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Blue Bird D3RE 2014 Driver's Handbook Manual

All american rear engine, tx3 rear engine, global transit rear engine
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D3RE
2014
D R I V E R S
APPLIES TO THESE MODELS
ALL AMERICAN REAR ENGINE
TX3 REAR ENGINE
GLOBAL TRANSIT REAR ENGINE
COUNT ON BLUE BIRD
H A N D B O O K

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Summary of Contents for Blue Bird D3RE 2014

  • Page 1 D3RE 2014 D R I V E R S H A N D B O O K APPLIES TO THESE MODELS ALL AMERICAN REAR ENGINE TX3 REAR ENGINE GLOBAL TRANSIT REAR ENGINE COUNT ON BLUE BIRD...
  • Page 3 D3RE 10032199 Edition C...
  • Page 4 © 2012 Blue Bird Body Co. All rights reserved. All Blue Bird products sold for use in the United States of America and its insular areas comply with all applicable Federal Motor Vehicle Safety Standards (FMVSS) as of the date of manufacture indicated on the compliance label and applicable Federal ADA requirements.

  • Page 5: Table Of Contents

    CONTENTS Introduction / 7 Enroute Emergencies / 41 About This Manual / 7 EMERGENCY EXITS Reporting Safety Defects / 8 Transpec™ Safety Vent / 42 Noise Emissions / 8 EMERGENCY EQUIPMENT About 2010 Emissions Standards / 9 Regarding Modifications / 10 Fire Extinguisher / 44 Before Placing the Bus in Service / 12 First Aid Kit / 44...
  • Page 6 Using The Engine As A Brake / 58 Hydraulic Retarder (If Equipped) / 87 Exhaust System / 59 BRAKING DPF Regeneration In Blue Bird Buses / 60 Air Brakes / 88 Levels of Notification / 61 Antilock Braking System (ABS) / 89...
  • Page 7 CONTENTS Care & Maintenance / 95 ENGINE & RUNNING GEAR Air Intake System Inspection / 108 ELECTRICAL Engine Cooling System / 109 Interior Lights / 96 Transmission / 112 Exterior Lights / 96 Rear Axle / 112 Doran Warning Light Monitor / 97 WINDSHIELD WIPERS Circuit Breakers / 99 Washer Solution Reservoir / 113...
  • Page 8 DRIVER’S HANDBOOK...

  • Page 9: Introduction

    About This Manual This Drivers Handbook has been prepared to acquaint you with the operation of the Blue Bird All American, and should be read by all Drivers before operating the unit. Familiarity with automotive operation and control is assumed to be common knowledge to all who will be operating this bus.

  • Page 10: Reporting Safety Defects

    Washington, DC 20590 You can also obtain other information about motor vehicle safety from: http://www.safercar.gov. Noise Emissions This vehicle was designed, built, and equipped by Blue Bird to conform to all ap- plicable United States Environmental Protection Agency Noise Control Regulations.

  • Page 11: About 2010 Emissions Standards

    INTRODUCTION About 2010 Emissions Standards Buses equipped with 2010 diesel engines are designed to conform to stringent fed- eral emissions standards. These standards affect both the equipment installed at the factory and the fuel at the pump. Buses powered by 2010 emissions standards engines are equipped with special exhaust systems to reduce emissions.

  • Page 12: Regarding Modifications

    DRIVER’S HANDBOOK Regarding Modifications Blue Bird Body Co. offers many items as standard and optional equipment to meet federal, state, and local specifications and individual customer requirements. This includes, but is not necessarily limited to, stop arms, crossing guards, warning...
  • Page 13 INTRODUCTION For the terms of the Limited Warranty of this Blue Bird product, refer to the Warranty certificate provided in the owner’s documents that came with the vehicle. In addition to the safety issues involved in the modification of the unit, any “un- authorized”...

  • Page 14: Before Placing The Bus In Service

    DRIVER’S HANDBOOK Before Placing the Bus in Service It is the responsibility of the bus Owner/Operator to ensure compliance with all fed- [WARNING] Emergency eral, state, and local regulations for school bus operation and equipment. As part of a equipment must be checked for daily pre-trip inspection, the Driver should consider it his/her responsibility to verify proper operation daily.

  • Page 15: Orientation

    ORIENTATION his section is to familiarize the Blue Bird All American Driver with the locations of controls and other bus features with which he or she will interact daily. Product Identification Information Federal Vehicle Compliance Label certifies that the vehicle complies with all applicable Federal Motor Vehicle Safety Standards (FMVSS) in effect on the date of manufacture.

  • Page 16: Entrance And Exit

    The manual control is the Blue Bird over center locking type with built in Saf Latch. The door’s ease of operation allows use of a short handle arm, so the handle is six inches closer to the driver in the open position than with the jack-knife door.

  • Page 17: Emergency Pneumatic Door Release

    ORIENTATION Emergency Pneumatic Door Release An emergency release valve is located above the door in the header cover. To use the emergency release, push the lever in the direction of the arrow. This valve exhausts air pressure in the door cylinder, allowing the door to be opened and closed manu- ally.

  • Page 18: Security Lock (Outward Opening Door)

    DRIVER’S HANDBOOK Security Lock (Outward Opening Door) Outward opening doors have an optional key locking mechanism, accessible from outside the bus. A key operated bolt slides into a hole in the header when the door is in the closed position and locked. This option also requires use of the hinged stop on the door control.

  • Page 19: Wheelchair Lifts

    ORIENTATION Wheelchair Lifts Blue Bird All American school buses may be fitted with lifting platforms designed to aid in loading and unloading passengers. There are two optional wheelchair lifts available. The units available are the Ricon™ and the Braun™. Both offer a maximum of 48 inches (122 cm) lift from the ground to the level of the bus floor.

  • Page 20: Driver's Area

    DRIVER’S HANDBOOK DRIVER’S AREA Driver’s Compartment 1. See Driver’s Instrument Panel. 2. See steering column with horn and controls. 3. Automatic transmission shift control range selector or electronic push but- ton pad location. 4. See Left switch panel. 5. See Right switch panel. 6.

  • Page 21: Driver's Instrument Panel

    ORIENTATION Driver’s Instrument Panel 1. Speedometer. Indicates vehicle speed in miles/hour or 7. Front Air Gauge. Indicates air pressure in front brake kilometers/hour. reservoir and includes a low air warning indicator. (Air 2. Tachometer. Indicates engine speed in revolutions per Brakes only.) 8.
  • Page 22 DRIVER’S HANDBOOK QUAD 2A QUAD 2A Priority Messages QUAD 1 QUAD 1 QUAD 2B QUAD 2B No Engine Communication QUAD 2C QUAD 2C No Transmission Communication QUAD 3 QUAD 3 No ABS Communication QUAD 4 QUAD 4 Data Link Warning Vehicle Speed Error Engine Door Open Quad 1.
  • Page 23 Engine Warn. The engine Seat Belt. Indicates driver System under Routine Op- needs service. seatbelt not engaged. eration. (Optional) Oil Pressure. Indicates Diesel Exhaust Fluid. DEF low oil pressure. warning light. See SCR System in Blue Bird Buses under Routine Operation.
  • Page 24 DRIVER’S HANDBOOK Set the Clock To set the clock, be sure the park brake is set then press and hold the bottom button on the face of the instrument cluster for approximately 5 seconds. This will display the Settings and Diagnostics screen. Press either the top or bottom button to move to the highlighted bar to menu item 6 –...
  • Page 25 ORIENTATION Contrast Adjustment Set the park brake then press and hold the bottom button on the face of the instru- ment cluster for approximately 5 seconds. This will display the Settings and Diag- nostics screen. Press either the top or bottom button to move the highlighted bar to menu item 3 –...

  • Page 26: Left Switch Panel

    DRIVER’S HANDBOOK Left Switch Panel The left switch panel located under the driver’s side window and shown here consist of the exterior reaview mirror controls and switches for standard and optional equip- ment. The left switch panel will be equipped only with switches for options that are included on your bus and therefore may differ from the panel shown here.
  • Page 27 ORIENTATION Rear dome lghts. Lift. Provides power for lift operation. Sets Brake Interlocks. PANEL Lift door open indicator light. DEST SIGN OVRD Emergency door open indicator light. HIGH TIRE IDLE CHAINS Strobe light. Roof vent fan. High, Off, and Low positions. Chimes.

  • Page 28: Right Switch Panel

    DRIVER’S HANDBOOK Right Switch Panel The right switch panel as shown here consists of switches and controls for optional equipment installed on the bus. There are three banks of switches. The first bank of switches are for optional equipment that may be installed. The second bank of switches control heater options installed.
  • Page 29 ORIENTATION Air or electric entrance door switch with blue be- zel. Warning light start with orange bezel. Initiates warning light sequence Warning light master. Enables entire warning light system. Warning light indicators. Red and yellow. Stop arm and/or crossing arm cancel. Interrupts stop arm and/or crossing arm sequence.

  • Page 30: Heat And Air Control Panels

    Comfort Aire publica- tion supplied with your air conditioned bus. Fan Control Temperature Control Defrost to Driver Fresh Air to Off, Low, Medium and High Cold to Hot Compartment Recirculation Blue Bird Heater Control Panel...
  • Page 31 ORIENTATION Temperature Controls (Upper Knobs) Fan Controls (Lower Knobs) Off, Low, Medium and High Comfort Aire Manual Controls Temperature controls Temperature controls (Front) (Rear) Front Fan Control Rear Fan Control Off, Low, Medium and High Off, Low, Medium and High Display Settings Control System Diagnostics Comfort Aire Electronic Controls...

  • Page 32: Steering Column

    DRIVER’S HANDBOOK Steering Column The steering column of the new All American is designed for better access to the driver’s area with easier adjustment and a greater range of movement. Steering Wheel Position A lever at the lower side of the column sets the tilt and telescopic adjustment of the steering wheel.
  • Page 33 ORIENTATION Intermittent Windshield Wipe / Wash Turn for Wipe. Press for wash Left Switch Stalk Right Switch Stalk Turn Signals Hazard Flasher Control Cruise Control Set High / Low Beam Resume, Accelerate, On / Off Wipe / Wash Steering Column Positioning Tilt / Telescopic Release...

  • Page 34: Mirrors And Adjustment

    DRIVER’S HANDBOOK Mirrors And Adjustment [WARNING] The vehicle’s mirror system has been designed to comply with all field-of-view requirements, but it is the operator’s responsibility to adjust Periodic tightening the mirrors properly before placing the vehicle in service and to maintain the may be required adjustment during the service life of the vehicle.
  • Page 35 ORIENTATION Proper adjustment is necessary for any mirror system to perform as designed. The following adjustment sequence should be used to allow the driver maximum viewing area with the mirror system. 1. Adjust the driver’s seat to the desired position. 2.

  • Page 36: Seating

    DRIVER’S HANDBOOK SEATING Seat Back Tilt Adjustment Standard Driver’s Seat To adjust seat position forward or backward, hold lever (A) to the left. Shift the seat forward or rearward to the desired posi- tion and release the lever. A hand operated lever (B) on the right side of the seat allows adjustment of the height of the seat.To raise the seat, crouch in the sitting position but do not apply your weight to the seat.

  • Page 37: Driver's Seat Belt With Shoulder Harness

    ORIENTATION [WARNING] Do not attempt to adjust the driver’s seat, while the vehicle is in motion. Do not adjust height while sitting in the driver’s seat. Keep feet and other items away from height adjustment handles and pedals while vehicle is in motion.

  • Page 38: Child Restraint Seats

    DRIVER’S HANDBOOK Child Restraint Seats Young Children And Infants Everyone in a vehicle needs protection. This includes infants and all other children. Neither the distance traveled nor the age and size of the traveler changes the need for everyone to use safety restraints. In fact, the law in every state in the United States and in every Canadian province says children up to a certain age must be restrained while in a vehicle.
  • Page 39 ORIENTATION Universal Child Restraint Anchorage Seats in this bus equipped with the universal child restraint anchors are identified by a decal located over the seat above the window. (See Decal illustration on the following page.) This vehicle may be equipped with a universal child restraint anchorage system. If so, you’ll find two anchors in the front lower seatback where the bottom of the seatback meets the back of the seat cushion and a third anchor in the lower rear seatback.

  • Page 40: Compartments & Access Panels

    DRIVER’S HANDBOOK COMPARTMENTS & ACCESS PANELS All American Front Access Release press button latches on the driver’s side front access panel to gain access to the windshield wiper motor and the windshield wash reservoir. Air tank bleeder valves and a schrader valve can also be accessed. The right side panel can be opened to gain access to the windshield wiper motor and the exterior heater filter.

  • Page 41: Engine Access

    ORIENTATION Engine Access To open the door, press release button latches located in four places on the engine door. Pull and lift the access cover allowing it to fully open, up and out of the way. This will allow access to engine components, such as the oil dipstick, engine oil fill, transmission fluid dipstick, etc.

  • Page 42: Additional Access Panels

    DRIVER’S HANDBOOK Additional Access Panels Other access panels include the electrical access panel, PDU (Power Distribution Unit) access panel, fuel fill, and battery compartment. The electrical panel access door is located on the outside of the bus below the driver’s window. Behind this panel you will find circuit breakers and fuses to the bus body electrical circuits.

  • Page 43: Enroute Emergencies

    ENROUTE EMERGENCIES assenger safety is the bus driver’ s first priority. In the event of enroute emergency or roadside hazard, the driver must be confidently famil- iar with the location and use of safety devices, emergency equipment and roadside procedures in order to maintain order, guide passengers to safety, and properly position and secure the bus until assistance arrives.

  • Page 44: Emergency Exits

    DRIVER’S HANDBOOK EMERGENCY EXITS Emergency exits are clearly identified by the words “EMERGENCY EXIT. ” Operating in- structions are printed near each exit. Some units are equipped with an audible alarm which sounds if an emergency exit is unlatched or open. If a buzzer sounds when turning on the ignition switch, check emergency exits to see that they are closed.
  • Page 45 ENROUTE EMERGENCIES Transit Sliding Pushout Window Split Sash Pushout Window Rear Emergency Window Side Emergency Door...

  • Page 46: Emergency Equipment

    DRIVER’S HANDBOOK EMERGENCY EQUIPMENT Each state or province has unique laws regarding emergency equipment. Your unit may have some or all of the items listed below. Because of variations in option pack- ages, the placement of this equipment inside the bus may vary from one unit to another, but it is important for you to recognize and know the locations of all the emergency equipment on your bus.

  • Page 47: Triangular Warning Devices

    ENROUTE EMERGENCIES Triangular Warning Devices For states requiring the triangular warning devices be located in the driver’s com- partment, this container is mounted above the windshield at the upper center near the roof line or floor mounted between the stepwell and the driver. For other states, it is located on the left-hand rear floorboard, under the rear seat.

  • Page 48: Tire / Wheel Emergencies

    DRIVER’S HANDBOOK TIRE / WHEEL EMERGENCIES Tire Pressure Monitoring System (Optional) The SmarTire™ Tire Pressure Monitoring System (TPMS) is a wireless communication network that constantly monitors the pressure and temperature of each tire on your vehicle in order to provide real-time, on-demand tire status information and to warn the driver of a tire-related problem before it becomes dangerous.

  • Page 49: Damaged Tires

    ENROUTE EMERGENCIES Damaged Tires [WARNING] An inflated tire and rim can be very dangerous when misused or worn out. Many accidents, some fatal, have resulted from improper handling and operation of bus rims and wheels. To help avoid personal injury and/or property damage, get expert tire service help if you can.

  • Page 50: Wheel And Rim Safety

    DRIVER’S HANDBOOK Wheel And Rim Safety Wheels and wheel components must be properly maintained to avoid adverse ef- fects on the life of the tire and/or wheel. An inflated tire is potentially very destruc- tive. Careless handling and inexperience cause accidents. Safety literature can be ob- tained from your wheel and rim distributor, a wheel and rim manufacturer, NHTSA, or OSHA.

  • Page 51: Jacking Instructions

    ENROUTE EMERGENCIES Jacking Instructions Rear Jack Point [WARNING] Proper jacking procedures and basic safety measures must be observed to ensure safety of personnel while working under the bus. Always check the serviceability of any lifting equipment prior to use. Ensure that the lifting device is of sufficient strength to handle the bus, and that the surface provides the necessary firmness to support the weight of the bus concentrated on the footprint of the jack.

  • Page 52: Changing A Flat Tire

    DRIVER’S HANDBOOK Changing a Flat Tire The lug nuts are tightened to a torque value of 450 - 500 Ft lb (610 – 678 Nm). With- out the proper power tools, it is very difficult to remove the lug nuts. The lug nuts must be “broken loose”...
  • Page 53 Tow hooks are designed to tow or pull with both hooks simultaneously. Do not pull or tow with an individual hook. Bumpers provided on Blue Bird buses are designed to protect the vehicle and occupants from front and rear collisions.

  • Page 54: Releasing Spring Brake Manually

    DRIVER’S HANDBOOK Releasing Spring Brake Manually When air pressure fails in the rear service brake chamber, the power spring applies the rear service brakes. Unless pressure can be re-established, the park brakes must be released, as follows, to move the bus. [WARNING] Do not release the spring brake until the bus is secured by wheel chocks or tow vehicle.

  • Page 55: Routine Operation

    ROUTINE OPERATION lthough the controls of a modern bus may appear similar to those of a regular passenger car or truck, the size and weight of the bus and its payload require many differences in design, components, and oper- ating procedures. This section describes special considerations in opera- tion of the engine, transmission, brakes, and other systems.

  • Page 56: Pre-Route Inspection

    DRIVER’S HANDBOOK PRE-ROUTE INSPECTION To keep your bus in the best operating condition, any malfunction or defect should be corrected before the next trip. Report needed services to responsible mainte- nance personnel. Engine/Transmission: • Check fuel level. • Drain air tanks. • Drain fuel/water separator. • Check engine oil level. • Check automatic transmission fluid level.

  • Page 57: Weekly Inspection

    ROUTINE OPERATION Starting the engine: • Be sure parking brakes are on. • Put the transmission in Neutral. • With the key in the “ ON” position, check the fuel gauge. Check the brake warn- ing buzzer or light, and the neutral safety switch. • Start the engine. Look and listen for trouble signs; check the gauges. With the engine running, check (from driver’s seat): • Mirrors, interior and stepwell lights, service door seal. • Does the steering feel OK? Is there any unusual noise? • Check the horn, defroster and heater blower, and windshield wiper opera- tion.

  • Page 58: Engine Operation

    DRIVER’S HANDBOOK ENGINE OPERATION Engine Exhaust Caution (Carbon Monoxide) [WARNING] Never idle the engine in a confined area. Never sit in a parked or stopped vehicle with the engine running. Exhaust gases, particularly carbon monoxide, can build up. These gases are harmful and potentially lethal. Carbon monoxide is colorless and odorless, but can be present with all other exhaust fumes.

  • Page 59: Diesel Engine Starting Procedure

    Always wear protective glasses when working with batteries. The Blue Bird All American bus has a 12-volt starting system. Use only 12 volts for booster starting. The use of a higher voltage will damage the electrical system.

  • Page 60: Using The Engine As A Brake

    DRIVER’S HANDBOOK Using The Engine As A Brake While going down a steep or long grade, it is a good practice to use the engine to retard vehicle speed. Reduce speed before the grade and shift into a lower gear (with either automatic or manual transmissions), being careful to select a gear which will slow the vehicle without over speeding the engine.

  • Page 61: Exhaust System

    90 percent from 2004 levels. The exhaust system of the Cummins Ultra Low Sulfur, per the engine engine in Blue Bird buses are aftertreatment systems which incorporate a Diesel Par- manufacturer’s specifications. ticulate Filter (DPF) and a Selective Catalytic Reduction (SCR) system instead of or- In Cummins, use oils meeting API dinary mufflers.

  • Page 62: Dpf Regeneration In Blue Bird Buses

    The Cummins equipped Blue Bird bus exhaust system is not complicated. Nor while driving. should the regeneration process be regarded with alarm. Both Drivers and service technicians should be at least conceptually familiar with the regeneration process.

  • Page 63: Levels Of Notification

    ROUTINE OPERATION HEST Indicator (High Exhaust System Temperature). An instrument panel indicator which appears when the exhaust temperature is unusually high due to recent regen- eration. This is normal behavior of the aftertreatment system, intended to notify the driver and technician that the exhaust system temperature is high and that caution should be observed around the exhaust system.
  • Page 64 DRIVER’S HANDBOOK Level 1 Regeneration Notification: DPF Indicator Appears Level 1 In low-demand operating conditions, it is possible that the regeneration system does not have sufficient opportunity to prevent particulate build-up in the DPF. The ECM Regen senses that accumulation is occurring and that regeneration is needed. The driver is notified as follows: Needed The DPF Regeneration alert appears in the Message...
  • Page 65 ROUTINE OPERATION Level 3 Notification: Check Engine Indicator Appears Level 3 If the bus continues to be operated without taking the measures indicated by a Level Regen 2 Notification, particulate accumulation worsens. These indicators are activated: Needed • The DPF Regeneration alert continues to flash. Regen • The audible alert sounds continuously.

  • Page 66: Stationary Regeneration Precautions

    DRIVER’S HANDBOOK Stationary Regeneration Precautions During active regeneration, the exhaust system can reach extremely high temper- atures. Automatic active regeneration, which occurs while driving the bus, is pro- grammed to occur only when the bus is moving at a minimum speed, and it stops when the vehicle slows or stops.

  • Page 67: Scr System In Blue Bird Buses

    Exhaust gas and exhaust surface temperatures will remain elevated until they have had time to cool to normal levels. SCR System in Blue Bird Buses Selective Catalytic Reduction (SCR) is a Nitrous Oxide control technique for diesel engine exhaust.
  • Page 68 SCR system. [CAUTION] DO NOT put diesel fuel in the DEF tank. DO NOT put Refer to Blue Bird and Cummins Service Manuals for detailed description of the af- DEF in the fuel tank of the bus. tertreatment system.
  • Page 69 ROUTINE OPERATION DEF Levels of Priority Notification Level 1 A system of driver alerts keeps the driver informed of when the DEF is in need of service. When fluid is low or contaminated, several levels of alerts occur in sequence, DEF Level Low each indicating a more imperative warning.
  • Page 70 DRIVER’S HANDBOOK Level 4 DEF Level 4. When the DEF level reaches 0% in the tank, a DEF TANK EMPTY warning will appear in Quad 1 of the Message Display, this DEF TANK EMPTY warning dis- DEF Tank Empty play will flash from positive to negative. The amber DEF Warning icon will continue flashing in the lower left warning bank and the amber Engine Warning light will be DEF Tank Empty illuminated.
  • Page 71 ROUTINE OPERATION Level 1 DEF Type Level 1. When incorrect fluid or mixture is introduced into the tank, a DEF FLUID TYPE warning will appear in Quad 1 of the Message Display, this DEF FLUID DEF Fluid Type TYPE warning display will flash from positive to negative. The amber Engine Warn- ing light will appear in the lower left warning bank.
  • Page 72 DRIVER’S HANDBOOK Level 1 SCR Fault Level 1. When an SCR System Fault is detected, an SCR SYSTEM FAULT SEE ENGINE DIAGNOSTIC warning will appear in Quad 1 of the Message Display, this SCR SYSTEM FAULT SEE ENGINE DIAGNOSTIC will flash from positive to negative. The amber Engine Warning light will appear in the lower left warning bank.

  • Page 73: Compressed Natural Gas

    Testing and recertification of the compressed gas cylinders is not covered by Blue Bird warranty. Replacement of compressed gas cylinders, at the end of their service life, is not covered by Blue Bird warranty. National Fire Protection Association #52 States: Cylinders shall be manufactured, inspected, marked, tested, retested, equipped and used in accordance with U.S.

  • Page 74: Fuel System Description

    DRIVER’S HANDBOOK When a vehicle is involved in an accident or fire causing damage to any part of the CNG fuel system, the system shall be retested before being returned to service. Damaged supply lines must be replaced, not repaired. The owner or user, or both, shall maintain all containers, container appurtenanc- es, piping systems, venting systems and other components in a safe condition.

  • Page 75: Safety Cautions And Warnings

    ROUTINE OPERATION Do not uncouple fittings until all tanks are closed and pressure has been purged from the line. The lines are high pressure rated 3/8 stainless steel seamless tubing which carries the fuel to the high pressure regulator. In refilling, the fuel enters the fill valve on the entrance side of the bus and then flows through a check valve into the common tubing before reaching the tanks.
  • Page 76 DRIVER’S HANDBOOK [WARNING] Protect against extremely cold escaping CNG. Compressed natural gas is stored at an extremely high pressure. If compressed natural gas escapes from a leak, it will expand into an extremely cold (-260° F) gas. Severe frostbite may occur from contact with escaping natural gas or its associated components.

  • Page 77: Compressed Natural Gas Fuel

    [CAUTION] It is the owner’s/operator’s responsibility to ensure that clean, quality fuel is used to prevent damage to the fuel system components and power plant. Damage caused by poor quality fuel is not covered by Blue Bird warranty. Fuel control systems used on engines fueled by compressed natural gas contain electronic sensors and other delicate components that are not tolerant of contami- nants.

  • Page 78: Refueling

    DRIVER’S HANDBOOK Replacement filter elements are available through the Blue Bird Service Depart- ment. [WARNING] Compressed natural gas is highly flammable, and pressurized gas can cause serious personal injury or death. Refueling [WARNING] Refueling must be conducted in well-ventilated areas to prevent accumulation of dangerous gas levels.

  • Page 79: Specific Gravity

    ROUTINE OPERATION The tanks are full at 3,000 psi, or 3,600 psi at 70° F. The pressure will vary with temperature, decreasing with lower temperature and increasing with higher tem- peratures. Filling apparatus compensates for the temperature effect. [WARNING] Never fill to more than permissible pressure. Contact the manu- facturer if an accidental overfill occurs.

  • Page 80: Antiknock Properties

    DRIVER’S HANDBOOK Antiknock Properties Natural gas has a research octane rating of about 130, making it relatively resistant to engine knock. The antiknock property is a result of the high ignition temperature, resistance to auto-ignition, and the relatively low flame speed of natural gas. An- tiknock properties allow the use of engine compression ratios in the range of 15:1 (compared to 8:1 to 10:1 for gasoline).

  • Page 81: Cold Start

    ROUTINE OPERATION Cold Start For cold starts, in low ambient temperatures, natural gas has an advantage over liq- uid fuels because it is already in the vapor phase. With correct conversion kit instal- lation and vehicle maintenance, cold start ability is better with natural gas than with gasoline.

  • Page 82: Transmissions

    If you did not receive this manual with your bus, please contact the transmis- sion supplier. Both Blue Bird Body Co. and Allison Transmissions continually strive to improve the quality and performance of their respective products. For this reason, information and instructions in the Allison Transmission Operator’s Manual supplied...
  • Page 83 ROUTINE OPERATION Allison Model 3000 Series Transmission Gear Selection [WARNING] When leaving the vehicle while the engine is running, the opera- tor must ensure the transmission is in “Neutral”, the parking brake is engaged, and the wheels are chocked. The vehicle may move unexpectedly without these precautions.

  • Page 84: Allison Model 2000 Series Transmission

    DRIVER’S HANDBOOK Allison Model 2000 Series Transmission The Allison transmission provides five forward speeds and one reverse. The transmis- sion is controlled with the selector lever located to the driver’s right. The selector lever must be in the “N” position (neutral) to start the engine. If the engine starts in any other position, the neutral start switch is malfunctioning and should be repaired immediately.

  • Page 85: Range Inhibited Light

    ROUTINE OPERATION 1, 2, D Gears. Occasionally, the road conditions, load, or traffic conditions will make it desirable to restrict shifting to a higher gear. Positions “D”, “2”, and “1” provide pro- gressively greater engine power and braking for going down grades (the lower the gear, the greater the braking effect).

  • Page 86: Allison Automatic Transmission Driving Tips

    DRIVER’S HANDBOOK Allison Automatic Transmission Driving Tips Accelerator Control The pressure of your foot on the accelerator pedal influences the automatic shift- ing. An electronic signal tells the ECU how far the driver has depressed the pedal. This provides the accurate shift spacing and control necessary for maximum perfor- mance.

  • Page 87: Transmission Indicators

    ROUTINE OPERATION [WARNING] If you only downshift or only use the service brakes when driv- ing down a steep grade, you can lose control. To maintain control, combine downshifting, braking, and other retarding devices. Downshifting to a lower transmission range increases engine braking and helps maintain control. The transmission has a feature to prevent automatic up shifting above the lower range selected.

  • Page 88: Transmission Service Prognostics

    DRIVER’S HANDBOOK Transmission Service Prognostics Service prognostics is standard equipment on all Allison Gen 4 transmissions and requires the use of Allison approved TES 295 or TES 389 fluids and Control Main filter. Prognostics is used to predict the need for transmission maintenance. Transmission operating parameters monitored by the prognostics feature are: 1.

  • Page 89: Hydraulic Retarder (If Equipped)

    ROUTINE OPERATION 3000 Series Product Electronic shift selectors used with 3000 series transmissions have an integrated service icon in the shape of an open-end wrench located between the SELECT and MONITOR displays, which illuminates or flashes when a specified service threshold is reached for one of the three prognostic parameters.

  • Page 90: Braking

    DRIVER’S HANDBOOK BRAKING Air Brakes All Americans equipped with air brakes employ separate systems for the front and rear service brakes. A separate reservoir and air gauge is provided for each of these systems. A dual treadle valve is provided for operating the service brake system. In the event there is a failure in the air reservoir for the front brakes, the rear ser- vice brakes can still be applied using the treadle valve, since the two service brake systems operate independently.

  • Page 91: Antilock Braking System (Abs)

    ROUTINE OPERATION Air Brake/Throttle Interlock System (Optional) All Americans equipped with air brakes may include an optional Brake/Throttle Inter- lock feature which, when active, automatially applies the service brake and disables the throttle when the vehicle ignition is on and the lift or entrance door is open. A Brake Override switch in the Driver’s left switch panel enables the Driver to temporarily override the interlock system.

  • Page 92: Heaters

    DRIVER’S HANDBOOK HEATERS Blue Bird heaters depend on engine generated heat to function. Heat from the en- gine is picked up by the engine coolant, which is pumped through the heater cores inside the bus, and then back into the engine. A typical heater inside the bus includes a heat exchanger coil, (core) and fans which move air across the coil.

  • Page 93: Control Panel Outlet Locations

    ROUTINE OPERATION Control Panel Outlet Locations The heater control panel is located on the dash to the right of the instruments. The indicated switches and levers control the motors and air outlets as shown. The heater is located in the right front corner, forward of the entrance door. An optional auxiliary unit is located under the driver’s seat.

  • Page 94: Defrosting

    DRIVER’S HANDBOOK Defrosting Windshield fogging and frosting is caused by warm, humid air coming into contact with a colder windshield, which causes the moisture in the air to condense and freeze if the windshield is cold enough. The warmer the windshield, the less mois- ture will condense.

  • Page 95: Standard Heater Cut Off Valves

    ROUTINE OPERATION Standard Heater Cut Off Valves Valves are provided in the heater piping to permit isolation of the heating circuit from the engine coolant circuit. This is useful in case a leak occurs within the system, or to restrict the flow of hot water through the bus during warm weather. When Valves No.
  • Page 96 DRIVER’S HANDBOOK...

  • Page 97: Care & Maintenance

    Actual operating conditions must be considered and maintenance intervals adjusted accordingly. If at any time a system does not perform satisfactorily, corrective service should be performed at once. It is important that personnel attempting the repair or maintenance of this vehicle have access to, and a thorough knowledge of, the appropriate Blue Bird Service Manual.

  • Page 98: Interior Lights

    DRIVER’S HANDBOOK ELECTRICAL Interior Lights Lamp Description Trade Name Trade No. Color Bulb No. Dome Weldon™ 8020 (Standard) Stepwell Arrow™ Soundoff™ SWLT LED Non-Replaceable Emergency Door Light Soundoff™ LED Non-Replaceable Switch Panel Pilots Eaton™ Switch Panel Illumination 1314962 Exterior Lights Directional CRS™...

  • Page 99: Doran Warning Light Monitor

    CARE & MAINTENANCE Doran Warning Light Monitor The Doran Monitor™ is a current sensing device. If current is Calibration flowing through one of the bus lamp circuits, the monitor Button senses it and illuminates the corresponding monitor light emitting diode (LED). When a lamp burns out, current flow through the circuit stops and the corresponding LED on the monitor does not illuminate, indicating the outside lamp is not functioning.
  • Page 100 DRIVER’S HANDBOOK A particular LED on the Doran Warning Light Monitor™ does not display, but the bus running lights are operating properly: [CAUTION] Do not attempt 1. There is an open coil in the monitor to check a light emitting diode • The coil is burned due to an overload. Replace the coil kit.

  • Page 101: Circuit Breakers

    The shorted circuit should be corrected immediately. Refer to body or chassis master wiring diagrams. A complete wiring diagram is available from Blue Bird Body Co. Technical Publications. To access the electrical panel, open the access door located outside the bus be- low the driver’s window.

  • Page 102: Door Adjustment & Lubrication

    DRIVER’S HANDBOOK DOOR ADJUSTMENT & LUBRICATION Maintenance procedures for entrance doors must be performed by qualified techni- cians at intervals of one month or 1,000 miles, whichever occurs first. Continuing Maintenance Requirements • Keep working parts of control tightened. • Lubricate all working parts periodically, including hinges and overhead con- trols. • Repair or replace worn seals. • Maintain proper door opening and closing adjustment. Outward Opening Door Adjustment Outward Opening Doors are mounted in a prefabricated framework, which elimi- nates the effect of body construction variations on door and seal operation.

  • Page 103: Sliding Bolt Vandal Lock

    CARE & MAINTENANCE Sliding Bolt Vandal Lock Lubricate the sliding bolt mechanism of the Sliding Bolt Vandal Lock every six months or 6,000 miles (whichever occurs first). Use LPS-1 spray lubricant, or equivalent. Security Lock Lubrication (Outward Opening Door) If the Outward Opening Door Security Lock becomes difficult to operate, remove the access plate on the inner door panel and lubricate with No.

  • Page 104: Seating Care

    [WARNING] Do not bleach or dye the webbing. Such processing may se- verely weaken the assembly. Seat Inspection And Maintenance Blue Bird seats are built to meet Federal Motor Vehicle Safety Standards. In order to provide a greater margin of safety during passenger transportation, follow these guidelines: • Inspect and, if necessary, tighten seat leg and wall side mounting bolts every...
  • Page 105 CARE & MAINTENANCE SEAT CARE AND CLEANING It is imperative that the interior of the bus be kept clean; seats are an important part of this maintenance. Regular cleaning and care will prolong the life of the seats and improve the general appearance of the bus. Everyday dirt and soil.
  • Page 106 All passenger seats must have a seat or barrier in front of it to provide compart- mentalization required by Federal Motor Vehicle Safety Standards. As you reconfig- ure your bus, you may need additional barriers, which are available from Blue Bird Body Co. Part Sales.
  • Page 107 BARRIER OF AT LEAST THE SAME WIDTH. SEATS MUST BE INSTALLED BETWEEN MINIMUM AND MAXIMUM SPACING AS LISTED BELOW IN ORDER TO MEET FMVSS 222 REQUIREMENTS. A CHILD RESTRAINT DECAL BLUE BIRD TRACK CEW CHILD 12 (MIN) MUST BE LOCATED ADJACENT...

  • Page 108: Signs & Signals

    DRIVER’S HANDBOOK SIGNS & SIGNALS Stop Arms Stop arms are required on Blue Bird All American school buses by, and in accordance with, Federal Motor Vehicle Safety Standard 131. Stop arm assemblies are purchased as a kit to meet state re- quirements.

  • Page 109: Destination Signs

    CARE & MAINTENANCE Destination Signs Hinged Sign Front Mounted on the outside of the front roof cap, with internal control for changing the display. Periodically lubricate hinges and lever assembly with lightweight lubricating oil. Hinged Sign Rear Mounted on the outside of the rear roof cap, manually changed from outside. Peri- odically lubricate hinges with lightweight lubricating oil.

  • Page 110: Engine & Running Gear

    Charge-Air Cooler (CAC) Maintenance Check this system every 3 months or 7,500 miles. Inspect the charge-air cooler (CAC) for dirt and debris blocking the fins. Check for cracks, holes, or other damage. If dam- age is found, refer to your Blue Bird Dealer.

  • Page 111: Engine Cooling System

    Fleetguard ES Compleat OAT 60/40 premix, which is red in color. Blue Bird installs a decal on or near the deaeration tank filler which state the type of coolant installed at the factory. The decal states the approved premixed coolant and coolant manufacturer’s part number for one gallon quantities.
  • Page 112 Blue Bird recommends strictly abiding by the engine manufacturer’s testing and maintenance schedules and draining, flushing, refilling procedures to maintain com- pliance with the engine warranty requirements. Blue Bird also recommends that you maintain accurate vehicle-specific service records of all coolant system maintenance procedures performed.
  • Page 113 Blue Bird buses equipped with Cummins engines may also be equipped with an optional coolant filter. The coolant filter should be replaced every 6 months or 6,000 miles; whichever occurs first . The coolant filter element installed at the Blue Bird fac- tory is compatible with all of the above-described coolants:...

  • Page 114: Transmission

    DRIVER’S HANDBOOK Transmission Transmission Breather The transmission has a self-contained breather at the top left rear of the transmis- sion main housing. The breather provides a passage for normal expansion and con- traction of air and fluid within the transmission. Be careful to avoid plugging this breather with paint, undercoating, or any other material.

  • Page 115: Windshield Wipers

    CARE & MAINTENANCE WINDSHIELD WIPERS Washer Solution Reservoir Periodically check the windshield washer solution reservoir, located behind the driv- er’s side front access panel. Be sure there is an adequate supply of fluid at all times. The solution used is a 50/50 mixture of methanol and water. Wiper Assembly Replacement To replace wiper assembly, loosen lock nut, remove screw, and pull wiper assembly loose from wiper arm.

  • Page 116: Heater Care

    Maintenance and inspection of all the heater cores and filters and/or screens in the heater system is critical to prevent loss of efficiency, function and/or premature Heater Filter Access Panel heater motor failure. Replace parts with OEM parts purchased from you Blue Bird above Stepwell Dealer.

  • Page 117: Cleaning Auxiliary Fans

    CARE & MAINTENANCE Motors, Switches, Blowers, and Fans Maintenance free motors are used and do not require lubrication or cleaning over their operating life. However, excessive vibration caused by damaged blower wheels or fans can cause motor damage. Inspect wheels and fans for obstruction or damage by running each fan individually, listening and feeling for irregularities.

  • Page 118: Cleaning

    2 = Moderate 3 = Serious 4 = Severe To wash units, Blue Bird Body Co. recommends Bird Bath™ Bus Wash & Wax Con- centrate, available from authorized Blue Bird Dealers. Bus Wash & Wax is a concen- trated vehicle wash (rated triple-zero) that is recommended to be mixed at up to a 20/1 ratio for new and reconditioned buses.
  • Page 119 Bus Downtime Treatment During periods of bus downtime, Blue Bird Body Co. recommends the application of Bird Bath™ Bus Guard Protectant available from Blue Bird authorized dealers to protect exterior surfaces. Bus Guard is a triple-zero product that, when properly ap- plied, protects against harmful UV rays and other damaging environmental condi- tions.

  • Page 120: Floor Cleaning

    DRIVER’S HANDBOOK Floor Cleaning Regular cleaning and care will prolong the life of floor covering and improve the gen- eral appearance. Floor coverings should be swept daily and mopped weekly with a mild detergent and water. Do not use floor sweeping compounds. Be sure to remove dirt, pencils, paper, and any other debris that may cause the emergency door to seal improperly.

  • Page 121: Maintenance Schedule

    CARE & MAINTENANCE MAINTENANCE SCHEDULE Maintenance Task Schedule, D3RE Ensure that the Safety information, warnings and instructions are read and under- stood before operation or maintenance procedures are performed. Use whichever interval listed (time, mileage, engine hours) occurs first. Engines operated in severe operating conditions may require more frequent maintenance.
  • Page 122 DRIVER’S HANDBOOK First 1000 Miles Then Every 3 Months or 6000 Miles Frame Inspect & Tighten Body Tie Downs Body Inspect for missing, damaged rubber pads. Tighten clamps Tie Down Clamps to 37–41 ft lb. Inspect & Tighten Body Tie Downs Rear Inspect for missing, damaged rubber pads.
  • Page 123 CARE & MAINTENANCE Every Day Doors Test Wheelchair Lift Follow the manufacturers recommendations. Emergency Equipment Inspect Fire Extinguisher Charge Ensure that Extinguisher Charge is not expired. Inspect Fire Extinguisher Mounting Bracket Ensure that Extinguisher bracket is secure and operates correctly. Inspect First Aid Kit Contents Ensure that kit supplies are fully replenished, clean, and not expired.
  • Page 124 DRIVER’S HANDBOOK Electrical Inspect All Lights Check all running, stop, marker, hazard, and warning lights for proper operation. Engine Inspect Oil Level Fuel System Inspect Fuel Cap Inspect Water Separator Petcock Drain Check for water contamination. Intake System Inspect Intake Tract Restriction Indicator Replace primary filter element when gauge on Filter Minder goes into the red area, regardless of time or mileage.
  • Page 125 CARE & MAINTENANCE Every Month or 3000 Miles Doors Lubricate All Doors Vandal Locks Apply spray lubricant into key locks. Use LPS #1 for sliding bolt locks. Adjust Outward Opening Door Control Rod Adjust Outward Opening Door Control Rod Adjust for full and secure closure without binding. Bracket Adjust &...
  • Page 126 DRIVER’S HANDBOOK Every Month or 5000 Miles Warning Devices & Signs Inspect Stop Arm, Air Pressure Adjust for full deployment and retraction. Every Month or 10,000 Miles Axle & Suspension, Rear Inspect Rear Axle Breather Inspect Rear Axle Lubricant Level If low, refill to bottom of filler opening.
  • Page 127 CARE & MAINTENANCE Every 3 Months or 5000 Miles Brakes Lubricate Air Brakes S-Cam See Meritor Cam Brakes Appendix in Air Brakes Chapter of Service Manual for guidelines. Cooling System Inspect Intake Tract Charged Air Tubing Inspect for signs of contaminate infiltration, loose clamps, wear spots, holes in piping.
  • Page 128 DRIVER’S HANDBOOK Steering Lubricate Axle Steering Linkage Drag Link NLGI #2 EP multipurpose grease rated GC-LB or equivalent. Lubricate Axle Steering Linkage King Pins NLGI #2 EP multipurpose grease rated GC-LB or equivalent. Lubricate Axle Steering Linkage Tie Rod NLGI #2 EP multipurpose grease rated GC-LB or Ends equivalent.
  • Page 129 CARE & MAINTENANCE Every 6 Months or 6000 Miles Axle & Suspension, Front Inspect AirTek Suspension Whole Visually inspect for damage. Assembly Lubricate SofTek Spring Suspension NLGI #2 Grease. Steering Grease Fittings Inspect SofTek Spring Suspension Whole Visually inspect for damage. Assembly Axle &...
  • Page 130 DRIVER’S HANDBOOK Every 6 Months or 12,000 Miles Brakes Lubricate Air Brakes Cam Shaft Housing NLGI #2 EP multipurpose grease rated GC-LB or equivalent. Use hand-operated grease gun. Lubricate Air Brakes Haldex Slack See Haldex lubricant specs in Air Brakes chapter of Service Adjusters Manual.
  • Page 131 CARE & MAINTENANCE Every 12 Months or 12,000 Miles Heaters & Defrosters Tighten Front Heater Fasteners All fasteners holding such heaters in place in unit. For details on fasteners check installation prints. Inspect, clean and replace Front Heater Wash filter and screen. If filter cannot be washed or is Filter &...
  • Page 132 DRIVER’S HANDBOOK Cooling System Clean Charge Air Cooler Fins Clean as required. Test Entire Cooling System Pressure Test Cooling system. Clean Radiator Clean as required. Engine Test Engine Starting Aid Block Heater Intake System Test Air Restriction Indicator Test indicator with a calibrated vacuum gauge and pump. Replace Air Cleaner Filter Element Steering Inspect Hydraulic Pump Body &...
  • Page 133 CARE & MAINTENANCE Every 24 Months or 24,000 Miles Brakes Clean Air Brakes Parking Brake Valve See Bendix Appendixes in Air Brakes Chapter. Clean Air Brakes Quick Release Valves See Bendix Appendixes in Air Brakes Chapter. Clean Air Brakes Relay Valves See Bendix Appendixes in Air Brakes Chapter.

  • Page 134: Maintenance Locations

    DRIVER’S HANDBOOK Maintenance Locations 1. Intake Air Restriction Indicator 8. Not Applicable 2. Rear Axle Lubricant 9. Brake Camshaft 3. Axle Vent 10. Brake Slack Adjusters 4. King Pin 11. Automatic Transmission 5. Tie Rod 12. Universal Joints 6. Drag Rod 13.

  • Page 135: General Data

    CARE & MAINTENANCE General Data Dimensions : 78 headroom inches exterior height approximately inches exterior height w inches : 96 exterior width inches : 90.75 interior width inches Fluid Capacities (In Quarts) NOTE: All fluid capacities should be re-checked to full level after initial fill, bleeding, or changing. Crankcase Oil **Engine Coolant Auto Trans.
  • Page 136 DRIVER’S HANDBOOK...
  • Page 138 COUNT ON BLUE BIRD...

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