24-Scope of Services, Attachment B - Fleet Preventative Maintenance.pdf

Section PM

Preventative Maintenance L9 CM2350 / Allison 300 Series

SAFETY

Safety Procedures:

PREVENTIVE MAINTENANCE

Introduction Run – In Maintenance

PREVENTIVE MAINTENANCE CHECK LIST

Engine L9 CM2350 Oil Drain Interval

LUBRICATING OIL AND FILTER INTERVALS

OIL DRAIN INTERVALS

Oil Drain Interval

LUBRICATING OIL RECOMMENDATIONS AND SPECIFICATIONS

GENERAL INFORMATION

Normal Engine Operation Fuel Economy Cold Weather Operation

ENGINE OIL VISCOSITY

General Information

AFTERMARKET OIL ADDITIVE USAGE

Transmission Fluid & Filter Changes Driveshaft Hydraulic Cooling Exhaust System Diesel Fuel System

DIESEL EXHAUST FLUID

Air System Air System (Continued)

AIR COMPRESSOR

Electrical Air Conditioning Air Conditioning Air Conditioning Chassis Undercarriage

Attachment B

Undercarriage Undercarriage A.D.A. Access Wheel Nut Torque Recommendations Firestone Air Springs Preventive Maintenance Check List

CONVERSION TABLE

Road Test Weld Disconnect List

FLUID & LUBRICATION GUIDE

Fluid & Lubrication Guide Fluid & Lubrication Guide ElDorado National Fluids/Lubrication Chart

DRIVESHAFT LUBRICATION POINTS

Lubrication

VEHICLE STORAGE REQUIREMENTS

SUSPENSION

ALLISON TRANSMISSION® B300/400

Preservation and Storage

RESTORING TRANSMISSION TO SERVICE

Operating Instructions Specifications and Data

CUMMINS® ENGINE

ENGINE STORAGE

Introduction Engine Storage - Short Term Preparatory Steps Remove from Storage

ENGINE STORAGE - LONG TERM

Introduction Preparing Spare or Rebuilt Engine for Long Term Storage Preparing an In-Use Engine for Long Term Storage Removing Engine from Long Term Storage

COACH APPEARANCE & CARE

Exterior Care and Cleaning Interior Care and Cleaning

SAFETY

Safety Procedures:

This section of the service manual contains procedures which require the mechanics to strictly observe safety procedures in order to ensure personal and equipment safety.

Always ensure that the vehicle is appropriately hoisted and block for procedures which require elevating the vehicle. Be aware of the limitations of the blocking equipment, and always ensure that the jarring and shaking created by component removal and installation procedures does not overload the blocks, or cause the vehicle to come unstable.

Certain procedures may require the vehicle be operated in an elevated position in order to accurately trouble- shoot and diagnose a problem. If the vehicle must be running while elevated, become familiar with the repair area prior to starting the engine.

Take special care in noticing areas which will become hot, electrically energized, and areas where moving and rotating components are located. Limit the work in these areas as personal and equipment safety is at risk.

For procedures which involve air lines, ensure the line is safely depressurized prior to disconnecting.

Disconnecting pressurized lines will cause solid particles deposited in the line to be uncontrollably propelled, and will also cause the hose end to whip randomly as the air escapes.

During electrical diagnosis procedures, an understanding of the vehicle’s electric circuit is important to anticipate the results of connecting test equipment. During component removal or installation, ensure the Battery Disconnect switch is in the OFF position.

Failure to follow this procedure may result in personal injury or component failure.

Observe the following procedures involving hydraulic line removal.

• Hydraulic fluid is corrosive and should not be exposed to skin for extensive periods of time.

• Wear eye protection at all times.

• Pressurized lines should not be disconnected until the pressure is safely and controllably released.

CAUTION: Follow all safety precautions regarding spray painting. Use a filtering mask with the proper filter cartridges for this type of paint. Wear eye protection and proper protective clothing. The paint booth or work area must be properly ventilated, with filtered exhaust fans removing fumes and over spray. The painting area should be a safe distance from any source of flame, spark or other means of combustion. Atomized paint, thinner, cleaner and solvent fumes are highly volatile with an extremely low flashpoint that can cause explosive combustion. DO NOT smoke or permit anyone else to smoke in or near the painting area.

WARNING: Before performing any work or repair requiring use of open flame such as welding, brazing, acetylene torch cutting or grinding, ensure that insulation foam is either removed from the area being repaired, or is properly shielded from the open flame.

WARNING: Failure to follow the recommended periodic maintenance and service and repair intervals will result in circumstance leading to vehicle system failure, breakdown, fire, or injury to passengers and service personnel.

Information enclosed in the following publication is intended to provide the vehicle owner or service personnel with the necessary information to maintain this vehicle in a safe and serviceable condition.

It is imperative that a regular periodic maintenance schedule is observed in the relation to all operative systems on the vehicle. In the event that any part or adjustment is found to be outside of the published requirements or parameters, the item(s) in question must be immediately repaired or replaced to avoid any further deterioration. Failure to do so may lead to a situation causing the vehicle to fall out of service or to become dangerous to occupy or operate.

Periodic maintenance includes, but is not limited to, the following items:

Correct levels of fluid in all operating systems

Immediate attention to fluid leaks from the engine, transmission, hydraulic system, cooling system, or other fluid-dependent equipment.

Integrity of all belts, hoses, fluid-transport lines, ducts, exhaust tubing, and electrical cables, connectors, and wires.

Cleanliness of the engine compartment (free from combustible buildup).

Cleanliness and component integrity of all undercarriage parts and coatings.

Condition of tires, brakes, steering components and traction systems.

Status of all safety components and systems.

There are numerous variations in procedures, techniques, tools and parts for performing service, as well as in the abilities and skill of the individual(s) who do the work. This manual cannot possibly anticipate all such variations nor provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided with in this manual must first establish that their actions compromise neither personal safety nor vehicle integrity through personal choice of methods, tools or parts.

Preventive Maintenance Introduction:

The transit authority is responsible for the performance of all scheduled maintenance as outlined in this preventive maintenance manual to maintain the ElDorado vehicle warranty. ElDorado National (California), Inc. reserves the right to deny warranty coverage on claims due to lack of maintenance, misuse, abuse or neglect.

The maintenance intervals indicated in this manual are based upon average vehicle use and typical operating conditions. Unusual vehicle operating conditions, such as geographic environmental conditions, will require service at more frequent intervals. It is the customer’s responsibility based upon experience with localized environmental conditions and local regulations to determine if more frequent intervals are required. If you are unsure, contact your ElDorado Customer Service Technical Support representative.

All the described maintenance operations must be performed by qualified personnel using standard shop practices. All replacement parts used for maintenance services or repairs must be OEM parts or parts with equivalent quality and performance. Use of inferior parts will void the warranty. Warranty claims in question must be supported by preventive maintenance records.

Consumable maintenance items such as (but not limited to) lights, bushings, and items with progressive wear characteristics, lubricants, fluids, filters, hoses, wiper blades and tires are not covered by warranty.

Refer to the illustrations or schedules provided with in this section as a guide to location of servicing points.

For compliance to warranties covering the following equipment, refer to complete preventive maintenance intervals and procedures contained in the applicable vendor information:

Engine Transmission HVAC Unit

Run – In Maintenance

Certain procedures describe in this Preventive Maintenance Section are designed to ensure a smooth vehicle run-in process. The following operations are part of this process:

• Driveshaft: Lubricate upon receipt of vehicle, and thereafter every 6,000 miles (9,600 km). Refer to Preventive Maintenance chart of this section for more information.

• Front & Rear Axles & Brakes – Refer to Fluid and Lubrication Guide on this section for axle and brake system components which require maintenance upon receipt of vehicle or after 300 miles (480 km) of vehicle operation, after first 3,000 miles (4,800 km) and thereafter as indicated in the appropriate guide.

• Transmission – See Fluid and Filter Changes table on this Section.

• After Suspension has been in operation for 6,000 Miles all Fasteners should be checked to the specified torque. Repeat every 6,000 miles.

WARNING: Do not use Air Impact Tool to tight any Suspension Nut or Bolt.

This Page Intentionally Left Blank

Preventive Maintenance Check List

Engine L9 CM2350 Introduction: The maintenance schedule that follows is intended to serve as a ready reference for systems and components that require periodic service. The intervals given are manufacturer’s recommendations and should be as a guideline only.

Preventative maintenance begins with day to day awareness of the system. Prior to engine operation, check for the following:

• Excessive oil, coolant, or fuel consumption.

• Leaks.

• Worn or damaged belts.

• Worn or damaged wiring harnesses.

• Any change in system appearance.

• Odor of fuel.

• Odor of electronic devices.

When operating the engine, listen for any unusual system noises which can indicate service is required.

Take appropriate action to rectify any abnormalities or contact a Cummins® Authorized Repair Location.

Maintenance Procedures Daily Air Intake Piping - Check Fan, Cooling – check Crankcase Breather Tube - check Air Tanks and Reservoirs - Drain Coolant Level - Check Fuel – Water Separator - Drain Lubricating Oil Level - Check Aftertreatment Exhaust Piping - Check Aftertreatment Diesel Exhaust Fluid (DEF) – Level -Check

Routine Maintenance Schedule

Kilometers x 1000 12 24 48 96 96 241.5 321.5

Miles x 1000 7.5 15 30 60 60 150 200

Hours 250 500 1000 2000 2000 5000 6500

Months 3 6 Years 1 2 4

Procedure Step Air Cleaner Restriction Check X

Charge Air Piping Check X

Charge Air Cooler Check X

Fuel Filter (Spin on Type) Change See the Lubricating Oil System Interval procedure 359-009 Batteries¹ Check X

Lubricating Oil and Filters Change See the Lubricating Oil System Interval procedure 359-009 Battery Cables and Connections Check X

Coolant Filter Change X

Supplemental Coolant Additive (SCA) and Antifreeze Concentration

Check X

Radiator Pressure Cap Check X

Cooling System Flush X

Drive Belt, Cooling Fan Check X

Belt Tensioner, Automatic (Water Pump) Check X

Crankcase Breather Element Change X

Engine Steam Cleaning Clean X

¹ See equipment manufacturer service information.

Routine Maintenance Schedule Continued

Kilometers x 1000 12 24 48 96 96 241.5 321.5

Miles x 1000 7.5 15 30 60 60 150 200

Hours 250 500 1000 2000 2000 5000 6500

Months 3 6

Years 1 2 4

Procedure Step Vibration Damper, Rubber Check X

Vibration Damper, Viscous Check X

Radiator Hoses Check X

Air Compressor Discharge Lines Check X

Overhead Set Adjust X

Engine Brake Assembly Adjust X

Aftertreatment Diesel Particulate Filter Clean X

Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter

Change X

Oil Drain Interval

Standard Oil Pan 16 to 20 qt. [15.1 to 18.9 Liter] ¹ Shuttle or Transit Bus Kilometers Miles Hours Months Below 5 mph average 2400 1500 500 6 5 to 10 mph average 6450 4000 500 6 10 to 15 mph average 9650 6000 500 6

1. If the type/oil capacity of the oil pan is not known:

a. Contact a Cummins® Distributor/Dealer

b. Determine the capacity of the oil pan option for the engine being serviced, use QuickServe™ Online and the engine serial number.

Engine Oil Specifications Oil Pressure

At Low Idle (minimum allowed) 69 kPa [10 psi] At Rated Speed (minimum allowed) 207 kPa [30 psi] Regulated Oil Rifle Pressure 379 kPa [55 psi] to 517 kPa [75 psi] Lubricating Oil Filter Capacity 3.78 Liters [4 qt.]

Lubricating Oil Capacity Standard Oil Pan 15.1 to 18.9 liters [16 to 20 qt.] High Capacity Oil Pan 18.9 to 22.7 Liters [20 to 24 qt.] Total System 22.7 liters [24 qt.] NOTE: If the type/oil capacity of each lubrication oil pan is not known:

Contact Cummins® Authorized Repair Location Determine the capacity of the oil pan option for the engine being serviced by using QuickServe™ Online and the engine serial number.

Fill the lubrication oil pan to the smallest oil pan capacity listed for the engine being serviced. Then add 0.95 litters [1 qt.] of oil at a time until it reaches the high mark on the dipstick.

For normal engine operation Cummins Inc. recommends the use of a high quality 15W40 viscosity heavy duty engine lubricating oil that meets the requirements of Cummins® Engineering Specification (CES) 20086 or 20081.

For further details and an explanation of engine lubricating oils for Cummins® engines, refer to the latest revision of Cummins® Engine Oil and Oil Analysis Recommendations, Bulletin 3810340 and/or Service Manual 5411406.

Lubricating Oil and Filter Intervals Oil Drain Intervals

CAUTION: Extending the oil and filter change interval beyond the recommendations will decrease the engine life due to factors such as corrosion, deposits, and wear.

See the following table to determine the maximum recommended oil change and oil filter change intervals in kilometers [miles]/hours or months, whichever comes first.

☞ NOTE: Idle time must be factored into calculating average vehicle speed.

The intervals are based on the vehicle’s average vehicle speed/mile per hour (mhp). Locate your vehicle’s average vehicle speed/mph in the first column to determine the oil change/filter change interval to use. If the vehicle is equipped with an hour meter, it is acceptable to use the engine hours listed for the oil change and oil filter change interval.

If the average vehicle speed is unknown and the vehicle is not equipped with an hour meter:

1. See the Typical Application(s) column. Use the lowest interval listed for your application.

2. Connect an electronic service tool. The electronic service tool can provide the average vehicle speed recorded by the engine’s ECM. This can be done at a Cummins® Authorized Repair Location.

☞ NOTE: A Maintenance Monitor feature is available through the engine’s ECM.

This feature can be enabled by a Cummins® Authorized Repair Location. Reference Service Bulletin 2883397.

Oil Drain Interval

Shuttle or Transit Bus Vehicle Average Speed Kilometers Miles Hours Months Below 5 mph Average 2,400 1500 500 6 5 to 10 mph Average 6450 4000 500 6 10 to 15 mph Average 9650 6000 500 6

Cummins Inc. bases the oil drain specifications on duty cycle and oil contamination. This contamination occurs in all engines at varying rates regardless of drain interval.

Maintaining the correct oil and filter change interval is a vital factor in preserving the integrity of an engine. Lubrication Oil Filters must be changed when the oil is changed.

High quality, heavy duty engine oil is required. Use the following procedure for lubrication oil and recommendations. Refer to Procedure 018-003 in Section V of your Cummins® Owner’s Manual L9 CM2350 L116B.

Lubricating Oil Recommendations and Specifications General Information

CAUTION: Extending the oil and filter change interval beyond the recommendations will decrease the engine life due to factors such as corrosion, deposits, and wear.

CAUTION: API Classification FA-4, CES 20087 is not approved for this engine. Engine damage may occur if used.

The use of quality engine lubricating oils, combined with appropriate oil drain and filter change intervals, is a critical factor in maintaining engine performance and durability.

Extending the oil and filter change interval beyond the recommendations will decrease engine life due to factors such as corrosion, deposits, and wear. Determine which oil drain interval to use for an application. Refer to Procedure 359-009 in Section 3 of your Cummins® Owner’s Manual.

☞ NOTE: If engine oil and drain interval recommendations are ignored, warranty could be affected. The responsibility is with the owner to follow the guidelines.

API: American Petroleum Institute CES: Cummins® Engineering Standard Cummins Inc. allows, for midrange applications, the use of lubricating oils that meet or exceed CES 20086 or CES 20081 with no change in oil drain interval.

Cummins Inc. recommends the use of high-quality SAE 15W-40 heavy-duty engine oil, such as Valvoline Premium Blue™.

Normal Engine Operation

• For normal engine operation Cummins Inc. recommendation is for the use of 15W-40 viscosity heavy duty engine lubricating oil that meets the requirements of Cummins® Engineering Standard (CES) 20086 or 20081 (Such as Valvoline™ Premium Blue™ 8600 ES or Valvoline™ Premium Blue™ 8100 ES).

Fuel Economy

• For fuel economy, sensitive application Cummins Inc. approves the use of 10W-30 viscosity heavy duty engine lubricating oil that meets the requirements of Cummins® Engineering Standard (CES) 20086 or 20081 (Such as Valvoline™ Premium Blue™ 8600 ES or Valvoline™ Premium Blue™ 8100 ES). Refer to Procedure 359-009 in Section 3 of your Cummins® Owner’s Manual.

• The use of a fuel economy oil such as an API FA-4 oil or CES 20087 is not approved for this engine.

Cold Weather Operation

• For cold weather applications, the engine is compatible with 5W-40 30 viscosity heavy duty engine lubricating oil that meets the requirements of Cummins® Engineering Standard (CES) 20086 or 20081 (Such as Valvoline™ Premium Blue™ 8600 ES or Valvoline™ Premium Blue™ 8100 ES).

For further details and an explanation of engine lubricating oils for Cummins® engines, refer to Cummins® Engine Oil and Oil Analysis Recommendations, Bulletin 3810340.

Engine Oil Viscosity

General Information Viscosity is a measure of the resistance to flow oil. The viscosity characteristics of all fluids are affected by temperature. Multigrade oil (e.g. 15W-40) viscosities tend to be less sensitive to temperature changes than monograde oil (e.g. SAE 40) because of the addition of viscosity improvers in their formulation. A correctly formulated multigrade oil not only protects the engine at startup, but also throughout the life of the engine.

The selection of oil of the correct viscosity is extremely important for optimum performance and for maximum engine life. If the oil is too viscous, engine drag is increased with the following effects:

Engine is difficult to start.

Engine power output is reduced.

Engine cooling is reduced.

Internal wear is increased.

Engine parts run hotter.

Fuel consumption is increased.

If the oil viscosity is too low, the engine experiences:

Increased wear from metal-to-metal contact.

Increased oil consumption and leakage.

Increased engine noise.

A specific viscosity advertised (e.g. SAE 15W-40) on a product is a viscosity designation only.

This designation alone does not imply that the product meets the Cummins Inc. requirements above.

Some oil suppliers might claim significant fuel economy improvements with lower viscosity oils.

Make sure that the oil’s viscosity grade is permitted in your Owner’s manual and the oil is registered to a Cummins Engineering Standard recommended for your engine. Otherwise, obtain the oil supplier's commitment that they will assume warranty liability, or do not use the oil.

Not all viscosity grades are approved for use in all Cummins® engines. Reference the engine specific Owners/Operations and Maintenance Manual for approved viscosity grades and specific recommendations for operating in cold ambient temperatures.

AfterMarket Oil Additive Usage

Cummins Inc. does not recommend the use of aftermarket oil additives. High-quality CES approved engine lubricating oils are very sophisticated, with precise amounts of additives blended into the lubricating oil to meet stringent requirements.

Aftermarket lubricating oil additives are not necessary to enhance engine oil performance and, in some cases they can reduce the furnished oil's capability to protect the engine.

Transmission Fluid & Filter Changes

Transmission fluid and filter change frequency is determined by the severity of transmission service. Most frequent changes may be necessary than recommended in the general guidelines when operating conditions create high levels of contamination or overheating.

TRANSMISSION – 300 / 400 Series ☞ NOTE: If you steam or pressure wash transmission, do not let water enter transmission vent tube.

Clean and inspect the exterior of the transmission at regular intervals. Severity of service and operating conditions determine the frequency of these inspections.

Check for loose Bolts, Transmission and mounting components.

Fluid leaks – Repair immediately.

Check for loose, dirty, or improperly adjusted throttle sensor or shift selector linkage.

Damaged or loose hoses-Inspect and repair.

Inspect for worn, frayed, or improperly routed electrical harness.

Dented, worn, or out of phase driveline U-Joint and slip fittings-Repair or replace.

Clogged or dirty vent assembly-Inspect and clean.

Check the vehicle cooling system occasionally for evidence of transmission fluid which would indicate a faulty oil cooler.

3000 Series

Sump Initial Fill Refill Liters Quarts Liters Quarts

4 Inch 27 29 18 19 2 Inch 25 26 16 17

High Capacity Filters Fluid And Filter Change Interval Recommendations

PROGNOSTICS TURNED OFF OR

NOT CALIBRATED IN TCM

PROGNOSTIC TURNED ON

DUTY

CYCLE

ALLISON

APPROVED

TES 295®

FLUID

ALLISON

APPROVED

TES 389®

FLUID

ALLISON

APPROVED

TES 295®

FLUID

ALLISON

APPROVED

TES 389®

FLUID

300,000 Miles 25,000 Miles (480,000km) (40,000km) General* 6,000 Hours 1,000 Hours When indicated When indicated or or by controller by controller

FLUID

48 Months 12 Months or

60 months, or

24 months, 150,000 Miles 12,000 Miles (240,000km) (20,000km) whichever whichever Severe** 6,000 Hours 500 Hours occurs first occurs first or or 48 Months 6 Months

*General Vocation: All vocations not classified as Severe.

**Severe Vocation: 2000 MH, On/Off Highway, Refuse, City Transit and Shuttle Transit.

☞ NOTE: Change fluid and filters at or before the recommended mileage, months or hours have elapsed, whichever occurs first.

High Capacity Filters Fluid and Filter Change Interval Recommendations

PROGNOSTICS TURNED OFF OR

NOT CALIBRATED IN TCM

PROGNOSTIC TURNED ON

DUTY

CYCLE

ALLISON

APPROVED

TES 295®

FLUID

ALLISON

APPROVED

TES 389®

FLUID

ALLISON

APPROVED

TES 295®

FLUID

ALLISON

APPROVED

TES 389®

FLUID

FILTERS

Main Filter

General*

75,000 Miles (120,000 km) or 3,000 hours or 36 Months

25,000 Miles (40,000 Km) or 1,000 Hours or 12 Months

When indicated by controller or 60 months, whichever occurs first or 24 months, Severe**

(120,000 km) or 3,000 hours or 36 Months

12,000 Miles (20,000 km) or 5,000 hours or 6 Months

Internal Filter

All Overhaul Overhaul Overhaul Overhaul

Lube/ Auxiliary

Filter

General*

(120,000 km) or 3,000 hours or 36 Months

25,000 Miles (40,000 Km) or 1,000 Hours

12 Months or 60 months, or 24 months, Severe**

(120,000 km) or 3,000 hours or 36 Months

12,000 Miles (20,000 km) or 5,000 hours

6 Months

*General Vocation: All vocations not classified as Severe.

**Severe Vocation: 2000 MH, On/Off Highway, Refuse, City Transit and Shuttle Transit.

☞ NOTE: Change fluid and filters at or before the recommended mileage, months or hours have elapsed, whichever occurs first.

Driveshaft

Lube U Joints Every 6,000 miles or 9,600 km Inspect for excessive play in U Joints Every 3,000 miles or 3 months, whichever occur first Check U Joint Clamps tightness Every 3,000 miles or 3 months, whichever occur first Lube Slip Yoke Every 3,000 miles or 3 months, whichever occur first

Hydraulic

Maintenance Procedures at Daily Interval Oil & filter change after the first 50 hours.

Inspect for leaks.

Inspect steering box for leaks.

Check Oil level.

Maintenance Procedures at each 3,000 Mi, whichever comes first Inspect lines for chafing.

Maintenance Procedures at each 24,000 Mi, whichever comes first Oil & filter change

Cooling Maintenance Procedures at Daily Interval Inspect for leaks.

Coolant Level - Check Maintenance Procedures at each 3,000 Mi Grease Zerk® fittings on fan driveline.

Check fans, and all related mounting bolts Check hose clamps.

Test coolant protection level.

Pressure test coolant system.

Inspect water circulation pump for indications of water leakage at the weep hole; check pump shaft for side to side play.

Maintenance Procedures at each 15,000 Mi, 500 Hours, whichever comes first Change coolant filter (if applicable).

Maintenance Procedures at each 60,000 Mi, 2000 Hours, whichever comes first Cooling System - Flush

Exhaust System

Muffler-Inspect for leaks and loose mounting straps and bolts Every 3,000 miles or 3 months, whichever occur first

Inspect exhaust manifold for leaks Every 3,000 miles or 3 months, whichever occur first Check tail pipe for restrictions or kinks Every 3,000 miles or 3 months, whichever occur first

Inspect exhaust blanket Every 6,000 miles or 6 months, whichever occur first

Catalyst housing-Inspect for damage, leaks or indication of extreme heat

Every 3,000 miles or 3 months, whichever occur first

Check U-bolts clamps for tightness Every 3,000 miles or 3 months, whichever occur first

Diesel Fuel System

Maintenance Procedures at Daily Intervals Inspect for leaks Fuel Filter (spin-on type)-Drain Maintenance Procedures at 15,000 Mi (24,000 Km) 500 Hrs or 6 Months Fuel Filter primary (spin-on type)-Change Fuel Filter Secondary (spin-on type)-Change Conditions Requiring Inspection

☞ NOTE: An inspection shall be conducted if any of the following conditions exist:

Accidents and heat: The fuel container or vehicle in which it is installed is involve in a fire, is subjected to impact, is exposed to excessive heat or is believed to have been damage by any means Chemicals and pressure: The fuel container is over pressurized, is suspected to have damage from cargo, vehicle and/or environmental chemicals, or is believed to have been damage by any means Unusual behavior: Unusual behavior may include, but is not limited to, presence of Diesel odor, rattling or other indications of looseness, unusual snapping or banging Installation: The fuel container is transferred to another vehicle, or the container installation is change significantly

Diesel Exhaust Fluid

WARNING: It is unlawful to tamper with or remove any component of the aftertreatment system. It is also unlawful to use a Diesel Exhaust Fluid (DEF) that does not meet the specifications provided or to operate the vehicle/equipment with no Diesel Exhaust Fluid (DEF).

WARNING: Diesel Exhaust Fluid (DEF) contains urea. Do not get the substance in your eyes. In case of contact, immediately flush eyes with large amounts of water for a minimum of 15 minutes. Do not swallow internally.

In the event the diesel exhaust fluid is ingested, contact a physician immediately. Reference the Materials Safety Data Sheet (MSDS) for additional information.

CAUTION: Never attempt to create Diesel Exhaust Fluid by mixing agricultural grade urea with water. Agricultural grade urea does not meet the necessary specifications required and the aftertreatment system may be damaged.

Cummins Inc. requires the use of Diesel Exhaust Fluid meeting ISO 22241-1. There is NO acceptable substitute.

☞NOTE: Some locations may reference the DIN 70070 standard. Diesel Exhaust Fluid specification limits of this standard are identical to ISO 22241-1.

Cummins Inc. is not responsible for failures or damage resulting from what Cummins Inc. determines to be abuse or neglect, including but not limited to:

operation without correctly specified Diesel Exhaust Fluid; lack of maintenance of aftertreatment;

improper storage, or shutdown practices;

unauthorized modifications of the engine and aftertreatment. Cummins is also not responsible for failures caused by incorrect Diesel Exhaust Fluid or by water, dirt or other contaminants in the Diesel Exhaust Fluid.

For further details and discussion of Diesel Exhaust Fluid (DEF) for Cummins® engines. Refer to the Diesel Exhaust Fluid Specifications for Cummins® Selective Catalytic Reduction Systems, Service Bulletin Number 4021566.

For engines using SCR operating in the United States and Canada, it is also strongly recommended that the Diesel Exhaust Fluid (DEF) used be certified by the American Petroleum Institute (API).

For more information on Diesel Exhaust Fluid and Tank, refer to Section 7 of this Manual

Air System

Maintenance Procedures Action Interval

Air Dryer Ensure the dryer purges when compressor unloads. Weekly.

Drain the purge tank (dedicated purge tank dryers).

Weekly, or as recommended by the manufacturer.

Check for moisture in the system by opening the drain cock on vehicle system reservoirs slowly.

Weekly, or as recommended by the manufacturer, whichever is most frequent.

Replace the standard desiccant cartridge. Every two to three years, or more often depending on usage, vocation, and condition of compressor.

Whenever compressor is rebuilt.

Replace the coalescing cartridge. Every one to two years.

Air Governor Operating and Leakage Tests Every six months or 48,000 miles

Whichever comes first Air Reservoir Check for corrosion or other damage. Every time undercarriage inspection is performed. If corrosion or other damage has weakened a reservoir, it must be replaced.

Safety Valve ST-3 Operating and Leakage Tests Every 48,000 Miles or Annually, whichever comes first.

Single Check Valve SC-3 Leakage Tests Every time undercarriage inspection is performed. Replace if defective.

Double Check Valve DC-4 Operating and Leakage Tests Every 48,000 Miles or Annually, whichever comes first.

Pressure Protection Valve PR-3

Operating and Leakage Tests Every three months or 18,000 miles whichever comes first.

Low Pressure Indicator Device

Operating and Leakage Tests Every 6 months or 36,000 miles whichever comes first.

Service Brake System E-6 Visually check, apply 2 to 4 drops of oil between plunger and mounting plate - do not over oil.

Every 6,000 miles

Disassemble, clean, replace all rubber parts, replace worn or damaged parts Every 48,000 miles

Quick Release Valve

QR-N

Inspect/Operating and Leakage Tests Every 12 months or 3600 operating hours, whichever comes first.

Rear Service Brake Relay Valve R-12DC

Inspect/Operating and Leakage Tests Every 18,000 miles Disassemble, clean, replace all rubber parts, replace worn or damaged parts Every 48,000 miles

Stop Light Switch SL-5 Inspect/Operating and Leakage Tests Replace if defective.

Continue on next page

Air System (Continued)

Maintenance Procedures Action Interval

Parking Brake Valve PP-1 Inspect/Operating and Leakage Tests Every 48,000 miles Spring Brake Control Valve

SR-1

Disassemble, clean, replace all rubber parts, replace worn or damaged parts Every 48,000 miles

Park/Emergency Brake Relay Valve R-14

Inspect/Operating and Leakage Tests Every three months or 18,000 miles whichever comes first

Disassemble, clean, replace all rubber parts, replace worn or damaged parts Every 48,000 miles

ABS System for E Version ECUs 12V and 24V

No regularly scheduled maintenance is required for the Anti-Lock Braking System and its components.

N/A

AIR COMPRESSOR

Maintenance Procedures

Action Interval Twin Cylinder Air Compressor

Air compressor receives inlet air, oil and coolant from the engine.

Follow the engine manufacturer’s recommendations and maintenance schedules regarding fluid levels, air filter and recommended change intervals.

Visual Inspection

1. Check water ports for leakage

2. Check air inlet and discharge ports for leakage

3. Check around end covers for oil leakage

4. Check flanges for cracks or breaks

These checks should be performed every time the engine is serviced

Performance Testing Air System Leakage Test

Electrical Battery-Clean and inspect for damage. Every 3,000 miles Battery cables-Check for frayed or damaged cables inspect for loose or corroded terminal connections and clamps. Every 3,000 miles

Battery disconnect switch-Check for proper operation. Every 3,000 miles Battery Load Test Every 24,000 miles Alternator Output Test Every 3,000 miles Alternator Load Test Every 24,000 miles Starter Draw Test Every 24,000 miles Check J-box for loose or damage components, inspect circuit breakers. Every 3,000 miles

PM CHECK LIST

Introduction: The maintenance schedule that follows is intended to serve as a ready reference for systems and components that require periodic service. The intervals given are manufacturer’s recommendations and should be as a guideline only.

Air Conditioning Electrical Maintenance Inspection Schedule Monthly

6,000 Miles Quarterly

18,000 Miles Semi-

Annually Annually

System or Item

Inspect evaporator blower motor bearings, speed, voltage, and amperage.

See “Specifications” chapter for normal readings.

Bearings: OK , Replace Speed RPM, Voltage Vdc, Amperage amps

X

Inspect condenser fan motor bearings, speed, voltage, and amperage.

See “Specifications” chapter for normal readings.

Bearings: OK , Replace , Brushes Speed RPM, Voltage Vdc, Amperage amps

Check thermostat cycle sequence on all modes (e.g., Cool/Vent, Cool/Reheat, and Vent/Heat).

OK Diagnose thermostat/unit

X

Visually check alternator belt wear, alignment and tension.

Condition: OK , Replace Alignment: OK , Adjusted Tension: OK , Adjusted

Clean alternator, check for signs of corrosion, and check wire connections.

Clean control panel area and return air sensor. X

Check boost pump motor (OEM supplied) operation, voltage, and inspect brushes.

Voltage Vdc Brushes: OK , Replace Operation: OK , Replace motor

Inspect all wires and terminals for damage or corrosion. X

Check high pressure cutout. X

Introduction: The maintenance schedule that follows is intended to serve as a ready reference for systems and components that require periodic service. The intervals given are manufacturer’s recommendations and should be as a guideline only.

Air Conditioning Refrigeration/Heating Maintenance Inspection Schedule Monthly

6,000 Miles Quarterly

18,000 Miles Semi-

Annually Annually

System or Item

Check refrigerant charge. Make sure discharge pressure is 250 psig (1724 kPa) on R-407C systems. The ball in the top receiver tank sight glass should be floating and the liquid line sight glass (if equipped) should be full and clear—no bubbles.

Charge: OK , Needs charging

Visually inspect condition of refrigerant hoses and tubing for signs of deterioration or chafing.

Hoses and tubing OK Hose and/or tubing needs replacement.

Specify which ones

X X X

Visually inspect for leaks of refrigerant and oil.

No leaks , Leaks detected

X X X

Check dry eye in the liquid line sight glass for moisture content.

OK , Perform system cleanup X X

Check compressor oil level and color (1/4 to 1/2 sight glass after 30 minutes of operation). X X X

Install service gauge manifold set. Record operating pressures, temperatures, and suction line condition.

Suction: Fast Idle psig, Full Throttle psig Discharge: Fast Idle psig, Full Throttle psig Ambient F, Return Air F, Suction Line

Check compressor oil for acidity.

Safe , Marginal , Acidic

X

Check compressor efficiency.

OK , Replace or rebuild compressor

X

Replace filter-drier (liquid line dehydrator). a minimum of once a year or any time the system is opened.

X

Check hot water control (coolant) valve operation.

OK , Repair or Replace

X430 Compressor Clutch

Check condition of or service the following: Monthly 6,000 Miles (10000 Km)

Quarterly 18,000 Miles (30000 Km)

Semi- Annually

Annually

System or Item

Visually inspect clutch armature for wear and overheating caused by slippage. X X X

Visually inspect compressor drive belts for excessive wear, tension and alignment (refer to bus manufacturer and/or belt supplier for proper tension).

X X

Check clutch air gap 0.045 ± 0.005 in. (1.143 ± 0.127 mm) and surface flatness—X430 compressor.

X X

Steam clean compressor and clutch. X Check clutch coil resistance and voltage. X Lubricate X430 compressor clutch bearing (Exxon Unirex N2). X

Introduction: The maintenance schedule that follows is intended to serve as a ready reference for systems and components that require periodic service. The intervals given are manufacturer’s recommendations and should be as a guideline only.

Air Conditioning A/C Structural Maintenance Inspection Schedule Monthly

6,000 Miles Quarterly

18,000 Miles Semi-

Annually Annually

System or Item

Inspect condenser coil for cleanliness. X X

Inspect evaporator coil for cleanliness. X X

Inspect outer areas of the unit for loose, damaged, or broken parts.

OK , Make repairs Specify defect

X X X

Clean or replace return air filter (more frequently if necessary). X X X Clean condenser and evaporator drains. Make sure the evaporator drain-hose check valves (Kazooes) are in place and in good condition.

X X X

Check engine coolant hose and hose clamp condition on heater coil system.

X

Clean condenser and evaporator coils. X Check engine coolant for antifreeze protection down to -30 F (-34 C) to prevent heater-coil freeze up.

Antifreeze protection F, ( C).

Tighten all Compressor, unit and fan motor mounting bolts and brackets (more frequently if necessary).

Check condenser air seals and air deflector (when equipped) X

Active HVAC Systems

HVAC UNIT TYPE FREON VEHICLE MODEL

EZRM II-MAX XHF TMRE PASSPORT AXESS

AMOUNT IN SYSTEM

Thermo King™ T-14 R-134a 407c

18 lbs.

19 lbs.

18 lbs.

19 lbs.

18 lbs.

19 lbs.

- 18 lbs.

19 lbs.

Thermo King™ ATHENIA® 1000 407c 22 lbs. 22 lbs. 22 lbs. - 22 lbs.

Thermo King™ ATHENIA® 960 R-134a 22 lbs. 22 lbs. 22 lbs. - 22 lbs.

Thermo King™ S30 R-134a 6 lbs. 6 lbs. 6 lbs. 6 lbs. - Thermo King™ S40

ROOF TOP

R-134a 13 lbs. 13 lbs. 13 lbs. 13 lbs. -

Thermo King™ S40

UNDERMOUNT

R-134a 11 lbs. 11 lbs. 11 lbs. 11 lbs. -

☞ NOTE: If front HVAC is used add 1 additional pound of Freon to the system.

Inactive HVAC Systems

HVAC UNIT TYPE FREON VEHICLE MODEL

EZRM II-MAX XHF TMRE PASSPORT AXESS

AMOUNT IN SYSTEM

Thermo King™ T-2 with Front A/C

R-22 18 lbs.

19 lbs.

18 lbs.

19 lbs.

18 lbs.

19 lbs.

- 18 lbs.

19 lbs.

Thermo King™ MRT with Front A/C

R-134a 20 lbs.

21 lbs.

20 lbs.

21 lbs.

20 lbs.

21 lbs.

Carrier™ 86,000 BTU with Front A/C

R-134a 4.25 lbs.

5.25 lbs.

4.25 lbs.

5.25 lbs.

4.25 lbs.

5.25 lbs.

Carrier™ 96,000 BTU with Front A/C

R-134a 5.25 lbs.

6.25 lbs.

5.25 lbs.

6.25 lbs.

5.25 lbs.

6.25 lbs.

Thermo King™ LRT-SP with Front A/C

R-134a 26 lbs.

27 lbs.

26 lbs.

27 lbs.

26 lbs.

27 lbs.

- 26 lbs.

27 lbs.

Thermo King™ LRT-HP with Front A/C

R-134a 32 lbs.

33 lbs.

32 lbs.

33 lbs.

32 lbs.

33 lbs.

- 32 lbs.

33 lbs.

Thermo King™ T-11 R-134a 407c

18 lbs.

19 lbs.

18 lbs.

19 lbs.

18 lbs.

19 lbs.

- 18 lbs.

19 lbs.

Thermo King™ T-11 (Electric) 407c 19 lbs. 19 lbs. 19 lbs. - 19 lbs.

Thermo King™ ATHENIA® E1000 (Electric) 407c 22 lbs. 22 lbs. 22 lbs. - 22 lbs.

Thermo King™ ATHENIA® E800 (Electric) 407c 22 lbs. 22 lbs. 22 lbs. - 22 lbs.

PM Check List Introduction: The maintenance schedule that follows is intended to serve as a ready reference for systems and components that require periodic service. The intervals given are manufacturer’s recommendations and should be as a guideline only. The underbody and wheel wells should be inspected in the Fall prior to Winter when snow and de-icing conditions exist and in the Spring after Winter when snow and de-icing conditions ceased.

Chassis Axle Front – Non-Driving Steering, After First 200,000 Mile Unitized wheel ends – No Lubrication Required.

Inspection - Do Not Exceed 50,000 Miles intervals

Tie Rod End Service Intervals Inspection Intervals 20,000 Miles Lube Intervals 40,000 Miles

Lube Recommendations (Refer to Arvin Meritor® Tie Rod and Cross Tube Assembly Inspection and Maintenance) For Complete information (TP-97117)

Multipurpose 0-617-A NLGI Grade 1 Grease Class – Non-Synthetic 6% Lithium 12 Hydroxystearate or lithium complex

Single Reduction Differential Carriers – Drive Axle. Check Oil Level and Breather Every 25,000 Miles or the fleet maintenance interval, whichever come first

Petroleum based oil change. Every 100,000 Miles or annually, Whichever Comes First.

Axle assembly – Check alignment and loose bolts. First 6,000 Miles and Every 25,000 Miles Thereafter

Undercarriage Air springs- Inspect for irregular wear or heat cracking, air lines for leaks or chaffing, clearance around springs, clean any buildup of foreign materials.

Every 3,000 Miles or quarterly, Whichever Comes First.

Correct ride height-check/correct. Every 3,000 Miles or quarterly, Whichever Comes First.

Air spring hardware-Make sure all nuts and bolts are tight. Use manufacturer’s specifications to re-torque. (For more information see last page of this list)

Every 100,000 Miles or annually, Whichever Comes First.

Axle assembly-Check alignment and loose bolts. First 6,000 Miles and Every 25,000 Miles Thereafter Axle and suspension mounting - Check mounting bolts for tightness. Inspect for cracks and damage.

First 6,000 Miles and Every 25,000 Miles Thereafter

Inspect undercoating for damage and integrity. Every P.M. Schedule Re-spray undercoating on damage areas, especially on and around wheel wells. (See section 11 of this Manual). AS NEEDED

UNDERCOATING GUIDELINES for Harsh conditions i.e snow/ice

The underbody and wheel wells should be inspected in the Fall prior to Winter and during snows when de-icing conditions exist. The underbody and wheel wells should be inspected in the Spring after Winter when de-icing conditions have ceased. Inspect entire underbody during regular P.M. Scheduled inspections.

☞ DO NOT use a high-pressure washer; pressure washing may cause chips/tears in the film coating allowing corrosion to occur behind the protective coating. During each Spring inspection, touch up any chips/tears on wheel wells and underbody using the same undercoating film by brush or spray. See Section 11 for Mfg Brand of undercoating.

Introduction: The maintenance schedule that follows is intended to serve as a ready reference for systems and components that require periodic service. The intervals given are manufacturer’s recommendations and should be as a guideline only.

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Undercarriage Underbody– Check welds at frame joints, bulkheads, body frames, and air suspension for cracks and or damage.

X X X X X X X X X X X X

Air Bag control valve linkage – Check for wear and loose connections.

X X X X X X X X X X X X

Air bag height control valve Check operation, Clean and inspect. X X X X X X X X X X X X Front suspension – Check for proper height. X X X X X X X X X X X X Height Control Valve – Check operation. X X X X X X X X X X X X Air spring – Check for cracks, abrasions, damage, and proper height. X X X X X X X X X X X X Front and rear shock absorbers – Check for leaks, damage or worn rubber bushings.

X X X X X X X X X X X X

Front suspension – Check for loose or damaged suspension mounting parts.

X X X X X X X X X X X X

Steering king pin knuckle assembly – Check wear, up and down motion, and end play.

X X X X X X X X X X X X

Suspension air system – Inspect airlines for chafing or damage. X X X X X X X X X X X X Suspension air tanks – Check mounting bolts for tightness. X X X X X X X X X X X X Axle shaft flange – Check gasket for damage. X X X X X X X X X X X X Carrier to housing gasket – Inspect gasket for leakage. X X X X X X X X X X X X Carrier to housing stud nuts, Check for proper torque. X X X X X X X X X X X X Drive line bolts – Check for proper torque. X X X X X X X X X X X X Pinion oil seal – Check for leakage. X X X X X X X X X X X X Propeller shaft – Inspect yoke flanges, nuts tightness, excessive movement and looseness, inspect U joint for wear and damage.

X X X X X X X X X X X X

Rear axle flange nuts – Check for proper torque. X X X X X X X X X X X X Multi-links - Check for loose bolts, and rubber bushings, bent or damaged parts.

X X X X X X X

Brake assemblies – Check operation, X X X X X X X X X X X X X Moisture ejector valve – check operation, remove, disassemble, clean and inspect.

X X X X X X X X X X X X X to serve as a ready reference for systems and components that require periodic service. The intervals given are manufacturer’s recommendations and should be as a guideline only.

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Undercarriage Brake assemblies – Check lining thickness. X X X X X X X X X X X Mounting brackets – Check for damage or loose mounting. X X X X X X X X X X X X X Start cables – Inspect cables and connections for chafing and looseness.

X X X X X X X X X X X

Starter motor – Inspect cables for chafing, wear or damage, inspect brushes for wear and lube oil wicks and reservoirs.

X X X X X X X X X X X

Inspect undercarriage for fluid leaks. X X X X X X X X X X X Fuel tank – Inspect for damage, leaking and loose mounting bolts. X X X X X X X X X X X Fluid lines - Inspect for damage or fuel leaks. X X X X X X X X X X X Lines and fittings – Inspect for damaged lines, loose connections and leakage.

X X X X X X X X X X X

Wiring – Check and insure that cables in away from sharp edges and rotating parts.

X X X X X X X X X X X

Power steering pump – Check operation and mounting bolt tightness.

X X X X X X X X X X X

Steering tie rod assembly – Inspect ball studs for excessive up and down motion and end play at ball studs. Inspect for bent condition or damaged tube threads. Check mounting stud nuts and end socket bolt nuts for tightness.

X X X X X X X X X X X

Steering drag link assembly – Inspect ball studs for excessive up and down motion and end play at ball studs. Inspect for bent condition or damaged tube threads. Check mounting stud nuts and end socket bolt nuts for tightness.

X X X X X X X X X X X

Steering drag link arm – Inspect pitman arm for wear or looseness. X X X X X X X X X X X Steering column gearbox – Check mounting bolt torque, inspect for wear, damage and leaks.

X X X X X X X X X X

Transmission fluid cooler – Inspect water and fluid lines for leakage clean and inspect.

X X X X X X X X X X X

Undercoating Inspection. X X X X X X X X X X X X X Undercoating-Re-spray. (AS NEEDED) X X X X X X X X X X X X X

Daily PM Check List Introduction: The maintenance schedule that follows is intended to serve as a ready reference for systems and components that require periodic service. The intervals given are manufacturer’s recommendations and should be as a guideline only.

Interior-System or Item Daily Front Windshield- Inspect for damage, cracks and fogging. X Horn-Check operation. X Driver and Passenger Windows- Inspect for damage, cracks. Check operation of egress windows and lubricate release handle components.

X

Sun Visor-Check operation. X Driver Seat and Seat Belt-Inspect for damage, functionality and loose seat mounts. X Steering Column-Check tilt lock secures the column in each position. X Master switch-Check for proper operation in each switch position. (DAY, NIGHT, RUN) X Heater controls-Front -Check for proper operation. X Defroster Switch-Check for high, medium, and low speed operation and air flow. X Wiper control-Check wiper arm operation. X Headlights-Ensure light are working, high & Low Beams. X Heater and Air Conditioning Controls-Rear or top of coach-check heater/air conditioning controls and fan speed switches.

X

Windshield Washer/Wiper-Check spray and operation. X Fire Suppressor/Gas detection System-Check control panel status (make sure SYSTEM “OK” is illuminated). X Door Controls- Check operation, move control lever through each position. X Door Dump Valve- Check operation. X Door Sensitive Edges- Check operation, light and alarm. X Door Operation-Check for proper opening and closing, bumper stops. Adjust and lubricate as required. X Brake Interlock-Check operation with exit door and wheelchair ramp. X Grab Rails, Stanchions and Modesty Panels- Inspect for damage, missing or lose screws. X Warning Decals-Check for damage and/or missing decals. X Roof hatch-Check operation and proper sealing. X to serve as a ready reference for systems and components that require periodic service. The intervals given are manufacturer’s recommendations and should be as a guideline only.

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Interior-System or Item Steering wheel column and shaft-Inspect steering wheel shaft and universal joints for wear or damage.

X X X X X X X X X X X

Steering column mounting brackets and support bracket-Check mounting bolts for tightness.

X X X X X X X X X X X

Grab-rails and stanchions-inspect for damage and loose mounting bolts.

X X X X X X X X X X X X X

Interior trim-Inspect for damage and missing screws. X X X X X X X X X X X X X Passenger seats-Check mounting bolts tightness. X X X X X X Modesty panels, inspect for damage and missing or loose mounting bolts.

X X X X X X X X X X X X X

Roof escape hatch and ventilator-Check for damage seals or water leaks.

X X X X X X X X X X X

Steering wheel column and shaft-Inspect steering wheel shaft and universal joints for wear or damage.

X X X X X X X X X X X

Steering column mounting brackets and support bracket-Check mounting bolts for tightness.

X X X X X X X X X X X

Grab-rails and stanchions-inspect for damage and loose mounting bolts.

X X X X X X X X X X X X X

Interior trim-Inspect for damage and missing screws. X X X X X X X X X X X X X Passenger seats-Check mounting bolts tightness. X X X X X X Modesty panels, inspect for damage and missing or loose mounting bolts.

X X X X X X X X X X X X X

Roof escape hatch and ventilator-Check for damage seals or water leaks.

X X X X X X X X X X X

A.D.A. Access

☞NOTE: The procedures and intervals described herein are not intended to be all-inclusive. They are intended to cover the foreseeable service contingencies. Maximum interval under normal conditions is 12 months.

*Operation, Lubrication and Cleaning of accumulated debris *Check daily as part of routing service Ramp platform surfaces Check for wear, damage and overload…