULATE FILTER

The aftertreatment system comes equipped with a

diesel particulate filter, which uses wall-flow

substrates to capture exhaust gas and remove

particulate matter or soot particles.


VERSION 1.0


MAINTENANCE

CAUTION: The aftertreatment diesel particulate filter

cannot be cleaned using conventional cleaning

methods. All maintenance and cleaning should be

performed only by a Cummins Inc. Authorized Repair

Location and/or personnel.

The aftertreatment DPF can become plugged with ash

or soot. In this case it is necessary to clean the

aftertreatment DPF before performing a stationary

regeneration in order to prevent any system damage

from occurring. The aftertreatment DPF should be

changed at 321,500 km (200,000 miles) or 6,500

hours.

Note: The aftertreatment DPF service interval is

based on the use of lubricating oils that meet the

Cummins Inc. Engineering Standard (C.E.S.) 20081 oil

specification. If a non-low ash lubricating oil meeting

the American Petroleum Institute (API) performance

classification CI-4/SL and/or C.E.S. 20078 is used, the

service intervals for the aftertreatment systems will

be reduced to 241,000 km (150,000 mi) or 5,000

hours.

REGENERATION

Regeneration refers to the process of converting the

soot accumulated in the aftertreatment diesel

particulate filter into carbon dioxide.

The engine contains an aftertreatment diesel

particulate filter (DPF) lamp that will flash or

illuminate when the aftertreatment DPF requires

regeneration.

Regeneration can be achieved by either changing to a

more challenging duty cycle (e.g. highway driving for

a minimum of 20 minutes) or performing a stationary

regeneration.

This process has two subtypes: passive regeneration

and active regeneration.

PASSIVE REGENERATION

Occurs when the exhaust reaches high enough

temperatures in order to oxidize the soot collected in

the aftertreatment DPF at a faster rate than the soot

is collected. This typically occurs when the vehicle is

operated under heavy loads.

ACTIVE REGENERATION

Occurs when the exhaust temperatures are not high

enough to oxidize the soot accumulated in the

aftertreatment DPF at a faster rate than it is collected.

The engine provides assistance to increase the

exhaust temperature by injecting a small amount of

diesel fuel into the exhaust stream, which is then

oxidized by the aftertreatment diesel oxidation

catalyst. This creates the heat needed to regenerate

the aftertreatment DPF.

During active regeneration, the following may be

observed:

An increase in turbocharger noise.

Illumination of the high exhaust

temperature lamp if the exhaust

temperature is greater than the high exhaust

system temperature threshold.

WARNING

Materials captured in the diesel particulate filter

may contain elevated concentrations of metals

such as primarily zinc and molybdenum, as well as

polynuclear aromatic hydrocarbons. These

materials must be characterized, handled, and

disposed of according to local regulations.


VERSION 1.0


An exhaust temperature higher than when

the engine is operating at full load.

STATIONARY REGENERATION

Manual (or parked) regeneration may be required in

some circumstances (e.g. low speed, light load, or

stop and go duty cycles) when the engine does not

have enough opportunity to regenerate the

aftertreatment DPF during normal operation. The

engine will illuminate the aftertreatment diesel

particulate filter lamp to inform the operator that

performance of manual regeneration is required.

The driver’s side console contains two DPF

regeneration switches.

Regen Initiate forces the DPF to regenerate, provided

all other conditions for the stationary regeneration

process are met. According to Cummins Inc., these

entry conditions must be satisfied in order to force

regeneration:

Engine must be running.

Accelerator must be at idle.

Clutch switch must show that the clutch

is engaged/pedal released (if applicable).

Service brake switch must indicate that

the service brakes/pedal are released.

Vehicle must be at a complete standstill.

Engine must be set to operate via the

accelerator pedal.

Transmission must be in Neutral.

Note: Changing any one of the above entry conditions

will interrupt the stationary regeneration.

CAUTION: Turning the ignition off in order to

interrupt the stationary regeneration should only be

used in emergency situations.

Regen Inhibit prevents the DPF from actively

regenerating. It uses a switched pull-up input, which

can exist in either an open (not grounded) or closed

(grounded) state. An open switch will inhibit the

active regeneration of the DPF.

Note: The DPF regeneration inhibit switch takes

precedence over the DPF regeneration initiate switch.

Inhibit priority is enforced regardless of whether

either signal is multiplexed on the SAE J1939 data link

or hardwired.

For further information on the DPF regeneration

switches, consult AEB 15.139.

WARNING LAMPS

MALFUNCTION INDICATOR

The Malfunction Indicator lamp glows amber when a

system malfunction occurs. It resembles the following:

The Malfunction Indicator lamp can be illuminated

along with any of the engine indicator lamps. It is not

used to indicate an engine protection or maintenance

required condition.


VERSION 1.0


AFTERTREATMENT DIESEL PARTICULATE FILTER

When illuminated or flashing, the Aftertreatment

Diesel Particulate Filter lamp indicates that the

aftertreatment DPF requires regeneration.

A solid illuminated Aftertreatment Diesel Particulate

Filter lamp indicates that the aftertreatment DPF

needs to be regenerated at the next changing

opportunity. This can be accomplished by:

Changing to a more challenging duty cycle,

such as highway driving, for at least 20

minutes

Performing a stationary regeneration.

A flashing Aftertreatment Diesel Particulate Filter

lamp indicates that the aftertreatment DPF needs to

be regenerated immediately.

Note: Engine power may be reduced automatically.

Attempting to operate the vehicle with an empty DEF

tank will reduce the vehicle speed to 8 km/h (5 mph).

HIGH EXHAUST SYSTEM TEMPERATURE

An illuminated High Exhaust System Temperature

lamp indicates that exhaust temperatures are high

due to regeneration of the aftertreatment DPF. This

lamp could illuminate during normal engine

operation or during regeneration.

Note: The High Exhaust System Temperature lamp

does not signify the need for any kind of vehicle or

engine service. It merely alerts the vehicle operator to

high exhaust temperatures. It is common for the High

Exhaust System Temperature lamp to come on and

off during normal vehicle operation as the engine

completes regeneration.

AFTERTREATMENT DIESEL EXHAUST FLUID

The Aftertreatment Diesel Exhaust Fluid lamp

indicates that the diesel exhaust fluid (DEF) level is

low.

A solid illuminated Aftertreatment Diesel Exhaust

Fluid lamp indicates that the DEF level has fallen

below the initial warning level. This can be corrected

by filling the DEF tank.

A flashing Aftertreatment Diesel Exhaust Fluid lamp

indicates that the DEF level has fallen below the

critical warning level. This can also be remedied by

filling the DEF tank.

An illuminated or flashing Aftertreatment Diesel

Exhaust Fluid lamp combined with an illuminated

Warning or Check Engine lamp indicates that the DEF

level has fallen below the initial derate level. The

engine power will be reduced automatically. This can

be corrected by filling the DEF tank.

Note: If the engine has been shut down or has idled

for an extended period of time after the DEF tank has

been emptied, the Stop Engine lamp will also be

illuminated along with the flashing Aftertreatment

Diesel Exhaust Fluid lamp and solid Check Engine

lamp. The engine power will continue to remain

reduced and the vehicle speed will also be limited to

8 km/h (5 mph).

WARNING

When this lamp is illuminated, the exhaust gas

temperature could reach 800°C (1,500°F), which

is hot enough to cause severe burns, and to ignite

or melt common materials.


VERSION 1.0


DEF TANK

The DEF tank is located in the road side of the engine

compartment. It contains a multifunction head unit

that monitors the temperature and level of DEF in the

tank.

For more information on the DEF tank and its

multifunction head unit, refer to the Shaw

Development DEF tank service manual and DEF

sensor manual.

FILLING

The following procedure outlines how to fill the DEF

tank using an ISO-22241 approved magnetic actuating

DEF nozzle:

1. Inspect the exterior surface of the DEF cap

and surrounding areas for any debris that

may fall into the tank when the cap is

removed. Clean if any debris is found.

2. Remove the cap and clean the underside if

necessary.

3. Insert the nozzle securely into the inlet

adapter and press the nozzle handle until the

DEF flows into the tank assembly.

4. Continue filling until the nozzle

automatically shuts off.

5. Remove nozzle and replace the cap onto the

adapter. Reattach the lanyard onto the tab.

CAUTION: Do not press the nozzle handle again after

it automatically shuts off, as this might cause the DEF

tank to overfill.

MAINTENANCE

WARNING

Diesel exhaust fluid contains urea. Keep away

from children and pets. Avoid contact with eyes.

In case of contact, immediately flush with water

for at least 15 minutes. Do not swallow. If

ingested, contact a physician immediately.

Vendor%20Manual%20Links/Shaw_Development/DEF_tank_service_manual_TB2839model.pdf

Vendor%20Manual%20Links/Shaw_Development/DEF_level_temperature_sensor.pdf

Vendor%20Manual%20Links/Shaw_Development/DEF_level_temperature_sensor.pdf


VERSION 1.0


EXTERIOR CLEANING

Scheduled cleaning of the DEF tank assembly

prevents DEF contamination and prolongs the life of

the unit.

1. Clean the area around and inside the DEF cap,

checking for debris that may fall into the

adapter inlet.

2. Inspect the exterior of the tank assembly for

cracks that water could seep into.

3. Rinse the tank with water, using soap if

needed. Ensure that all debris (e.g. dirt, fuel,

oil, hydraulic fluid, etc.) is completely rinsed

off, paying particular attention to the areas

around the multifunction head unit and cap

adapter assembly.

INTERIOR CLEANING

In order to avoid damage to the SCR system, the

interior of the DEF tank must be cleaned as soon as

contamination occurs. Contamination is defined as

the intrusion of liquid and particles that do not equate

to at least 32.5% concentrated DEF.

1. Completely drain the tank. Do not attempt to

filter or reuse the contaminated DEF.

2. Remove the multifunction head unit from

the tank.

3. Inspect the debris saturation of the DEF

suction filter. If the filter is damaged or dirty,

replace the filter.

4. Rinse out the interior of the tank with a hose

or a pressure washer with a strength of less

than 2,000 psi. Mild detergent may also be

used in the cleaning process.

5. Rinse off the multifunction head unit using

low water pressure.

6. Reinstall the multifunction head unit and

drain plug. Fill the tank with DEF, ensuring

that no leakage is present.

DEF CAP CLEANING

Periodic cleaning of the inside and outside of the DEF

cap is essential to ensure that contaminants do not

accumulate and enter the DEF tank.

1. Wipe off any debris from the cap and

adapter.

2. Rotate the cap counter clockwise until it

stops turning. Pull the lanyard off its tab and

remove the cap.

3. Place the cap in a clean pan. Fill with water

until the bottom half of the cap is fully

immersed. Do not allow the entire cap to

become completely submerged in water, as

this may affect the venting capabilities of the

cap.

4. Remove the cap assembly from water and

shake, ensuring that all excess water is

drained from it.

5. Clean off any remaining DEF crystals or dirt

using a damp cloth.

6. Wipe down the tank adapter with a damp

cloth. Fit the cap onto the adapter by turning

it clockwise until it stops. Reattach the

lanyard onto the tab.


VERSION 1.0


DRAINING

CAUTION: Do not attempt to filter or reuse

contaminated DEF.

The DEF tank requires draining in the following

instances:

DEF contamination

Prior to cleaning the interior of the tank

DEF overfill

Use the drain plug for easy draining of the DEF tank.

1. Ensure that the vehicle’s power supply is off

and is parked on level ground.

2. Position an auxiliary reservoir that has an

opening wide enough for the DEF to flow

without spillage directly beneath the drain

plug outlet.

3. Remove the DEF cap and set aside on a clean

surface.

4. Use a ¼” Allen wrench to unscrew the drain

plug from the reservoir by turning it counter

clockwise.

5. Allow DEF to flow from the tank into the

auxiliary reservoir.

6. Screw the drain plug back onto the drain

plug port, tightening to a torque of 4.5 – 6.7

Nm.

7. Refill the tank with clean, unused DEF,

checking for leakage.

WARNING

Drain the DEF tank in a well-ventilated area, as

the ammonia vapours may cause irritation.

WARNING

DEF can be harmful to the environment. Consult

with local regulatory authorities for proper

disposal process of DEF.


VERSION 1.0


CHAPTER 5 TRANSMISSION

ZF-ECOLIFE

OVERVIEW

If installed, this vehicle’s ZF-EcoLife automatic

transmission consists of a hydrodynamic torque

converter with a lockup clutch and a downstream six-

speed planetary transmission. It is equipped with a

torque converter, torsional vibration dampers, an

integrated hydrodynamic retarder, and 6-speed

planetary gears controlled by an electronic control

unit.

SPECIFICATIONS

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF-EcoLife

Torque convertor type . . . . . . . . . . . . . Hydrodynamic

Gears . . . . . . . . . . . . . . . . . . . . . . .Six-speed automatic

Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Integral

Oil capacity (initial fill) . . . . . . . . . . . .Approx. 38 litres

Oil capacity (oil change) . . . . . . . . . . .Approx. 24 litres

Oil grade . . . . .Must comply with ZF List of Lubricants

Recommended brand . . . . . . . . . . . . . . . . . . TE-ML 20

TOWING



do so will cause damage to the drive shaft and rear

axle.

Where there is no means of supplying air to the

vehicle being towed, the parking brake (spring brake)

must be released. Please refer to the rear brake

section for information on this process.

An air coupling to supply air to the vehicle is available

within the front road side access panel.

The air coupling contains a valve beneath its cap.

WARNING









in this section.


VERSION 1.0


A vehicle safety restraint system must be used that is

independent of the primary lifting and towing

attachments.

It is recommended to use a ramp truck only when

towing the Vicinity Bus. If a ramp style truck is not

available, then the Vicinity bus must be towed using

the tow eyes on the front of the bus.



towing.

CAUTION: The driveshaft or both rear axle shafts

must be removed when towing, regardless of

distance or speed traveled. Damage to the

transmission/drive unit may occur if the vehicle is

towed without first removing the driveshaft or rear

axle.

OIL LEVEL

RECOMMENDED LUBRICANTS

Only use oil as specified by the ZF List of Lubricants

TE-ML 20 to fill up EcoLife transmissions.

The latest List of Lubricants can be obtained from all

ZF Sales & Service Centres, or is available online from

the ZF website > Products & Services.

CHECKING OIL LEVEL

The transmission oil dipstick can be accessed from the

rear engine compartment door.



and damage. Too much oil can cause the transmission

to overheat.

Oil level should be checked at least once per quarter.

Steps for checking the transmission oil level are as

follows:

1. Confirm that the oil level is at operating

temperature (between 80°C and 90°C) in

order to obtain a definitive reading.


ground.


position.








WARNING




http://www.zf.com/


VERSION 1.0





transmission oil is cold, then checked again at normal

operating temperature.

For further instructions, refer to the ZF-EcoLife

manual.

CHANGING OIL

CAUTION: Only drain oil when it has remained at

operating temperature for at least 10 minutes.

Draining and filling the transmission oil can be

completed as follows:

1. Ensure the engine is at a standstill.

2. Unscrew oil drain plug and drain oil.

3. Unscrew filter cover and drain oil from the

filter chamber. Note that the pressure filter

must be replaced each time the oil is

changed.

4. Tighten filter cover using a torque of 29 Nm

(21 lb-ft).

5. Screw in oil drain plug using a torque of 35

Nm (26 lb-ft).

6. Pour oil into filler tube and check level on

dipstick. Only use oil as specified by the ZF

List of Lubricants TE-ML 20 may be used to

fill up EcoLife transmissions.

MAINTENANCE

For a schedule of transmission maintenance

procedures, refer to Transmission Schedule.

WARNING




WARNING






VERSION 1.0


MOUNTING



VERSION 1.0


TRANSMISSION TO ENGINE CONNECTION

The proper mounting and handling of a transmission







Before mounting the transmission to the engine,

ensure the following that the following checks are in

order:

The transmission’s oil sump bottom does not

run parallel to the longitudinal axis. When

assembling the engine and transmission,

take care to ensure that the torque

converter centering pin does not become

damaged in the process.

Assembly opening must be provided to both

the flywheel housing and flywheel.

All screws must be tightened to the correct

tightening torque (refer to Torque

Specifications).


VERSION 1.0


GEAR SELECTOR

DIAGNOSTICS

The electronic control unit’s function is to control and

monitor the EcoLife transmission. It features all

standard diagnostic protocols.

The signals for individual gearshifts are supplied by

the electronic control unit. Depending on various

operating variables of engine, vehicle, brake system,

etc., the corresponding multidisc clutches or brakes

are controlled via the electrohydraulic control unit.

The diagnosis system of the electronic control unit

monitors the transmission status whenever the

vehicle circuit is switched on and during operation.

Errors are indicated by illuminated warning lamps

(red or yellow) and/or warning messages that appear

on the driver’s display panel.

If a selected driving range is not accepted by the

electronic control unit, the depressed pushbutton on

the speed range selector will flash.

RETARDER

OPERATION

Retarder operation is accepted by the electronic

control unit only under the following conditions:

Accelerator pedal is in idling position.

A forward gear is engaged.

The driving speed exceeds approximately 3

km/h.

The ABS system is not active.

If any one of these conditions is not fulfilled with the

retarder engaged, the retarder will be deactivated.

When the maximally permitted oil temperature is

approached, either the retarder's performance will be

reduced, or the retarder will be disabled by the

electronic control unit.


VERSION 1.0


DEACTIVATION

The retarder must be deactivated using the “Retarder

ON/OFF” switch when driving on icy roads or when

the permitted oil temperature is exceeded.

If an electronic braking system (EBS) and/or antilock

system (ABS) is available, manual retarder shutdown

is not required.

Options for manually deactivating the retarder:

Set the "Retarder ON/OFF" switch to the OFF

position (if available).

Set hand lever to zero position (if available).

Engage the transmission into neutral by

pressing "N" on the pushbutton range

selector.

ACTIVATION

Digital flex inputs can be configured as low-active or

high-active. All functions controlled via inputs or

outputs can also be requested via CAN (application-

dependent).

PIN 1 (ASIN) Starter Interlock

Function: Terminal 15 (positive pole connected) via

ignition switch (key-operated switch), activated

voltage supply.

PIN 2 (VP1) Battery power (un-switched)

Function: Terminal 30, positive via un-switched

battery voltage supply.

PIN 3 (VP2) Battery power (un-switched)

Function: Terminal 30, positive via un-switched

battery voltage supply.

PIN 4 (VPI)

Function: Terminal 15 (positive pole connected) via

ignition switch (key-operated switch), activated

voltage supply.

PIN 7 (EDFlx5) Input Program Selection

Function: Program changeover, digital.

WARNING

Deactivating the retarder increases the risk of

accident due to reduced braking power.

WARNING

Only manually deactivate the retarder in

emergency situations on black ice if there is no

other option available for switching off the

retarder.


VERSION 1.0


The vehicle electric system (+ level), high-side must be

connected when changing over to 2nd driving program.

PIN 9 (EDFlex4) Digital input, flexible

Function: Shift release, if a driving range is selected

from “Neutral” (drive or reverse), the vehicle

electrical system (+ level) high-side must already be

connected via switch in brake system or within two

seconds. Otherwise, requested driving range must be

selected again by means of “Speed Range Selector to

Neutral”.


Function: Retarder request step 1, digital.

If retarder step 1 (1/3 of retarder torque) is requested,

the electrical system (+ level), high-side must be

connected.

PIN 14 (AD3) Digital output Retarder Brake Light

Function: Retarder, active

Output by vehicle electrical system (+) during retarder

operation, e.g. to control stop light.

PIN15 (EDFlex2) Digital input, flexible


If retarder step 2 (2/3 of retarder torque) is requested,


connected.

PIN 16 (AD2) Digital output

Function: Temperature warning.

Output by vehicle electrical system (+), when certain

temperature threshold value is exceeded at retarder

output or in the transmission sump.

PIN 17 (AD1) Digital output

Function: Backup light.

Output by vehicle electrical system (+), when “R”

button on CAN speed range selector is pressed.

PIN 18 (ASOUT) Digital output

Function: Starter interlock.

Output by vehicle electrical system (+), when N

button on CAN speed range selector is pressed. Due

to the contact path in the CAN speed range selector,

which has its own voltage supply (ASIN, pin1), it is

possible to start engine also when the ECU or the CAN

fails.


Function: Retarder deactivation when ABS is

activated.

Vehicle electrical vehicle electrical system (- level),

low- side must be connected.



If retarder step 3 (full retarder torque) is requested,


connected.

PIN 21 (VM1) Ground/Earth supply, external

Function: Terminal 31, ground/earth supply (-) for

CAN speed range selector, vehicle to ground.

PIN 22 (VM2) Ground/Earth supply, external

Function: Terminal 31, ground/earth supply (-) for

CAN speed range selector, vehicle to ground.


VERSION 1.0


ZF-ECOMAT 4

OVERVIEW

If installed, this vehicle’s ZF-Ecomat 4 automatic

transmission consists of a hydrodynamic torque

converter with a lockup clutch and a downstream

multi-ratio planetary transmission. It is equipped with

a torque converter, an integrated hydrodynamic

retarder, and planetary gears controlled by an

electronic control unit.

SPECIFICATIONS

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF-Ecomat 4

Torque convertor type . . . . . . . . . . . . . Hydrodynamic

Gears . . . . . . . . . . . . . . . . . . . . . . .Six-speed automatic

Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Integral

Oil capacity (initial fill) . . . . . . . . . . . .Approx. 28 litres

Oil capacity (oil change) . . . . . . . . . . .Approx. 18 litres

Oil grade . . . . Must comply with ZF List of Lubricants

Recommended brand . . . . . . . . . . . . . . . . . . TE-ML 14

TOWING

WARNING









in this section.


VERSION 1.0




do so will cause damage to the drive shaft and rear

axle.

When there is no means of air supply to the vehicle

while it is being towed, the parking brake (spring

brake) must be released. Refer to the rear brake

section for more information on this process.

An air coupling used to supply air to the vehicle is

available within the front road side access panel. The

air coupling contains a valve beneath its cap.

A vehicle safety restraint system must be used that is

independent of the primary lifting and towing

attachments.

It is recommended to use a ramp truck only when

towing the Vicinity Bus. If a ramp style truck is not

available, then the Vicinity bus must be towed using

the tow eyes on the front of the bus. The maximum

towing time should not exceed 2 hours.



towing.

CAUTION: If transmission damage is suspected, the

flange between the transmission and drive shaft

needs to be disconnected. However, in extreme

circumstances the vehicle may be towed until it

leaves the immediate danger area (e.g. intersection,

tunnel, etc.) without first disconnecting the driveline

OIL LEVEL

RECOMMENDED LUBRICANTS

Only use oil as specified by the most current ZF List of

Lubricants TE-ML 14 to fill up Ecomat transmissions.

The latest List of Lubricants can be obtained from all

ZF Sales & Service Centers or is available online from

the Products & Services section of the ZF website.

CHECKING OIL LEVEL

WARNING




http://www.zf.com/


VERSION 1.0


The transmission vent, oil filler tube, and oil dipstick

are one combined unit. They can be accessed from

the rear engine compartment door.



and damage. Too much oil can cause the transmission

to overheat.

CAUTION: The cap must be clean to allow the

breather to operate correctly. Failure to keep clean

will cause the oil to blow out when hot.

Oil level should be checked at least once per quarter.

Steps for checking the transmission oil level at

operating temperature are as follows:

1. Confirm that the oil level is hot (between

80°C and 90°C) in order to obtain a definitive

reading.


ground.


position.











transmission oil is cold, and then checked again at

normal operating temperature.

For further instructions, refer to the ZF-Ecomat 4

manual.

CHANGING OIL

CAUTION: Only drain oil when it has remained at

operating temperature for at least 10 minutes.

WARNING







VERSION 1.0


Draining and filling the transmission oil can be

completed as follows:

1. Ensure the vehicle is stationary and on level

ground.

2. Unscrew oil drain plug and drain oil.

3. Remove filter cover and drain oil from the

filter chamber.

4. Replace filter cartridge, copper rings and O-

ring. Note that the oil filter must be replaced

each time the oil is changed.

5. Tighten filter cover using a torque of 25 Nm

(18 lb-ft).

6. Screw in oil drain plug using a tightening

torque of 50 Nm (37 lb-ft).

7. Remove dipstick. Pour oil into filler tube and

check level using dipstick. Only use oil as

specified by the most current ZF List of

Lubricants TE-ML 14 to fill up Ecomat

transmissions.

MAINTENANCE

For a complete schedule of transmission maintenance

procedures, refer to Transmission Schedule.

MOUNTING

TRANSMISSION TO ENGINE CONNECTION

The proper mounting and handling of a transmission







Before mounting the transmission to the engine,

ensure the following that the following checks are in

order:

The transmission’s oil sump bottom does not

run parallel to the longitudinal axis. When

assembling the engine and transmission,

take care to ensure that the torque

converter centering pin does not become

damaged in the process.

Assembly opening must be provided to both

the flywheel housing and flywheel.

All screws must be tightened to the correct

tightening torque (refer to Torque

Specifications).


VERSION 1.0


DIAGRAM


VERSION 1.0



GEAR SELECTOR

DIAGNOSTICS

The electronic control unit’s function is to control and

monitor the ZF-Ecomat 4 transmission. It features all

standard diagnostic protocols. The electronic control

unit can be accessed within the interior electrical

compartment.

A pair of interface connectors transmit data from the

transmission to the electronic control unit.

The signals for individual gearshifts are supplied by

the electronic control unit. Depending on various

operating variables of engine, vehicle, brake system,

etc., the corresponding multidisc clutches or brakes

are controlled via the electrohydraulic control unit.

The diagnosis system of the electronic control unit

monitors the transmission status whenever the

vehicle circuit is switched on and during operation.

Errors are indicated by illuminated red or yellow

warning lamps and/or warning messages that appear

on the driver’s display panel.

If a selected driving range is not accepted by the

electronic control unit, the depressed pushbutton on

the speed range selector will flash.


VERSION 1.0


RETARDER ACTIVATION

The Ecomat retarder relies on the below inputs and

outputs for its continuous operation. The highlighted

areas represent the bus connections to the ZF harness.

10-PIN PLUG

Pin #5 of the 10-pin plug is the input from

the bus to ZF to show the brake pedal

position. It should have a reading of 0.5

volts with no pedal movement and 5.0

volts with full movement.

Pin #9 of the 10-pin plug is a ground signal

controlled through a relay by the ABS/TC

controller. The ground is removed when an

ABS/TC condition is present when turning

off the retarder.

For a complete wiring diagram of the ZF harness refer

to ZF circuit diagram 6029.749.018.

Vendor%20Manual%20Links/ZF/Ecomat%204/EcoMat%20wiring%20diagram.pdf


VERSION 1.0


22-PIN PLUG

Pin #11 of the 22-pin plug is the retarder

on/off switch. In order for the retarder to

work, this terminal should show 0 volts. A

reading of 24V at this terminal indicates

that the retarder is turned off.


VERSION 1.0


RETARDER DIAGRAM


VERSION 1.0


DRIVE SHAFT

DESCRIPTION

The drive shaft consists of two sections, each

incorporating a universal joint. Each universal joint

consists of a forged steel journal on which a trunnion

is fitted with a needle race.

One section has internal splines into which the

external splines of the other section engages. Both

sections have a non-metallic coating to reduce sliding

friction and to improve spline life.

The drive shaft is non-serviceable and therefore

requires replacement if worn or damaged.

INSPECTION

The drive shaft should be checked periodically as

follows:

Check that the flanges on the transmission

and the rear axle are tightly secured.

Ensure that there is no play in the bearings

supporting the transmission output shaft

and the axle input shaft.

Check the end float in the universal joints.

This should not exceed 0.15 mm (0.006 in).

Check the radial play between the two

splined sections. This should not exceed 0.18

mm (0.007 in).

Check the shaft for damage, such as bending.

Replace the drive shaft if it fails any of the above

checks.

LUBRICATION

The shaft should be lubricated every 3 months, or

approximately 10,000 km (6,000 miles).

Note: The slip joint is the only component that uses

grease.

REMOVAL

In order to disconnect the drive shaft, remove the

four locking nuts and bolts at the transmission end.

Then, remove the four locking nuts from the bolts at

the rear axle end.


VERSION 1.0


CHAPTER 6 FRONT SUSPENSION AND STEERING

FRONT SUSPENSION

DESCRIPTION

This vehicle is equipped with a double-wishbone

independent front suspension, containing upper and

lower control A-arms. The wheels have bearings,

which slide over the spindle. The spindle is connected

to the steering knuckle, which is attached to the

upper and lower control arms via T-joints. Each arm

consists of two mounting points that connect to the

frame and one joint at the knuckle. The shock

absorbers and air springs mount to the arms, allowing

for control of vertical movement. A stabilizer bar is

attached to the chassis using connecting brackets.

MAINTENANCE

The following checks should be performed during all

ordinary vehicle maintenance operation:

Visual inspection of the plastic joints

connecting the suspension to the chassis. If

breaks or cracks are observed on the plastic

joints, they must be replaced.

Visual inspection of the T-joint seals

between steering knuckle and arms. If

damaged, they must be replaced.

Visual inspection of any suspension

component condition, ensuring that there

are no cracks from shocks absorbers.

Visual inspection of brake pad and disc brake

thickness.

CAUTION: Inspection of the T-joint seals is vital to the

longevity of the suspension system, as damaged

sealing boots and winter climatic conditions can cause

deterioration of the corrosion protection coating

applied during manufacture.

For instruction on how to repair/replace components,

refer to the Voith manual.

For front suspension specifications, refer to Front End

Alignment Spec.

For front suspension alignment procedure, refer to

Vicinity bus suspension alignment procedure.

REPLACING RUBBER JOINTS

Instructions on how to replace the rubber joints on

the front suspension can be found in the Voith

manual.

WARNING

Never perform maintenance work, cleaning, or

greasing while engine is running.

WARNING

Ensure that the area in which maintenance work

is performed is clean and dry. Any water puddles

or oil spills must be cleared immediately.

Vendor%20Manual%20Links/Voith/Front%20Suspension.pdf

Vendor%20Manual%20Links/Voith/Front%20End%20Alignment%20Spec.pdf

Vendor%20Manual%20Links/Voith/Front%20End%20Alignment%20Spec.pdf

Vicinity%20bus%20suspension%20alignment%20procedure.pdf

Vendor%20Manual%20Links/Voith/Rubber_joint_replacement.pdf

Vendor%20Manual%20Links/Voith/Rubber_joint_replacement.pdf


VERSION 1.0


CHECKING HEIGHT

The front suspension height is measured by

calculating the distance from the bottom mounts to

the top plates of the air spring assembly. This

measurement should fall within the range of 205 mm

± 5 mm (8.1 in ± 0.2 in) for 27.5 ft buses, or 195 ± 5

mm for 30 ft buses (7.7 in ± 0.2 in).

CAUTION: It is imperative that the vehicle’s

suspension is to specification, particularly side-to-side

deviations, so that vehicle dynamics are not disturbed.


VERSION 1.0


COMPLETE ASSEMBLY DIAGRAM


VERSION 1.0


UPPER CONTROL ARM DIAGRAM


VERSION 1.0


LOWER CONTROL ARM DIAGRAM


VERSION 1.0


STEERING

OVERVIEW

This vehicle’s single steering gear system is comprised

of power steering with a hydraulic system. The

steering gear consists of a tilt telescopic steering

column at the driver’s station, which is connected to

an angle box. The angle box is attached to a Sheppard

steering box.

INSPECTION

The following inspections may be easily accomplished

without having to remove steering components from

the vehicle:

Inspect end play of front wheel bearings for

signs of wear or damage.

Check all steering gear mounting bolts and

nuts. Tighten if necessary.

Check front end alignment.

Check movement in ball joints.

Check for adequate lubrication of steering

gear and components (e.g. drag link ends, tie

rod ends, steering knuckle bearings).

Check steering fluid level in the reservoir.

Add fluid if required. For instructions, see

Changing Fluid and Filter.

Check and replace reservoir filter if

necessary. For instructions, see Changing

Fluid and Filter.

Check the steering gear for the following

conditions:

o Inspect steering column for drag. Note

that more than 69 kPa (10 psi) of drag

measured with the column suspended

at the angle of operation would be

considered excessive.

o Ensure that steering gear mounting is

tight as shifting on the frame can hinder

steering performance.

CHECKING BALL JOINTS

The movement of the radial and axial end floats can

be checked for looseness by performing a simple

check. If the ball joint parameters fall outside of the

limits outlined below, they must be replaced.

WARNING

Do not check for leaks by hand as hydraulic oil

when under pressure can penetrate the skin

causing severe bodily injury.


VERSION 1.0


AXIAL END FLOAT

The end float pointing in direction of ball pin axis

should be within the range of 0.4 to 2 mm (0.02 to

0.08 in). Apply 110 – 135 N (25 – 30 lb) of pressure by

sliding hands up and down under the ball stud socket.

The rod end must be replaced if any movement or

looseness is observed.

RADIAL END FLOAT

The radial end float joined at right angles to ball pin

axis should be within the range of 0.4 to 0.8 mm (0.02

to 0.03 in). Apply 110 – 135 N (25 – 30 lb) of pressure

by wiggling hands side to side at the ball stud socket.

The rod end must be replaced if any movement or

looseness is observed.

MAINTENANCE

Limited maintenance is required for the steering

system. Steering components should be checked

regularly, but note that most parts are not serviceable.

The following precautions should be used when

performing maintenance on the steering gear:

Only replace broken steering components

with unaltered equipment. Do not attempt

to weld any broken components.

Do not severely cold-straighten any

components.

Do not heat-straighten or bend any

components.

Only use new seals and O-rings for repairs

and overhauls.

For instruction on steering box repairs, replacement,

and assembly, refer to the Sheppard manual.

CHANGING STEERING FLUID

It is recommended that the power steering fluid and

filter should be changed annually as this is necessary

to keep the system clean. Only high quality fluids and

filters should be used in order to ensure removal of

contaminants and heat dissipation.

WARNING

Power steering system repairs should only be

performed by highly trained mechanics. Failure to

follow safety protocols could result in steering

system damage, failure, or personal injury.

WARNING

Never use old or worn seals, cotter pins, retainers,

or critical fasteners. Only use new, manufacturer-

approved replacement seal kits.

WARNING

Never use old or worn seals, cotter pins, retainers,

or critical fasteners. Only use new, manufacturer-

approved replacement seal kits.

WARNING

Used steering fluid and filter elements must be

safely disposed of in accordance with local

environmental regulations.

Vendor%20Manual%20Links/Sheppard/Steering%20Box%20Service%20Manual.pdf


VERSION 1.0


Use the following procedure to change the power

steering fluid and filter:

1. Park the vehicle on dry, level ground. Block

the rear wheels and shift the transmission

into Neutral.

2. Raise the front end of the vehicle until the

tires clear the hydraulic jack, then tilt the

hood.

3. Remove the pressure and return lines from

the steering gear and drain fluid into a drain

pan.

4. Wipe the area surrounding the power

steering fluid reservoir cap using a clean

towel.

5. Remove and discard the canister filter.

Note: Only the filter element needs to be

discarded. The other parts may be used to

secure the filter inside the reservoir

assembly.

6. Wipe the inside of the reservoir canister

clean.

7. Slowly turn the steering wheel from a full

left position to full right at least three times

to purge oil from the steering gear into the

drain pan.

8. Re-attach the pressure and return lines to

the steering gear and tighten.

9. Install a new filter element in the reservoir.

10. Clean the reservoir cap using an approved

solvent. Remove the used gasket from the

cap and replace with a new one.

11. Fill the reservoir with new steering fluid to

the “Max” fill line.

12. Start the vehicle and allow it to idle,

checking the fluid level and filling as needed.

13. Steer the wheels from full left to full right

several times, checking the fluid level again.

14. Once all fittings and hoses have been

checked for leaks, shut the vehicle off and

lower it.

CHANGING FILTER ELEMENT

Before changing the filter element, the steering fluid

reservoir needs to be drained. This can be done by

removing the pressure and return lines from the

steering gear and drain fluid into a drain pan.

1. Unscrew filter cap.

2. Push down on filter locating device and turn. Pull

it out of the reservoir.

3. Remove filter element from locating device and

discard safely.

4. Insert filter locating device into new filter

element and push into the hole at the bottom of

the reservoir.


VERSION 1.0


5. Fill with steering fluid until reservoir is

approximately 75% full. Top up with fluid as

needed while bus is running until fluid stops

draining and reaches the “Max” line.

BLEEDING STEERING GEAR

Bleeding the steering gear is necessary if the steering

box has been mounted in such a way that air becomes

trapped in the sector shaft bore. This procedure

should be followed whenever the steering box has

been disassembled or replaced and can be completed

as follows:

1. Ensure the vehicle is stationary and on dry, level

ground. Set the parking brake, block the wheels,

and shift the transmission into Neutral.

2. Tilt the hood and ensure that the fluid level in the

reservoir is full.

3. Start the engine and allow the vehicle to idle.

4. Steer the wheels from full left to full right several

times, ensuring that the pitman arm makes full

travel.

5. Open the bleeder screw located on the sector

shaft bore until non-aerated fluid pours out. Do

not turn the steering wheel while the bleeder is

open.

6. Repeat steps 3 to 5 until no aeration is found in

the bleed oil, then tighten the bleed screw.

7. Check the fluid level in the power steering

reservoir. If no fill is necessary, shut the vehicle

off, lower the hood, and remove wheel blocks.

CAUTION: Excessive heat will result if the power

steering gear is held in a full right or left turn for

longer than a few seconds. This can result in damaged

seals and/or pump.

WARNING

Used steering fluid and filter elements must be

safely disposed of in accordance with local

environmental regulations.


VERSION 1.0


DIAGRAM


VERSION 1.0



HYDRAULIC SYSTEM

The hydraulic system provides power to the steering

system. An engine-driven pump draws hydraulic oil

from the power steering fluid reservoir. The proper

operation of this vehicle’s Sheppard power steering

box is contingent upon an adequate supply of oil

pressure and flow from the hydraulic supply pump.

MAINTENANCE

The following maintenance procedures should be

performed regularly on the hydraulic pump system:

Visually inspect for air mixed with steering

system oil. The oil should be clear and not

frothing as this is a sign of air in the system.

Drain, refill, and bleed the system. Check for

leakage around the suction of the steering

pump.

Using a flow test kit, conduct a flow test by

measuring oil flow under the following

conditions:

o Flow at idle with back pressure only

o Flow at idle under a 10,342 kPa

(1,500 psi) load applied with the

shutoff valve

o Flow at full governed RPM with

back pressure only

o Flow at full governed RPM under a

10,342 kPa (1,500 psi) load applied

with the shutoff valve

Measure and record the pressure required

to turn the steering wheel from full left to full

right while the vehicle is parked. Input effort

is measured at the steering wheel retaining

nut. Normal input effort should be less than

689 kPa (100 psi).

For a complete maintenance service schedule, see

SECTION X. STEERING/HYDRAULIC SYSTEM

SCHEDULE.


VERSION 1.0


DIAGRAM


VERSION 1.0


CHAPTER 7 REAR SUSPENSION/AXLE

REAR SUSPENSION

DESCRIPTION

This vehicle’s rear suspension is provided by four air

springs mounted on suspension arms and suspended

on a rigid rear axle. An anti-roll bar is incorporated

that is rubber mounted to the frame using stabilizer

brackets. Shock absorbers are assembled to mounting

brackets on the chassis frame.

The suspension is controlled by an electronically

controlled air suspension (ECAS) system.


Height sensor . . . . . . . . . . . . . . . . . .21 Nm (15.5 lb-ft)

Torque rod to frame . . . . . . . . . . . .191 Nm (141 lb-ft)

Torque rod to axle . . . . . . . . . . . . . 191 Nm (141 lb-ft)

Suspension arm to axle . . . . . . . . . 480 Nm (354 lb-ft)

Reaction rod to frame . . . . . . . . . . 406 Nm (300 lb-ft)

Reaction rod to axle . . . . . . . . . . . . 440 Nm (325 lb-ft)

Bracket to axle (large) . . . . . . . . . . .440 Nm (325 lb-ft)

Bracket to axle (small) . . . . . . . . .200 Nm (147.5 lb-ft)

Stabilizer bar link . . . . . . . . . . . . . . .220 Nm (162 lb-ft)

Stabilizer bar to frame bolts . . . . . . .122 Nm (90 lb-ft)

Stabilizer bar mount to rear axle . . . .89 Nm (66 lb-ft)

MAINTENANCE

The following maintenance procedures should be

performed at regular intervals:

Check shock absorbers.

Check the height of the vehicle.

Inspect the air springs for cracks, bursts,

deterioration, or shearing. Replace if

damaged.

Ensure that none of the surfaces of the

upper and lower mounting plates and piston

contain cracks.

WARNING

Never perform work underneath the vehicle

solely using jacks as support. Additional support

that is able to hold the vehicle weight when the

jacks are removed must be provided under the

chassis framework.

WARNING

Pressurized air can cause serious bodily injury.

Release all air from the suspension system before

removing any component.

WARNING

To prevent serious eye injury, always wear

protective eyewear when performing vehicle

maintenance or service.


VERSION 1.0


CHECKING SHOCK ABSORBERS

Four hydraulic double acting shock absorbers are

used on the suspension system: one at each front

wheel, one adjacent to each rear air spring, and

another on either side of the rear axle.

The shock absorbers are sealed units with rubber

brushed mountings and therefore require no

servicing. However, they should still be checked and

re-fitted for the following issues:

Visually inspect for fluid leakage.

Check for dents or cracks.

Check for scored or bent piston rod.

Check resistance by slowly expanding and

contracting each shock absorber several

times. Even resistance should be observed

travelling in both directions.

CHECKING HEIGHT

The rear suspension height is measured by calculating

the distance from the bottom mounts to the top

plates of the air spring assembly, located in front of

the rear axle. This measurement should fall within the

range of 230 mm ± 5 mm (9 in ± 0.2 in) for 27.5 ft

buses, or 220 mm ± 5 mm (8.7 in ± 0.2 in) for 30 ft

buses.

CAUTION: It is imperative that the vehicle’s

suspension is to specification, particularly side-to-side

deviations, so that vehicle dynamics are not disturbed.


VERSION 1.0


DIAGRAM


VERSION 1.0


ECAS

OVERVIEW

This vehicle’s suspension system comes equipped

with a Meritor WABCO electronically controlled air

suspension (ECAS) system, which is designed to

enhance the performance of the air suspension. Its

function is to maintain an accurate leveling of the

chassis height through the use of level sensors, an

electronic control unit (ECU), and solenoid valves. The

ECAS system includes a customized set of parameters

for this vehicle. These parameters determine some of

the features and characteristics for the ECAS

configuration.

Two solenoid valve blocks, one located on the front

suspension and one on the rear, control the air

suspension on the vehicle.

ELECTRONIC CONTROL UNIT

The ECAS electronic control unit (ECU) is located

within the interior electrical compartment of the

vehicle. It connects to various other ECAS

components and performs the following functions:

Monitors level and pressure sensors.

Controls solenoid valves.

Monitors function of system components,

storing faults and performing diagnostics.

CAUTION: Avoid damaging the ECU connectors when

troubleshooting or testing the system.

For further details on these operations, refer to the

Meritor WABCO manual.

INDICATOR LAMP

The ECAS indicator lamp, which is integrated into the

LCD display panel standard on the instrument panel,

indicates when ECAS system faults are detected by

the electronic control unit (ECU). Faults are stored in

its memory as active and when the fault clears, it will

be stored as inactive. ECAS faults can be diagnosed

using the Meritor WABCO TOOLBOX™ software. For

more information on this software, refer to the

Meritor WABCO manual.

In the event of a system malfunction, the ECAS

indicator lamp will alert the driver and the suspension

will retain the existing air pressure in the air

suspension bellows.

For troubleshooting tips and diagnostic codes, refer

to the Meritor WABCO manual.

Vendor%20Manual%20Links/Meritor%20WABCO/ECAS%20Manual.pdf





VERSION 1.0


MAINTENANCE

Regularly scheduled maintenance is not required for

ECAS. However, the exhaust port filter, located

behind the buffer on the solenoid valve blocks, should

be unscrewed periodically and checked for debris. If

any is found, the airlines will also need to be checked

for contamination and cleaned if necessary.

Note: Proper maintenance should still be performed

on all other components of the vehicle’s suspension

system.

HEIGHT MEASUREMENT

Four level sensors provide monitoring of the vehicle’s

height (axle-to-frame distance) on each of its four

points. These sensors frequently send signals to the

ECU containing height information. If it is determined

that the vehicle height is uneven, the ECU will

increase or decrease air pressure in the air springs

accordingly.

The following vehicle height measurements can be

observed from the middle of the ramp:

Kneeling height . . . . . .260 to 270mm (10¼ to 10¾ in)

Normal ride height . . .340 to 350mm (13½ to 13¾ in)

Level II height . . . . . . . . . .410 to 430mm (16 to 17 in)

WARNING

To prevent serious eye injury, always wear

protective eyewear when performing vehicle

maintenance or service.

WARNING

Pressurized air can cause serious bodily injury.

Release all air from the suspension system before

removing any component.


VERSION 1.0


AIR DIAGRAM


VERSION 1.0


REAR AXLE

DESCRIPTION

This vehicle’s rear axle is a conventional rigid axle

contained within the axle housing. Power is

transferred through a differential and a set of

planetary gears. Four air springs mounted on

suspension arms attached to the rear axle provide air

suspension to the system. A stabilizer bar is attached

to the chassis using connecting brackets.

SPECIFICATIONS

Max. load capacity . . . . . . . . . . . . . . . . . . . . . .8,200 kg

Dry weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .740 kg

Oil type . . . . . . . . . . . . . . . . . . . . . . .... . See Filling Oil

Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 litres

MAINTENANCE

The rear axle requires the following periodic

maintenance checks:

Check oil level every 10,000 km.

Change oil every 120,000 km, or two years.

Check axle housing breather and wheel

bearing adjustment.

Inspect hub and pinion for leakage.

Ensure that half shaft and studs are secure.

Ensure that axle is secured within the

housing.

Examine the differential gear set for damage,

wear, and distortion. Check the pinion for

excessive wear and adjust the spider, if

required. Replace both the entire drive

pinion and crown wheel as a complete unit if

necessary.

Ensure that the vent breather tube is free

from obstruction every 10,000 km as

clogging can cause moisture to become

trapped in the axle and differential.

In addition to the above, the following service items

should be performed on the planetary final drive:

Thoroughly clean all components.

Check gears and screw thread for wear and

damage. Replace if required.

Lubricate bearings, ensuring that roller cages

rotate freely without resistance.

Replace all seals and gaskets when necessary.

CHECKING OIL

Sufficient lubrication is critical in order to prevent the

rear axle from seizing up.

Oil level should be checked every 10,000 km, or at

every regularly scheduled vehicle maintenance. It

must be replaced every 120,000 km, or two years.

To check the oil level:

1. Park the vehicle on level ground and shift the

transmission into Neutral. Apply the parking

brake and block the rear wheels.

2. Raise and support the vehicle at all four points.

3. Thoroughly clean the area surrounding the fill

plug to prevent oil contamination.

4. Remove the fill plug and ensure that the oil

reaches the bottom of the fill hole. If a slight

amount of fluid does not drip out of the fill hole,

it needs to be filled.

WARNING

Never perform work underneath the vehicle

solely using jacks as support. Additional support

that is able to hold the vehicle weight when the

jacks are removed must be provided under the

chassis framework.


VERSION 1.0


DRAINING OIL

CAUTION: Performing an initial oil change within

8,000 km (5,000 mi) of a new or rebuilt axle is critical.

This removes the fine particles of material produced

during vehicle operation and also prevents

accelerated wear. After the initial oil change, the

entire rear suspension should be inspected for

excessive particle accumulation.

Oil must be replaced every 120,000 km, or two years.

If an oil change is needed, it can be drained by

following these steps:

1. Unscrew and remove oil plug (a) and

corresponding seal.

2. Remove drain plugs from central case (b) and

side final drives (c).

3. Completely drain oil into a suitable container.

4. Replace seals.

5. Screw in and tighten drain plugs using a

torque of 35 to 40 Nm (26 to 30 lb-ft).

FILLING OIL

Oil should be checked and refilled, if necessary, at

every regularly scheduled vehicle maintenance.

After draining oil, fill as follows:

1. Unscrew level plug (a).

2. Fill with mineral oil corresponding to the

specifications MIL-L-2105 D and API GL5 with

a viscosity of SAE 85W 140 – SAE 80W 140.

The oil should be overflowing from the level

hole (a).

3. Wait 15 minutes to allow the oil to distribute

evenly within the axle housing.

4. Check oil through the level hole and fill up if

necessary. Proper level is reached when oil

sits just below the edge of the level hole.

5. Refit and tighten level plug using a torque of

50 to 55 Nm (37 to 41 lb-ft).

WARNING




VERSION 1.0


For more information on the rear axle, refer to the

Oerlikon Graziano manual.



VERSION 1.0


CHAPTER 8 PNEUMATIC SYSTEM

AIR SUPPLY

DESCRIPTION

The air system consists of an air compressor that

pumps filtered air through a copper coil to a

condenser, which separates oil and water from the air.

The air is carried to a Bendix AD-IS air dryer, where it

is cleaned and dried. The air is then delivered to the

vehicle’s primary reservoir, secondary reservoir, and

accessories.

CONDENSER

The condenser reduces the risk of the braking system

stalling. It is designed to condense, separate, and

remove oil and water from the pressurized air before

it reaches the air dryer. The contaminants accumulate

in the reservoir, found at the bottom of the condenser,

before they are drained upon each brake application

by an electrically heated automatic drain valve (ADV).

1. The ignition turns on and powers the

solenoid coil, which generates a magnetic

force that pulls the shuttle towards the

upper seat.

2. When the automatic drain valve opens, air

pressure forces the shuttle against the lower

seat.

3. When the brakes are applied, the solenoid

valve current is interrupted and the shuttle

moves to the lower seat.

4. Water, oil, and contaminants in the reservoir

fill the internal space surrounding the shuttle.

5. When the brakes are released, the current

pulls the shuttle against the upper seat once

again, allowing any water, oil, or

contaminants to drain automatically.

6. Turn off the ignition before pushing the

manual drain button to activate drainage.

MAINTENANCE

The condenser must be checked every 12 months to

ensure proper operation. Due to high temperatures

and compressor duty cycles, a build-up of carbon can

appear in the condenser, drain valve, and filter. This

contamination must be removed.

To inspect the condenser:

1. Check condenser fittings for air leaks during

the compressor loading cycle by applying

soap solution around pipe fittings. Check

bottom of drain valve for air leaks

surrounding manual drain port.

2. With ignition switch on and compressor

pumping, apply brakes. When the brakes are

applied, the drain valve will open and a slight

puff of air will be expelled.

If valve does not operate, release the brakes

and check electrical wiring for correct

voltage. Insure that the voltage matches the


VERSION 1.0


voltage mentioned on the drain valve label.

If there is no current, check the electrical

circuit at the relay valve and brake light

switch.

If the condenser unit fails any of the above checks, it

must be discarded instead of repaired as it is a non-

serviceable item.

CLEANING

To clean the condenser unit:

1. Disconnect the electrical connectors.

2. Unbolt the sump area from condenser and

remove internal separator from inside condenser

body.

3. Unbolt the bottom plate of the automatic drain

valve and remove shuttle valve.

4. Clean and inspect all components for damage,

contamination, and corrosion. Clean automatic

drain valve filter and blow dry with compressed

air, taking care not to remove filter from sump

area.

5. If any parts are found to be worn or damaged, the

unit can be rebuilt with the repair kits found in

the condenser maintenance manual. If no

damage is found, reassemble the unit and retest.

For complete installation instructions and

information on connector repair kits, refer to the

condenser maintenance manual.

AIR DRYER AND RESERVOIRS

Air dryer only. Reservoir not shown.

The air dryer and reservoirs have been designed as an

integrated air supply system. They work together to

collect contaminants before they enter the brake

system. The air dryer and reservoirs also control the

compressor/dryer charge cycle.

The AD-IS air dryer and reservoir systems are

designed to receive compressed air from the vehicle

air compressor, clean and dry the air, deliver air to the

vehicle’s primary reservoir, secondary reservoir and

accessories, and control the compressor/dryer charge

cycle.

WARNING

Do not attempt to service or adjust the air dryer

pressure protection valves. Incorrect pressure

settings can result in automatic application of

vehicle spring brakes without warning.

Vendor%20Manual%20Links/Pneumatic%20System%20File/Haldex%20condenser%20manual.pdf

Vendor%20Manual%20Links/Pneumatic%20System%20File/Haldex%20condenser%20manual.pdf


VERSION 1.0


The AD-IS air dryer incorporates pressure protection

valves that are pre-set. The function of the pressure

protection valves is to protect each reservoir from a

pressure loss in the other reservoir, or in an air

accessory.

Each of the pressure protection valves in the AD-IS air

dryer and reservoir systems have different pressure

settings. These are factory set and must not be

changed or adjusted.

CHARGE CYCLE

The purge reservoir fills, storing air that will be used

to regenerate the desiccant during the purge cycle.

This air is available to supply downstream

components during the charge mode.

When the air pressure reaches approximately 730 kPa

(106 psi) in the purge reservoir, the four pressure

protection valves will open and air will be supplied to

following components:

Primary reservoir.

Secondary reservoir.

Accessories.

If the pressure protection valves are pre-set to

different values the valves will open from the lowest

setting to the highest setting. The air dryer and purge

reservoir will remain in the charge cycle until the air

brake system pressure builds to the governor cut-out

setting of approximately 896 kPa (130 psi).

For instructions on performing field inspection service

on the AD-IS air dryer, refer to the Bendix guide.

Vendor%20Manual%20Links/Pneumatic%20System%20File/Bendix%20AD-IS%20Field%20Inspection.pdf


VERSION 1.0


DIAGRAM

Note: This diagram is for informational purposes only

to show the travel of air flow and the functionality of

the air dryer. Air system components shown in this

diagram may differ from those in this vehicle..


VERSION 1.0


MAINTENANCE

CAUTION: Do not inject alcohol, anti-freeze, or other

de-icing substances into the air dryer and reservoir

system. Alcohol is removed by the dryer, but reduces

the effectiveness of the device to dry air. Use of these

or other substances can damage the air dryer and

may void the warranty.

Since the air dryer and reservoir systems provide

filtered, dry air to the components of the brake

system, the life of the system is increased and the

need to manually drain the reservoirs on a daily basis

is eliminated.

However, the following preventive maintenance

checks should still be performed on the unit:

Every 900 operating hours, 40,000 km, or

three months, open the reservoir drain

valves and check for water in the air brake

system. A presence of moisture could

indicate that the desiccant cartridge needs

changing. However, the following may also

be the cause and should be checked before

doing so:

o If the air did not travel through the

drying bed due to the usage of an

outside air source to charge the

system.

o Check for high air system leakage.

o The air dryer is located too close to

the air compressor.

o Condensation has formed as a

result of a wide temperature range

(30 degrees or more) being

observed in one day. This type of

moisture accumulation is normal

and only temporary.

For a full list of air dryer and reservoir troubleshooting

items, see the Bendix manual.

If it is determined that one or more components of

the air dryer requires replacement or maintenance

during the routine operation and leakage tests, refer

to the Bendix® Quick Reference Catalog for the

appropriate maintenance kit(s), found on the Bendix

website.

WARNING

Air pressure must be drained from all reservoirs

before performing work on the air system.

WARNING

Never connect or disconnect a hose or line

containing pressure as it may whip. Ensure that all

system pressure has been drained before

removing a component or plug.

WARNING

Wear safety glasses at all times in case of a purge

blast, which can cause serious eye injury.

WARNING

Always completely depressurize the air dryer and

purge reservoir to 0 kPa (0 psi) before servicing

the air dryer.

Vendor%20Manual%20Links/Pneumatic%20System%20File/Bendix%20air%20dryer%20manual.pdf

http://www.bendix.com/en/



VERSION 1.0


TESTING

Before servicing the air dryer or reservoir system,

perform the following tests:

1. Ensure that all reservoir drain valves are

closed.

2. Increase system pressure to governor cut-

out and ensure that the air dryer purges air

with an audible sound, then air flows out of

the purge valve for approximately 30

seconds.

3. “Fan” the brakes to purge the system air

pressure.

4. Perform a leak test on the entire air system

in order to ensure that the air dryer and

reservoir system do not cycle excessively.

LEAK TESTING

CAUTION: The pressure protection valves are not

serviceable items. Do not attempt to adjust or service

them.

To test for leakage in the air system:

1. Check all lines and fittings connected to the

air dryer and reservoir system for leakage

and damage. Repair any leaks found.

2. Increase system pressure to governor cut-

out and ensure that the air dryer purges air

with an audible sound. Observe the pressure

for ten minutes. If the pressure drops more

than 6.89 kPa (1 psi) per minute, inspect the

vehicle air systems for leaks and repair them.

3. Check for leakage around the purge valve

with the compressor in charge mode. Apply

a soap solution to the purge valve exhaust

port. If leakage exceeds a one-inch bubble

per second, the purge valve needs to be

repaired or replaced.

If it is determined that one or more components of

the air dryer requires replacement or maintenance

during the routine operation and leakage tests, refer

to the Bendix® Quick Reference Catalog for the

appropriate maintenance kit(s), found on the Bendix

website.




VERSION 1.0


AIR SYSTEM DIAGRAM


VERSION 1.0


BRAKING SYSTEM

DESCRIPTION

The braking system is fully air operated with ABS, the

front and rear service brakes being applied and

released by the brake treadle during normal

operation. It incorporates an emergency braking

feature that utilizes parts of the rear service brake

and parking brake systems, which is mechanically

applied by spring brakes. These systems combine to

stop the vehicle in the event of a brake system/air

supply failure.

This vehicle’s braking system is in compliance with

CMVSS 121.

DISC BRAKES

The disc brakes encompass rotors, brake

calipers/pads, and air actuators.

See Front/Rear Disc Brake Sectioned View for a

diagram of the parts listed in the next three sub-

sections.

BRAKE ACTUATION

During actuation, the Push Rod of the Actuator (18/1

or 18/2) moves the Lever (19). The input forces are

transferred via the Eccentric Bearing (20) to the

Bridge (17). The force is then distributed by the Bridge

(17) and the two Threaded Tubes (16) to the Tappet

and Boot Assemblies (13) and finally to the inboard

Pad (12).

After overcoming the running clearance between the

Pads and the Disc, the reaction forces are transmitted

to the outboard Pad (12). The clamping forces on the

Pads (12) and the Disc (46) generate the braking force

for the wheel.

BRAKE RELEASE

After releasing the air pressure, the two Return

Springs (27/28) push the Bridge (17) and Lever (19)

back to the start position; this ensures that a running

clearance between Pads and Disc is maintained.

BRAKE ADJUSTMENT (AUTOMATIC)

To ensure a constant running clearance between Disc

and Pads, the brake is equipped with a low wearing,

automatic adjuster mechanism.

The Adjuster (23) operates with every cycle of

actuation due to the mechanical connection with

Lever (19). As the Pads and Disc wear, the running

clearance increases. The Adjuster (23) and Turning

Device (24) turn the Threaded Tubes (16) by an

amount necessary to compensate for this wear. The

total running clearance (sum of clearance both sides

of Disc) should be between 0.5 and 1.0 mm. smaller

clearances may lead to overheating problems.

WARNING

Only lift or move parts with a lifting device that has

sufficient weight capacity. Ensure that the

components are supported by suitable belts or

hooks.

Hub assembly weight: approx. 27 kg (60 lb)

Brake disc weight: approx. 35 kg (77 lb)

Caliper weight: approx. 45 kg (99 lb)


VERSION 1.0


FRONT/REAR DISC BRAKE SECTIONED VIEW


VERSION 1.0


BRAKE PADS

INSPECTION

Brake pad thickness should be manually checked at

least every three months. If the thickness of at least

one brake pad is 2 mm (0.08 in) or less, they must all

be replaced regardless of their condition.

REPLACING

CAUTION: Always check the function of the automatic

adjuster before removing the brake pads.

1. Remove the wheel.

2. Straighten the lugs and pull out the

protective plate.

3. Remove the split-pin and the locking washer.

Press the brake pad mounting bracket down

and pull out the pin. Remove the mounting

bracket.

o If the mounting bracket is damaged,

it must be replaced.

4. Unhook the springs and disconnect the

brake wear sensor cable from the pads.

5. Remove the cover.

6. Make more room for removal by turning the

adjuster pinion counter clockwise. An

audible click should be heard.

7. Push the pad inwards towards the disc.

8. Pull the brake pads straight out.

BRAKE DISCS

INSPECTION

Brake disc thickness should be checked periodically.

When the thickness of a brake disc reaches 37 mm

(1.46 in), it must be replaced. New brake discs will

have a thickness of 45 mm (1.77 in).

WARNING

Regularly check brake pads and discs for wear.

Worn-out pads and discs reduce braking action

effectiveness and can cause brake failure.

WARNING

Never replace individual pads, but rather all of the

pads as an axle set. Incorrect replacement may

lead to brake malfunction.

WARNING




WARNING

In order to prevent braking system failure, brake

discs must be replaced once they reach 37 mm

(1.46 in) or less.


VERSION 1.0


REMOVAL

To disassemble, follow the below steps for each brake

disc:

1. Remove the rim and tire from the

suspension.

2. Carefully disconnect the pneumatic pipe.

3. Remove the two screws that connect the

steering lever to the steering knuckle.

4. Remove the steering lever.

5. Remove the six screws that connect the

caliper to the steering knuckle.

6. Remove the caliper.

7. Remove all the screws that attach the hub to

the bearing, then remove the hub assembly.

8. Remove the brake disc.

WARNING

The caliper is connected to the suspension using

pressure piping. The connection piping is used to

actuate the braking function and therefore can

contain high amounts of pressure. Use caution

when disconnecting.

WARNING

Brake discs will remain at an extremely high

temperature for a considerable length of time

after use. Use caution when handling.


VERSION 1.0


ASSEMBLY

To reassemble new brake discs after removal:

1. Push the studs into the wheel hub with a

hammer or press machine.

2. Install the new brake disc and hub assembly.

3. Insert all 12 bolts and screw in with a

tightening torque of 440 Nm (325 lb-ft).

4. Install the caliper.

5. Insert the six bolts and screw in with a

tightening torque of 580 Nm (428 lb-ft).

6. Assemble the steering lever. Insert the two

bolts and tighten with a torque of 580 Nm

(428 lb-ft).

REAR BRAKES

The rear braking system is comprised of two main

components: service brakes and a

parking/emergency brake.

BRAKE PADS

INSPECTION

Brake pad thickness should be manually checked at

least every three months. If the thickness of the

friction material on at least one brake pad is less than

2 mm (0.08 in), they must all be replaced regardless

of their condition.

The friction material of a new brake pad will be 21 mm

(0.83 in). The overall thickness of a new brake pad will

be 30 mm (1.18 in).

REPLACING

CAUTION: Check the adjuster mechanism for correct

operation before removing brake pads.

Note: Do not overload or damage the adjuster. Only

use an 8 mm (0.3 in) ring spanner.

To remove and replace a rear brake pad:

1. Remove the wheel.

2. Push down on the pad retainer and remove

the protective plate.

3. Remove the clip and locking washer. Press

the mounting bracket down and pull out the

pin. Remove the mounting bracket.

o If the mounting bracket is damaged,

it must be replaced.

4. Unhook the springs and disconnect the

brake wear sensor cable from the pads.

5. Remove the adjuster cap and rotate the

adjuster counterclockwise.

6. Push the inboard pad towards the actuator

and pull out both pads.

WARNING




WARNING

Never replace individual pads, but rather all of the

pads as an axle set. Incorrect replacement may

lead to brake malfunction.


VERSION 1.0


For more information on the rear brake pads, refer to

the brake section of the Oerlikon Graziano manual.

SETTING CLEARANCE

In order to set the clearance between the brake pads

and discs:

1. Turn the automatic adjuster pinion until the pads

touch the disc.

2. Turn in the opposite direction two grid positions.

3. Apply the brake pedal several times. Determine if

the wheel hub is able to turn freely.

4. Replace the cover.

5. Insert the mounting bracket into the groove of

the brake caliper. Preload the bracket to allow

insertion of the pin.

6. Mount the washer and the split-pin onto the pin.

Apply and release the brake pedal. The wheel

hub must be able to manually turn with little

effort.

7. Mount the wheel.

The brake pad running clearance should be checked

on an annual basis.

WEAR SENSOR

An electronic wear sensor is connected to each of the

front and rear brake pads.

When the sensor detects that the brake pads are

worn out, one of the following indicator lamps will

illuminate on the dash, depending on the

manufacture date of the vehicle:

SPRING BRAKES

REPLACING BRAKE CHAMBERS

To remove and install new brake chambers:

1. Ensure bus is secure before attempting any

service on the braking system.

2. Raise bus and remove both rear wheels to

gain access to the brake chambers.

3. Release parking brake.

4. Screw out the caging rod on the chamber so

that it is fully extended. (Figure 3, item 3)

WARNING

The parking/emergency spring brake chamber

contains a very high spring load and should not be

disassembled. Serious or fatal injury may occur.

WARNING

The ATC function must be disabled (ATC indicator

lamp should be ON) prior to performing any

vehicle maintenance in which one or more

wheels on an axle are lifted off the ground and

moving.



VERSION 1.0


5. Engage the parking brake, and ensure the air

hoses are free of pressure.

6. Disconnect both air hoses from the brake

chamber. (Figure 3, item 4)

7. Unscrew spring brake mounting nuts. They

must not be re-used. (Figure 3, item 1)

8. Remove brake chamber from the contact

surface.

9. Clean contact surface. (Figure 3, item 2)

10. Install the hose fittings that were just

removed into the new brake chambers.

Note: New brake chambers will have drain plugs.

Remove the bottom plug and plug all others.

MAINTENANCE

The disc brake rotor should be checked for defects

every 10,000 km.

For a full service schedule, refer to SECTION VI.

PNEUMATIC/BRAKE SYSTEM SCHEDULE.

BRAKE TESTING

For a series of diagnostic brake tests, refer to the

braking system checklist.

PARKING/EMERGENCY BRAKE

The operation of the parking/emergency brake

should be checked on a daily basis. However, the

control valve is a non-serviceable item and should

therefore be discarded and replaced if it malfunctions

or any repairs are needed.

Parking brake application is made with the control

lever shown above. The handle is pulled up and will

auto release to the drive position. The movement of

the lever will apply or release air to the control port

#4-1 on the SR-7 valve. For more information, refer to

SR-7 Spring Brake Valve.

Note: The hand control valve can incorporate a micro-

switch that is used in the ramp inter-lock circuit.

EMERGENCY BRAKE APPLICATION

Emergency brake application is controlled by the SR-

7 valve.

The Bendix® SR-7® spring brake modulating valve is

used in conjunction with a dual air brake system and

a spring brake actuator. It performs the following

functions:

1. Provides a rapid application of the spring

brake actuator when parking.

2. Modulates the spring brake actuator

application using the dual brake valve should

a primary failure occur in the service brake

system.

Vendor%20Manual%20Links/Pneumatic%20System%20File/Braking%20System%20Checklist.pdf


VERSION 1.0


3. Prevents compounding of service and spring

forces. The valve has one park control, one

service control, one supply, one balance,

four delivery NPTF ports, and an exhaust

port protected by an exhaust diaphragm.

The valve incorporates two mounting studs for

mounting the valve to the frame rail or cross member

(where applicable).

ABS/ATC

This vehicle’s Bendix® Anti-lock Braking System (ABS)

uses wheel speed sensors, ABS pressure modulator

valves, and an Electronic Control Unit (ECU) to control

all four wheels. The EC-60™ controller monitors

individual wheel turning motion during braking,

checking for excessive wheel slip or lock-up, and

automatically adjusts the brake pressure accordingly

at the wheel end.

In addition to the ABS function, this vehicle’s EC‑ 60™

controller also provides an Automatic Traction

Control (ATC) feature. Similar to how ABS improves

vehicle stability during braking, ATC improves vehicle

stability and traction during vehicle acceleration. The

ATC function uses the same wheel speed information

and modulator control as the ABS function.

For more information on these features, refer to the

Bendix ABS manual.

DIAGNOSTICS

Computer-based Bendix® ACom® Diagnostics

software can be utilized to access fault codes. For

more information on interpreting trouble codes, refer

to the Bendix ABS manual. Alternatively, there is a

diagnostic switch that can be pressed to read the blink

codes.

Blink codes allow a technician to troubleshoot ABS

problems without using a hand-held or PC-based

diagnostic tool. Instead, information about the ABS

system is communicated by the ECU using the ABS

indicator lamp to display sequences of blinks.

PRESSURE MODULATOR VALVES

The Bendix® M-32™ pressure modulator valves (PMV)

modify driver applied air pressure to the service

brakes during ABS or ATC operation. When excessive

wheel slip, or wheel lock-up, is detected, the EC-60™

controller will activate the PMV to simulate a brake

application. The PMV are electro-pneumatic control

valves and are the last valves that air passes through

on its way to the brake chamber. The modulator hold

and release solenoids are activated to "modulate" or

"control" the brake pressure during an antilock

braking event. This design also allows for air delivery

to brake chambers in the event of electrical trouble.

Bendix® M-32™ pressure modulator valves

For information on how to perform a pressure

modulator valve chuff test, refer to the Bendix ABS

manual.

WARNING

The ATC function must be disabled (ATC indicator

lamp should be ON) prior to performing any

vehicle maintenance in which one or more

wheels on an axle are lifted off the ground and

moving.

Vendor%20Manual%20Links/Pneumatic%20System%20File/Bendix%20ABS%20manual.pdf





VERSION 1.0


TRACTION CONTROL VALVE

Automatic traction control minimizes wheel slippage

during acceleration by controlling both the engine

throttle and brake pressures at individual wheels

when required.

This is done by the use of traction control valve,

located in the rear engine compartment of the vehicle,

near the relay valve for the rear brakes.

WHEEL SPEED SENSOR

Bendix® WS-24™ wheel speed sensors (either 4 or 6,

depending on configuration) are installed with a

Bendix Sensor Clamping Sleeve.


VERSION 1.0


SYSTEM DIAGRAM


VERSION 1.0


CHAPTER 9 ELECTRICAL SYSTEM

SYSTEM AND COMPONENTS

DESCRIPTION

CAUTION: The vehicle master switch must be in the

OFF position before attempting to remove any

components or warning light bulbs from the

instrument panel. If these precautions are not strictly

adhered to, an electrical short may occur and damage

the instrument panel beyond repair.

This vehicle features a 24V multiplexed electrical

circuit system. Its main components are the

alternator, alternator drive belt, starting motor, and

two 12V batteries.

For system diagnostic information, refer to Electrical

Diagnostic Schematics.

PRECAUTIONS

The below precautions must be followed when

working on the electrical system. Note that this list is

not fully comprehensive.

1. Always check for electrical current polarity

and correct voltage before connecting a

battery.

2. Always turn all switches OFF and stop the

alternator before disconnecting any

electrical lead.

3. Always identify a lead to the correct terminal

before it is removed to ensure correct

reconnection.

4. Never check current flow by flashing

connections.

5. Always isolate the battery cables when using

a battery charger.

6. Always disconnect the battery before

connecting test instruments or before

replacing any unit or wiring. The voltmeter is

exempt from this.

ELECTRICAL COMPARTME NT

The interior electrical compartment is located behind

the driver’s cab. The following diagnostic controllers

and switches can be found inside:

WARNING

Always take the necessary safety precautions

before servicing or removing any electrical

component to avoid risk of personal injury or

equipment damage. Mark wiring prior to

disconnecting whenever possible to ensure

correct reconnection.

Electrical%20Diagrams/EDS%20Main%20Index.pdf

Electrical%20Diagrams/EDS%20Main%20Index.pdf


VERSION 1.0


1. Diagnostic port connectors

2. HVAC controller

3. Fuse holders

4. VIMs #1, 2, 3

5. ECAS ECU

6. ABS ECU

7. Diagnostic switches

DIAGNOSTIC SWITCHES

Diagnostic switches, found at the bottom of the

interior electrical compartment, activate the

following functions:

ZF Eco Mode: Switches transmission from

economy mode to power mode.

ZF Retarder: Turns retarder on/off.

ABS Diagnostics: Turns on ABS lights,

allowing for fault diagnosis.

Dash Diagnostics: Toggles the DPS, allowing

for adjustment of display functions, such as

the clock time.

ALTERNATOR

CAUTION: Keep the alternator clean and ensure that

the ventilation slots or air spaces are clear and free

from obstruction at all times.

The alternator is internally rectified with non-moving

windings and components. This means that there are

no brushes or slip-rings to wear out.

The alternator should be checked every day to ensure

that it is charging at the correct voltage.

For more information on the alternator, refer to the

C.E. Niehoff & Co. troubleshooting guide.

REGULATOR

The alternator’s voltage output is controlled by the

regulator, which is attached directly to the alternator.

It will trip, and the LED bulb will flash, when the

electrical system voltage reaches above 32V for

longer than three seconds.

For a list of troubleshooting items for the regulator

and alternator, refer to the C.E. Niehoff & Co.

troubleshooting guide.


Regulator mounting screws . . . . . . .8.5 Nm (6.3 lb-ft)

Pulley locknut . . . . . . . . . . . . . . . . . 163 Nm (120 lb-ft)

Terminal nuts . . . . . . . . . . . . . . . . . . 4.5 Nm (3.3 lb-ft)

ALTERNATOR DRIVE BELT

The alternator drive belt powers the alternator and

water pump. It should be maintained in good

condition at the correct tension without slippage.

Inspect the belts daily, checking for intersecting

cracks. Transverse (across the belt width) cracks are

acceptable. Longitudinal (direction of belt length)

cracks that intersect with transverse cracks are not

acceptable.

Vendor%20Manual%20Links/CE%20Niehoff/Alternator%20Troubleshooting%20Guide.pdf




VERSION 1.0


Belts need to be replaced if they are cracked, frayed,

or have chunks of material missing. Small cracks are

acceptable.

STARTER

The starter is controlled by the multiplexing system.

CAUTION: Do not replace a starter equipped with an

integral magnetic switch with a starter that does not

have one.

For additional details on the starting system, refer to

STARTING SYSTEM.

MAINTENANCE

The starter is a non-serviceable item and therefore

does not require periodic maintenance. If the starter

is damaged or defective, it must be replaced.

Before replacement, the following checks can be

performed if it suspected that the starter is defective:

Ensure that the battery is fully charged by

performing a high rate discharge test.

Inspect the wiring and connections for

looseness or corrosion. Clean and tighten if

necessary.

Inspect the integral magnetic switch and the

solenoid to determine their condition.

Connect a connecting wire around any

component suspected to be defective. If the

system operates correctly, replace the faulty

component.

If the other components of the starting system pass

the above checks, the starter needs to be replaced.

REPLACING

CAUTION: Do not overtighten the electrical

connections as starter damage can result.

Follow the below directions in order to safely remove

and install the starter:

1. Disconnect the batteries by turning the

battery disconnect switch counterclockwise.

WARNING

The starter is continuously live. Always turn off

the battery disconnect switch before performing

any work on the starter.

WARNING

Always wear proper eye protection when

replacing the starter.


VERSION 1.0


2. Remove the electrical connections from the

starting motor. Tag each wire according to its

location on the starting motor.

3. Remove the three cap screws and starting

motor.

If equipped with a starting motor

spacer, remove the spacer and

clean all surfaces between the

starting motor, starting motor

spacer, and flywheel housing with a

wire brush.

4. Clean any leftover sealant from the starting

motor mounting flange on both the wet

flywheel housing (if applicable) and starting

motor. Ensure that these components are

clean of oil and debris.

5. Re-install all removed parts and the new

starting motor per the Cummins installation

instructions.

6. Connect the electrical connection to the

starting motor.

7. Connect the batteries. Operate the starting

motor to ensure proper function.



VERSION 1.0


BATTERIES

OVERVIEW

Two 12V Optima absorbent glass mat (AGM) batteries

are located in the curb side of the engine

compartment. Each positive and negative bolt head is

protected by a heat shield.

The battery box is made of steel with a heat-

deflecting aluminum shield overtop.

SAFETY PRECAUTIONS

1. Do not smoke near batteries.

2. Do not expose batteries to naked flames.

3. Always switch off electrical current before

making or breaking electrical connections,

especially during charging.

4. Avoid short circuits.

5. Highly explosive hydrogen gas is given off by

the batteries. It is critical that no source of

ignition come close to the batteries.

INSPECTION

The following checks should be performed before

attempting to service the vehicle:

Inspect all connections in the starter system,

ensuring that battery connections are clean

and tight.

Remove all traces of corrosion, taking care to

first activate the battery disconnect switch

by turning it counterclockwise.

Lubricate terminal posts and lugs with

petroleum jelly in order to protect against

corrosion.

BATTERY DISCONNECT SWITCH

The main power for the vehicle is controlled by the

battery disconnect switch, which is located in the rear

of the engine compartment beside the power

steering filter.

WARNING

Working with batteries can be potentially

dangerous. Use extreme caution when handling.

WARNING

The battery disconnect switch only disconnects

the positive side of the battery.


VERSION 1.0


RAPID CHECK

To quickly check the condition of a battery, turn on

the vehicle lights and ignition. If the starter operates

and the lights dim slightly, the battery is considered

serviceable. However, if the lights fade drastically,

this may be an indication that the battery is in a poor

charge state and is incapable of supplying a strong

current. It may also indicate that there is high

resistance at the main connections between the posts

and cable lugs.

DISCHARGE TESTING

Use a high discharge tester to determine the battery

is at least 70% charged.

Optima battery should be tested as follows:

The discharge test should draw ½ of the

rated C/C amps for 15 seconds with battery

voltage staying above 9.6 Volts.

Note: If the vehicle remains unused for a lengthy

period of time, the battery will not maintain its charge.

CORROSION

CAUTION: Excessive corrosion of the battery lugs will

cause a voltage drop at the battery terminals, leading

to sluggish operation of the starter.

CAUTION: Allow batteries time to cool off after

charging. Battery failure can possibly result if heat

grows without cooling time, accelerating grid

corrosion.

Corroded battery lugs can be cleaned with petroleum

jelly. Both the lugs and battery posts should be

smeared with petroleum jelly or wax as a

preventative measure against corrosion. If excessive

corrosion prevents a lug from being removed, wet a

cloth with hot water and use it to twist off the

corroded lug. After removing the corroded lug,

proceed to remove all traces of corrosion.

Note: Always keep the tops and terminals of batteries

clean and free of corrosion. The film on top of the

battery can cause the current to migrate between the

posts, accelerating discharge.

CHARGING

CAUTION: It is normal for batteries to become slightly

warm while charging. However, if they become hot to

the touch, this could be an indication of a short.

Discontinue the charging process and check the

alternator immediately.

When using an automatic charger to charge the

batteries, let it run until it indicates that charging is

complete.

If using a manual charger, estimate total charging

time for a completely discharged battery by

multiplying the capacity (amp hours) by 1.2.

Fully charged batteries should measure

approximately 12.8V.

Note: If purchasing a new battery charger, ensure

that it has either AGM compatibility or a separate

AGM charge setting. Do not use gel or gel/AGM

settings as the batteries will not fully charge and can

become damaged over time.


VERSION 1.0


DEEP CYCLING

Deeply discharged batteries (1.25 – 10.5V) will

require deep cycling. To perform a deep cycle:

1. Wire another identical, fully charged

automotive battery (12V+) to the discharged

battery in parallel (positive (+) to positive

terminal, negative (-) to negative).

2. Connect the charger to the discharged

battery and set it at 10 amps. Leave for two

hours, checking periodically.

3. When the discharged battery reaches a

minimum of 10.5V, remove the other

battery and continue charging the

discharged battery until it is fully charged.

Fully charged deep cycle batteries should measure

approximately 13.1V (or 13.7 – 14.7V with the engine

running).

For more information on the batteries, refer to the

Optima user guide.

Vendor%20Manual%20Links/Optima/Battery%20User%20Guide.pdf


VERSION 1.0


MULTIPLEX SYSTEM

OVERVIEW

The multiplex system is fully modular and integrates

electronic control units into a network in which coded

digital information is transmitted via a single data

cable. Minimal sensors are required as common

sensor data (e.g. vehicle speed, engine temperature,

etc.) are shared on the network. This allows for

simplification of vehicle harnesses, reduction of fuse

and relay usage, and increased diagnostic capability,

thus reducing service time.

MULTIPLEX NODES

The chassis and body nodes are the input/output

modules. While they are identical in terms of

hardware, their individual functions are determined

by a master ladder logic program.

MULTIPLEX MODULE

CAUTION: Incorrectly positioned or mounted cabling

can be influenced by radio signals, which can interfere

with the functions of the system. Do not use the

product if electronic modules, cabling, or connectors

are damaged, or if the control system shows error

functions.

The VMM1615 multiplex module has 16 inputs and 15

outputs. The inputs are capable of being digital,

frequency, or analog. The VMM1615 also includes

two CAN communication ports that are used to

communicate the status of multiple modules

connected together in the same network.

For more information on the VMM1615 multiplex

module, including diagnostic LEDs, inputs and outputs,

and CAN connections, refer to the Parker Vansco user

guide.

Vansco multiplexing module software and drivers are

also available online for download.

WARNING

Do not start the module before the control system

has been mounted and its electrical functions

verified, or if anyone is near.

Vendor%20Manual%20Links/Parker/Multiplexing%20Module%20User%20Guide.pdf


http://divapps.parker.com/divapps/iqan/VanscoVMMS.html

http://divapps.parker.com/divapps/iqan/VanscoDLA.html


VERSION 1.0


CAN DIAGRAM

All components in the multiplex system are linked

together by a communication network (CAN).


VERSION 1.0


DISPLAY PANEL STANDARD SYMBOLS

The display panel standard (DPS) is a software-

programmable display panel capable of multiplexing

that controls indicator LEDs, gauges, and a graphic

LCD screen.

Note: The DPS backlight will appear white when DRL

lights are activated (see item #8 below), and blue

when all exterior clearance lights are on.

For more information on the DPS, refer to the Parker

Vansco manual.

Note: If this vehicle was manufactured prior to

December 2015, the DPS will contain different

functions than what is shown here. Refer to the

previous version of the DPS for an accurate

representation.



DPS_PriorToDec_1_2015.pdf


VERSION 1.0


LCD DISPLAY ICONS


VERSION 1.0


DRIVER’S STATION GENERAL LAYOUT


VERSION 1.0


LEFT FRONT DASH

The left front dash of the driver’s station is comprised

of the following switches.

AUXILIARY HEATER SWITCH

The auxiliary heater switch is a rotary switch that

displays heater activity. When the green light is in a

solid state, this indicates that the heater is active. A

flashing green light indicates that there is a fault with

the heater.

DRIVER’S FLOOR HEATER SWITCH

The driver’s floor heater is controlled by a standard

rocker switch that, when switched on, activates the

floor heater fans on the floor directly to the left of the

driver’s seat.

INSTRUMENT DIMMER SWITCH

The instrument dimmer switch is a variable scroll

wheel switch that can be turned to adjust the

brightness of the instrument switch lighting for the

driver’s station. Scrolling the wheel all the way

downwards will turn off all instrument switch lighting.


VERSION 1.0


RIGHT FRONT DASH

The right front dash of the driver’s station is

comprised of four main components.

DEFROSTER DIALS

Using round turn dials, the fan speed of the

windshield defroster system can be controlled. The

defroster mode dial controls which combination of

areas the windshield defroster unit is allowed to

move air through.

Note: The driver’s station A/C switch will only be

found on vehicles equipped with driver’s station air

conditioning.

TRANSMISSION GEAR SELECTOR

The gears of this vehicle’s ZF transmission can be

changed using a push button with built-in LED. A

flashing LED indicates that there is a problem with the

transmission or gear selector.

RAMP BUTTONS

Before pushing the green ramp deploy button: the

door must be open, the vehicle must be in neutral,

and the parking brake must be engaged. The black

ramp stow button stows the ramp.

LEVEL SWITCH

The kneeling switch is a rocker switch that commands

the vehicle to kneel the suspension to the lowest

height. The normal level switch returns the vehicle

suspension level to normal height.


VERSION 1.0


UPPER SIDE CONSOLE

The upper side console of the driver’s station contains

the following switches and mechanical components.

READING LIGHT SWITCH

The reading light switch activates the reading light

directly above the driver’s seat.

PARKING BRAKE LEVER

The parking brake lever activates or de-activates the

parking/emergency brake.

MASTER SWITCH

The master switch is a rotary switch that controls the

running state of the vehicle.

“Power Off” shuts down the engine. The fare

box will remain functional for 3 minutes.

“Run” is used for normal driving conditions

when daylight is sufficient. When the

engine is ready to start during daylight

hours, switch to “Run,” then press the

green “Engine Start” button.

“Night Run” is used for normal driving

conditions when daylight is insufficient. It

turns on the headlights and clearance lights.

Always operate the bus after dusk with the

switch in this position.

“Night Park” is used for prolonged stops

during nighttime, without the engine

running. This mode retains functionality of

interior lights, and forces clearance and

brake lights to stay on for visibility. Park at

layover with the switch in this position.

PASSENGER OVERHEAD LIGHTS SWITCH

The passenger overhead lights switch activates either

half of the passenger overhead lights (2nd position) or

all of the overhead lights (3rd position).

HAZARD LIGHTS SWITCH

The hazard lights switch activates the 4-way hazard

lights. If the vehicle is powered down, this switch can

still wake up key components necessary to carry out

a 4-way hazard light function, provided that the

battery disconnect switch in the engine bay

compartment is not disconnected.


VERSION 1.0


DOOR HANDLE

Opening and closing is controlled by a 5-position lever.

Before opening the entrance/exit doors, bring the bus

to a complete stop and apply the parking brake.

Starting from the top and turning clockwise, the

positions are:

1. Entrance and exit doors open;

2. Entrance door open, exit door closed;

3. Entrance and exit doors closed;

4. Exit door open, entrance door closed;

5. Entrance and exit doors open.

WINDSHIELD WIPER CONTROL SWITCH

The windshield wipers are controlled by a rotary

switch. The switch has four positions: off, intermittent,

low, and high. Rotate switch to intermittent to engage

the windshield wipers once every 7 seconds.


VERSION 1.0


DIAGRAM


VERSION 1.0


LOWER SIDE CONSOLE

The lower side console of the driver’s station includes

the following switches.

LIGHT/BUZZER TEST SWITCH

The light and buzzer test switch activates all exterior

lights and the reverse buzzer.

ECAS LEVEL II SWITCH

CAUTION: Remaining in Level II for prolonged periods

of time while mobile is not recommended due to

potential risks involving damage to suspension

components.

The ECAS Level II Switch is a rocker switch that

prompts the vehicle to achieve the highest possible

ride height. It is used for special driving circumstances,

such as dynamic terrain.

Note: Level II height can only be achieved at speeds

under 20 km/h (12 mph), or 10 km/h (6 mph),

depending on the vehicle year of manufacture.

PASSENGER FLOOR HEATER FAN SWITCH

The passenger floor heater fan rocker switch activates

the two floor heating fans in the passenger area of the

vehicle.

STOP REQUEST BUZZER PROHIBIT SWITCH

The buzzer noise caused by the depression of any stop

request button can be eliminated by activating the

stop request buzzer prohibit switch.

WINDSHIELD WASHER SWITCH

The windshield washer rocker switch activates the

windshield washers, as well as the wipers in low

speed for a short duration of time.

HVAC CONTROL SWITCH

The HVAC system will turn on a few moments after

activating the HVAC control switch.

REGENERATION SWITCHES

For information on the regeneration initiate and

regeneration inhibit switches, refer to Stationary

Regeneration.

ENGINE FAST IDLE SWITCH

The engine fast idle switch increases the engine’s

idling RPM to 1100. Fast idle can be cancelled by

pressing the switch again, or by any brake or throttle

application.

INTERLOCK BYPASS TOGGLE

The interlock bypass toggle switch should only be

used in emergency situations since it prevents the

interlock from activating when the passenger door is

opened.

SOS EMERGENCY TOGGLE

The SOS emergency toggle should only be used in

emergency situations. It displays “SOS,” “Emergency,”

and “Call 911” messages on the exterior destination

signs of the vehicle.


VERSION 1.0


DIAGRAM


VERSION 1.0


DESTINATION SIGNS

OVERVIEW

This vehicle is equipped with high-performance

electronic LED destination signs. Using the Control

Console, the front, side, and rear destination signs

display messages such as the route number and

destination, or public interest and emergency

messages. The destination signs run on 24V DC power,

which is supplied via the main ignition switch.

Destination signs do not run on the multiplex system.

Note: The information contained in this section

applies to vehicles equipped with Axion destination

signs. Some vehicles may have Luminator sign

systems instead; in which case, refer to the Luminator

user manual for service information.

FRONT DESTINATION SIGN

The front destination sign includes an electronic front

display in a GRP housing above the front windshield

dash. The display is fixed into a steel frame

incorporated within the GRP housing.

SIDE DESTINATION SIGN

The side destination display is located at the top front

corner of the first window behind the entrance door.

REAR DESTINATION SIGN

The rear destination sign is located below the upper

deck rear dummy window, near the centerline.

It functions as a “911” and “Route No.” sign by

activating the SOS emergency toggle on the driver’s

side console. Momentary switch control for “Yield” is

provided from the side console switch through a 7-

second delay timer module.

CONTROL CONSOLE

The destination sign system Control Console is

located on the driver’s header panel and contains

Flash Card input provision. It allows the operator to

select the route number and messages to be

displayed.

1. Control Console

2. Keyboard

3. PTU Programming Connector

4. FTT Programming Connector

5. Status LED Indicator

6. LCD Display

7. “Backlight” Key

8. DEST “A” Programming Key

9. DEST “B” Programming Key

10. Cursor Up/Cursor Down Keys

11. Menu Key

12. Number Sign Key

13. Public Interest Message Key

14. Last Entry Delete Key

15. Numeric & Alphanumeric Keys

16. “Enter” Key

Vendor%20Manual%20Links/Axion/Axion_User_Manual.pdf

Vendor%20Manual%20Links/Luminator/Luminator_Horizon_Titan%20SMT_Complete_Manual.pdf

Vendor%20Manual%20Links/Luminator/Luminator_Horizon_Titan%20SMT_Complete_Manual.pdf


VERSION 1.0


MAINTENANCE

The destination signs do not require special

equipment to be serviced and maintained. However,

it is strongly recommended that a record be kept of

every fault encountered and repair performed.

CLEANING

CAUTION: Do not use highly concentrated solvents as

cleaner as these could damage the acrylic window.

Destination sign components can be cleaned using a

clean, moist towel. Axion recommends using a mild

soap for the casing and a domestic glass cleaner for

the acrylic window of the rear sign.

FUSE REPLACEMENT

Fuses may require replacement if power to the

Control Console or signs are lost. To replace a fuse:

1. Turn off power supply to the sign.

2. Open the protection cover of the junction

board, located on the middle back plate of

the front destination sign.

3. Locate the faulty fuse and replace it with a

new one of the same specifications. For a list

of acceptable fuses, refer to Required Fuses.

CAUTION: Replacing a fuse with an inadequate or

higher rated unit automatically voids the warranty.

WARNING

Power must be switched off prior to cleaning or

servicing equipment.

WARNING

These signs contain components that are highly

sensitive to static electricity. Do not open or

handle without wearing static protection devices.


VERSION 1.0


REQUIRED FUSES

The following table lists which fuses are required to

be used with each sign:


VERSION 1.0


CHAPTER 10 WHEELS AND TIRES

WHEELS

INSPECTION

When servicing, the following checks should be

performed on the wheels:

Ensure that contact surfaces of the wheel

hubs are clean, and free of grease and rust.

Inspect wheels for cracks, centre hole

damage, bolt hole looseness, and burrs. If

necessary, repair or replace.

o Thread marks inside the bolt holes,

or wallowing out, are typically

indicative of the wheel running

loose.

Check wheels for dents along the

circumference and replace if necessary.

Inspect wheels for pitting caused by

corrosion. Pitting deeper than 0.4 mm (0.015

in) requires the wheel to be replaced.

Visually inspect wheels for cracks. Replace

immediately if any cracks are found.

Check wheel nut fasteners for any pitting,

cracks, or damage to the threads.

Inspect wheel stud threads for damage,

pulled threads, and corrosion.

SAFETY PRECAUTIONS

Abide by the below rules in order to ensure safety and

proper handling of wheels:

Always wear safety glasses, safety gloves,

and a dust mask when fitting or dismounting

wheels and tires.

Ensure that the wheel assembly is clean

before changing wheels or tires, and fitting

wheels on the hubs.

Avoid cutting or nicking the wheel. Handle

wheels on a wooden floor or rubber mat.

Only use hammers made of plastic, rubber or

leather. Do not use metal hammers.

Ensure that the inside of the wheel is dry

before fitting.

CLEANING

The wheel contact surfaces can be cleaned using

brake cleaner, wire brushes, and/or a rotary tool with

heavy duty pads.

FITTING

CAUTION: Do not use heat to remove a wheel nut. All

wheel components, including studs and nuts, must be

replaced if heat is applied.

In order to fit the wheels, proceed as follows:

1. Disengage the parking/emergency brake, if

applicable.

WARNING

Serious injury or death can occur from the

incorrect handling and operation of bus wheels

and tires. Do not repair wheels or tires without

proper training or equipment.

WARNING

Contact local authorities to determine proper

method of disposal as some jurisdictions may

have strict regulations regarding the disposal of

used tires and wheels.


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2. Clean wheel contact surfaces using brake

cleaner, wire brushes, and/or a rotary tool

with heavy duty pads, ensuring to remove all

rust, loose paint, and scale.

3. Lubricate wheel studs with engine oil in

order to prevent thread pickup between the

wheel nut and the stud. Do not get any

lubricant on the hub face, wheel face, or

brake drum.

4. Install wheels onto hub pilot, ensuring that

no dirt becomes trapped between the wheel

and hub.

5. Tighten the nuts in a diagonally opposite

sequence to a torque of 644 Nm (475 lb-ft).

6. Test drive the vehicle a short distance,

making sure to accelerate, apply brakes, and

corner. Use a torque wrench to check the

torque of the wheel nuts again.

CAUTION: After fitting the wheels, ensure that

there is sufficient space for the valve between

the brake caliper and wheel rim in order to

prevent any damage to the tire valve.

TIRES

SAFETY PRECAUTIONS

Abide by the below rules in order to ensure safety and

proper handling of tires:

Always wear safety glasses, gloves, and a

dust mask when mounting or dismounting

wheels and tires.

Ensure that the wheel assembly is clean

before changing wheels or tires, and fitting

wheels on the hubs.

Always inspect tires for damage before

mounting them.

Ensure that the inside of the tire is dry before

mounting it.

Use a non-water based lubricant to mount

the tire on rim.

Use a dryer to completely dehumidify air

before inflating the tire.

Follow recommended inflation pressures. Do

not overinflate tires.

Never try to inflate a tire that has completely

flattened or is at less than 80% of its

recommended pressure.

Only replace a tire with one of the same type

and size.

WARNING

Do not increase the rear tire pressures in isolation

as this could impair vehicle handling.

WARNING

Inflated tires can be highly dangerous. Serious

injury or death can occur from the incorrect

handling and operation of bus wheels and tires.

Do not repair wheels or tires without proper

training or equipment.

WARNING

Contact local authorities to determine proper

method of disposal as some jurisdictions may

have strict regulations regarding the disposal of

used tires and wheels.


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TIRE PRESSURE

CAUTION: Do not increase rear tire pressure in

isolation, as handling could be adversely affected.

This vehicle’s VIN plate is located at floor level

beneath the defroster access panel. Front (axle 1)

and rear (axle 2) tire pressures can be obtained from

here.

TIRE REPLACEMENT

When replacing tires, ensure that replacement tires

are of a similar specification. Combining tires of a

different rating will affect accuracy of speedometer

readings and plated weight ratings.

WARNING

Under no circumstances may cross-ply and radial

tires be mixed on the same axle.


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CHAPTER 11 HVAC

HEATING SYSTEM

AUXILIARY HEATER

This vehicle’s Spheros auxiliary heater is used to heat

the passenger compartment, defrost the windshield,

and preheat the engine. The auxiliary heater operates

independently from the engine. It is connected to the

cooling system, fuel system, and electrical system. Its

components include a combustion air fan, fuel pump,

heat exchanger, combustion chamber, and electronic

ignition coil.

The auxiliary heater can be turned on by activating

the auxiliary heater switch on the left front dash of

the driver’s station. When the green light is in a solid

state, the auxiliary heater is active. A flashing green

light indicates that there is a fault with it.

For more information, refer to the Spheros auxiliary

heater manual.

SERVICING

CAUTION: If the auxiliary heater is in operation or in

run-down, the battery main power supply must not

be disconnected. Doing so may result in the auxiliary

heater overheating.

The auxiliary heater should be removed before

performing any major repairs.

After working on the heating circuit, replenish with a

coolant mix prepared with water and anti-freeze and

bleed circuit afterwards.

MAINTENANCE

To ensure proper function of the auxiliary heater, the

following checks and maintenance tasks should be

performed at the time specified:

Inspect combustion air inlet and exhaust

outlet for contamination. Clean if necessary.

The auxiliary heater should be operated

outside the heating season when the vehicle

engine is cold approximately every four

WARNING

Due to the danger of poisoning and suffocation

the auxiliary heater must not be operated, not

even with timed operation, in enclosed areas that

are not equipped with an exhaust venting.

WARNING

The auxiliary heater must be switched off to

prevent explosions where flammable fumes or

dust may build up (e.g. when in the vicinity of fuel,

coal, wood, cereal depots, or similar installations).

WARNING

Due to the danger of poisoning and suffocation

the auxiliary heater must not be operated, not

even with timed operation, in enclosed areas that

are not equipped with an exhaust venting.

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weeks for 10 minutes at a time, setting the

heating system to "warm." This avoids future

difficulties when starting up.

The fuel filter, filter cartridge, and fuel pump

filter screen, should be replaced at least

once a year to avoid malfunctions due to

contaminated fuel.

Clean the inside of the heat exchanger at

least once per year.

Replace the fuel pump and fuel lines every

five years. In the event of leakage, replace

immediately.

Before heating season, the auxiliary heater

should be inspected in regular intervals by a

Spheros service agent or properly trained

technician.

For a series of steps on how to remove, repair, and

install auxiliary heater components, such as the heat

exchanger and combustion chamber, refer to the

Spheros auxiliary heater manual.

HEATER/DEFROSTER

The driver’s heater/defroster is located within the

defroster access panel in the driver’s station.

It consists of a fan-powered motor, radiator, air

cleaner, air intake line with a control flap, and a valve

with a control lever.

The defroster can be controlled using the front

ventilation control panel, located on the right front

dash of the driver’s station.

Note: The driver’s station A/C switch will only be

found on vehicles equipped with driver’s station air

conditioning.

For electrical information, refer to the Spheros

defroster wiring diagram.


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COMPONENTS


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DIAGRAM


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AIR CONDITIONING SYSTEM

DESCRIPTION

This vehicle’s air conditioning system is comprised of

and an air conditioner, an A/C compressor, a

condenser, and a control panel.

COMPONENTS

CONTROL PANEL

The air conditioner control panel, located in the

interior electrical compartment, contains all controls

and indicators for system settings, mode switching,

and operational indications.

For a full list of controls/indicators and their functions,

refer to the Spheros Midibus operating manual.

MAINTENANCE

CAUTION: To avoid any damage to components, all

required service activities on the air-conditioning

system should be performed by trained and qualified

personnel who are knowledgeable in the field of

refrigeration.

The following maintenance tasks should be

performed on the air conditioning components:

All attachments of the air conditioning unit

and refrigerant connection lines must be

checked for tightness within the first four

WARNING

For personal safety reasons, any component that

is not in perfect condition must be replaced.

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weeks following initial start-up of the air

conditioning system and/or vehicle.

Loss of refrigerant is possible even if the

refrigerant connections are tight. If a large

amount of refrigerant is lost within short

intervals, there is likely a leak in the system.

During long term non-use the air-

conditioning system should be operated for

approximately 15 minutes at least once per

month in order to prevent the shaft seals of

the refrigerant compressor from hardening.

Note that the outside temperature must be >

8°C (> 46°F).

Check the electromagnetic clutch for dry

sealant, belt tension, and other signs of wear

or damage.

The refrigerant receiver and all components

of the air conditioning system should be

inspected regularly for any signs of corrosion

or mechanical damage.

To ensure proper operation of the air

conditioner, the refrigeration oil and the

filter dryer must be replaced 6 months after

initial operation of the vehicle.

The filter dryer should be replaced every

year at the beginning of the operating

season.

For a full list of malfunctions and diagnostics, refer to

the Spheros Midibus operating manual.

HVAC ACTIVATION

The HVAC Auto mode is pre-selected by default on

the panel. It controls the passenger compartment

temperature according to the internal temperature,

external temperature, set-point, and parameters.

The HVAC system is activated using the HVAC

control switch, located to the left of the driver.

A/C COMPRESSOR

The A/C compressor activates in accordance with the

system temperature, pressure switches, and

programmed values of the set-point. The compressor

will start operation 10 seconds after the condenser

motor activates.

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CHAPTER 12 WINDSHIELD

WIPER SYSTEM

DESCRIPTION

This vehicle has a one-piece windshield that spans the

width of the bus. The windshield size is 1473 by 2667

mm (58 by 105 in). It is equipped with an electrically

controlled two-speed, dual-blade windshield wiper

system.

The windshield wipers are controlled by a rotary

switch on the left front dash of the driver’s station.

The switch has four positions: off, intermittent, low,

and high. Rotate switch to intermittent to engage the

windshield wipers once every 7 seconds.

This vehicle’s wiper system is in compliance with

CMVSS 104 Windshield Wiping and Washing System.

MAINTENANCE

The windshield wiper blades should be inspected and

lubricated regularly. Replace them when they wear

out.

PREVENTATIVE MAINTENANCE

Regardless of weather conditions, the windshield

wiper system should be operated at least once per

day. This promotes sufficient lubrication and prevents

rapid wear of components.

WIPER ARM REPLACEMENT

Complete the following steps to remove and mount

the wiper arms:

1. Park the wiper system by switching the

wipers on and then off. After turning off, the

wiper motor should continue to run until it

returns to the “park” position.

2. Remove the wiper motor from the vehicle

harness.

3. Remove and set aside the wiper arms and

blades. The wiper arms can be safely

removed using a 2-jaw puller.

4. Remove the wiper arm head splines with a

file, ensuring to maintain taper shape.

5. Beginning on the road side, assemble the

wiper arm to the pivot and position the blade

horizontally. Angle the blade up 2° and

tighten the pivot nut using a torque of 40 Nm

± 5 Nm.

6. Assemble the curb side wiper arm to the

pivot and position the blade horizontally.

Angle the blade up 1° and tighten the pivot

nut using a torque of 40 Nm ± 5 Nm.

7. Reattach wiper motor to vehicle harness.

8. Spray water on the windshield. Test wiper

system on Low and High to ensure correct

operation.

WARNING

Isolate the wiper system before performing

maintenance in the area to avoid personal injury

due to entrapment of moving parts.


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ALIGNMENT

ROAD SIDE

When aligning the road side wipers, ensure that the

motor crank and connecting rod are in a straight line.

If required, the motor crank can be removed and

torqued to 22 – 27 Nm (16 – 20 lb-ft). The angle

between the pivot crank and connecting rod should

be 44° ± 2°. If the angle falls outside of this range, the

connecting rod length can be adjusted by loosening

the bolts and sliding to desired position. Tighten bolts

to a torque of 23 – 25 Nm (17 – 18 lb-ft).

CURB SIDE

When aligning the curb side wipers, ensure that the

delay centre and connecting rod are in a straight line.

If required, loosen delay adjustment bolts and slide to

the desired position. Tighten bolts to a torque of 23 –

25 Nm (17 – 18 lb-ft). The angle between the pivot

crank and connecting rod should be 42° ± 2°. If the

angle falls outside of this range, the connecting rod

length can be adjusted by loosening the bolts and

sliding to desired position. Then, tighten bolts to a

torque of 23 – 25 Nm (17 – 18 lb-ft).

ADJUSTMENT

The curb side wiper can be adjusted to avoid over-

sweeping as follows:

1. Remove wiper arm using a 2-jaw puller.

2. Adjust curb side connecting rod to a length

of 627mm (24.7 in). Torque bolts to 23 – 25

Nm (17 – 18 lb-ft).

3. Adjust the delay connecting rod to align in a

straight line, as shown in the adjustment

diagram. Torque bolts to 23 – 25 Nm (17 –

18 lb-ft).

4. Remount the wiper arm and torque to 40 Nm

± 5 Nm (26 to 33 lb-ft). Clean splines if

necessary.


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ALIGNMENT DIAGRAM


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ADJUSTMENT DIAGRAM


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WASHER SYSTEM

DESCRIPTION

The windshield washer switch is located on the lower

side console of the driver’s station. When activated, a

washer pump directs washer fluid from the reservoir

via filler hoses. Washer nozzles mounted on the wiper

arms then spray the windshield with the washer fluid

and the wipers operate in low speed for a short

duration of time.

This vehicle’s washer system is in compliance with

CMVSS 104 Windshield Wiping and Washing System.

WASHER FLUID

Washer fluid helps windshield wipers get rid of rain,

dirt, or other buildup that can interfere with visibility.

If washer fluid does not release when the washer

control is activated, the reservoir may require more

fluid, or the hoses and nozzles may need to be

cleaned. In more severe cases, the washer pump may

require replacement.

WASHER FLUID RESERVOIR

The windshield washer reservoir is installed in the

front of the bus and can be accessed through the

interior front panel. It is capable of holding 8.7 litres

(2.3 gallons) of washer fluid.


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FILLING

A filling port is located in the front exterior of the bus

in a locked access panel under the windshield. The

washer fluid reservoir should be checked regularly

and refilled when necessary.

Documents

Service Manual - Grande West Transportation Group · vicinity service manual part i version 1.0 1.0 author: a. kedans return to main index table of contents table of contents .....1.0