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Blue Bird Corporation wish to thank you for your investment of trust in Blue Bird quality, and congratulate you on your oper- ation of one of Blue Bird’ s newest models; the Blue Bird Sigma (Y3FE). This manual is to acquaint the bus driver with operation of buses built upon the Y3FE chassis.
Y FE DRIVER HANDBOOK Regarding Modifications Blue Bird Body Co. offers many items as standard and optional equipment to meet regulatory specifications and individual customer requirements. This includes, but is not necessarily limited to, stop arms, crossing guards, warning lights, warning...
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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 modification may adversely affect the warranty of this product by Blue Bird Body Co.
Y FE DRIVER HANDBOOK Before Placing the Bus in Service It is the responsibility of the bus Owner/Operator to ensure compliance with all ap- [WARNING] Emergency plicable regulations for bus operation and equipment. As part of a daily pre-trip in- equipment must be checked for spection, the Driver should consider it his/her responsibility to verify that the vehicle proper operation daily.
The VIN number is used as a unique means of identifying each vehicle. It will also be used by Blue Bird for identification purposes and the manufacturer’s certificate of origin. See sample below for VIN identifiers.
Y FE DRIVER 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.
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.
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Y FE DRIVER 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.
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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.
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Y FE DRIVER 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 –...
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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 – Contrast. Press both buttons simultaneously to select “contrast” then use the upper and lower buttons to increase or decrease the contrast.
Y FE DRIVER 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.
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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.
Y FE DRIVER 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.
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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.
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...
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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...
Y FE DRIVER HANDBOOK Intermittent Windshield Wipe / Wash Steering Column Turn for Wipe. Press for wash 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.
Y FE DRIVER HANDBOOK 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- Seat Back Tilt Adjustment 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.
To remove the entire engine cover assembly for better ac- cess to the engine components, consult the Blue Bird Sigma Body maintenance manual. [CAUTION] Engine and components can be very hot. If the engine has been running, be careful to avoid burns during engine access and removal process.
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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.
Y FE DRIVER HANDBOOK TIRE / WHEEL 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.
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ENROUTE EMERGENCIES [WARNING] Improper handling of wheels and rims has caused many injuries and deaths. Failure to follow directions is the leading cause of such accidents. Obtain procedures from wheel and rim manufacturer before working with a wheel or rim. The tire and wheel must always be properly matched.
Y FE DRIVER HANDBOOK 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 pro- vides the necessary firmness to support the weight of the bus concentrated on the footprint of the jack.
ENROUTE EMERGENCIES 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” before lifting the wheel off the ground. [WARNING] Never work around or under a bus supported only with a hydraulic jack.
Y FE DRIVER HANDBOOK Towing Or Pushing If the bus is towed with the rear wheels on the road, the driveshaft must be removed in order to prevent the automatic transmission input shaft from turning which could damage the transmission. This is accomplished by removing the rearmost driveshaft. Also, on buses equipped with air brakes, if full normal air pressure cannot be pro- vided to the air system, the park brakes must be mechanically caged to prevent their engagement.
ENROUTE EMERGENCIES 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.
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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.
Y FE DRIVER HANDBOOK PRE-ROUTE INSPECTION Any malfunction or defect discovered should be corrected before the next trip. Re- port needed services to responsible maintenance personnel. Engine/Transmission: • Check fuel level. • Drain air tanks. • Drain fuel/water separator. • Check engine oil level. • Check automatic transmission fluid level. • Inspect engine air intake system, especially the air cleaner service indicator. See Air Intake System Inspection in the General Maintenance section of this manual.
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.
Y FE DRIVER 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.
ROUTINE OPERATION Diesel Engine Starting Procedure See the engine manufacturer’s operating manual for proper starting procedures. 1. Apply the parking brake. 2. Place the transmission shift lever in the neutral position. 3. Insert the ignition key and turn it to the ON position. All the instrument panel lights will come on momentarily.
Y FE DRIVER HANDBOOK Battery Disconnect Switch Battery Disconnect Switch The bus is equipped with a Battery Disconnect Switch which is intended for use by The Battery Disconnect Switch is provided for use by service service technicians. Do not use the Battery Disconnect Switch as a routine power technicians.
Y FE DRIVER HANDBOOK Exhaust SCR System Selective Catalytic Reduction (SCR) is a Nitrous Oxide control technique for diesel engine exhaust. The SCR system uses Diesel Exhaust Fluid (DEF) a nitrogenous com- pound which readily decomposes into ammonia. The system process involves the injection of DEF into the exhaust over a catalyst.
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12° F (-11°C). If the reservoir is overfilled and freezes, the expansion of the frozen DEF will cause catastrophic damage to reservoir and/ or the vehicle SCR system. Refer to Blue Bird and Cummins Service Manuals for detailed description of the af- tertreatment system. Level 1...
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Y FE DRIVER 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. Continued 25% engine torque derating.
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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.
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Y FE DRIVER 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.
ROUTINE OPERATION TRANSMISSION Allison Automatic Transmission Information and instructions in the Allison Transmission Operator’s Manual supplied with the bus takes precedence over the general information in this publication. Allison Model 3000 Series Transmission The Allison electronic transmission provides five forward speeds and one reverse. Fourth gear is a 1-to-1 ratio while the fifth gear is an overdrive with a 0.75-to-1 ratio.
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Y FE DRIVER HANDBOOK 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. R—Reverse. The vehicle must be completely stopped before shifting from for- ward to reverse or from reverse to forward.
ROUTINE OPERATION Range Inhibited Light Under certain operating conditions, the Transmission Control Module (TCM) may de- termine that it is necessary to restrict gear selection to protect the transmission from damage and provide safer operating conditions. When this happens, the “RANGE [CAUTION] If the transmission INHIBITED”...
Y FE DRIVER HANDBOOK Allison Automatic Transmission Driving Tips Accelerator Control The driver’s pressure on the accelerator pedal influences the automatic shifting. An electronic signal tells the ECU how far the driver has depressed the pedal. This pro- vides the accurate shift spacing and control necessary for maximum performance. Downshift or Reverse Inhibitor Feature with Allison 3000 PTS Transmission Although there is no limitation on upshifting, there is a limit on downshifting and shifts from neutral into drive or reverse.
ROUTINE OPERATION [WARNING] 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. However, dur- ing downhill operation, if the engine governed speed is exceeded in the lower range, the transmission may upshift to the next higher range.
Y FE DRIVER 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. Oil Life Monitor 2.
ROUTINE OPERATION BRAKING Antilock Braking System (ABS) In a vehicle equipped with an antilock braking system (ABS), motion sensors detect the speeds at which the wheels move. These sensors transmit this information to an Electronic Control Unit (ECU). If the wheels start to lock, the ECU signals the modula- tor assembly to regulate the brake pressure of each wheel.
Y FE DRIVER HANDBOOK 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.
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.
Y FE DRIVER 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.
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Driver’ s overall understanding of the vehicle, and may serve as a convenient reference for service tech- nicians rendering roadside assistance. For thorough service information and procedures, refer to the Blue Bird Sigma Chassis Service Manual.
Inspect the charge air piping and hoses daily for holes, cracks, or loose connections. Tighten the hose clamps as necessary. 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.
This coolant is considered standard life when installed in Cummins engines. 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.
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Therefore, refer to the engine Operator’s Manual for your bus and fol- low the engine manufacturer’s maintenance specifications. Blue Bird recommends strictly abiding by the engine manufacturer’s testing and maintenance schedules and draining, flushing, refilling procedures to maintain compliance with the engine warranty requirements, and keeping accurate vehicle- specific service records of all coolant system maintenance procedures performed.
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Whenever tap water alone has been added, the bus should be taken to a service facility and the entire cooling system should be completely drained, flushed, and refilled with premix coolant. See your Blue Bird Chassis Service Manual for detailed Coolant Fill procedures.
Y FE DRIVER 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.
CARE & MAINTENANCE MAINTENANCE SCHEDULE Maintenance Task Schedule 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.
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Y FE DRIVER HANDBOOK First 1000 Miles Then Every 12 Months or 12,000 Miles Axle & Suspension, Front Inspect & Torque AirTek Suspension Tighten to 285 to 305 ft. lbs. Suspension Fastners Inspect & Torque SofTek Spring Torque to 285 - 320 ft. lbs. Suspension U-Bolts Axle &...
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CARE & MAINTENANCE Every Day Brakes Inspect Air Brakes Air Lines & Fittings Inspect for leaks or physical damage. Drain Air Brakes Air Tanks Drain daily in cold weather; weekly in warm weather. Inspect Air Brakes Brake Chambers See Air Brakes Chapter for inspection criteria. Inspect Air Brakes Brake Shoes Wear depends upon application environment.
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Y FE DRIVER HANDBOOK Every Week Brakes Inspect Hydraulic Brakes Pads Replace if worn to within 1/8" lining remaining. Every Month Fuel System Clean DEF Tank Fill Cap Reference SU1219 for cleaning instructions. Every Month or 3000 Miles Doors Lubricate All Doors Vandal Locks Apply spray lubricant into key locks.
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Y FE DRIVER HANDBOOK 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. Lubricate Hydraulic Brakes Calipers Lube per Meritor specs. Cooling System Inspect Intake Tract Charged Air Tubing Inspect for signs of contaminate infiltration, loose clamps, wear spots, holes in piping.
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CARE & MAINTENANCE 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.
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Y FE DRIVER HANDBOOK Every 3 Months or 24,000 Miles Brakes Inspect Air Brakes Air Dryer See Bendix appendix for specific model in Air Brakes Chapter of Service Manual. Inspect Hydraulic Brakes Booster & Master Inspect for signs of leakage or physical damage. Cylinder Every 6 Months or 6000 Miles Axle &...
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CARE & MAINTENANCE Every 6 Months or 10,000 Miles Axle & Suspension, Rear Inspect & Tighten Comfort Air Suspension See diagram and appendices in Suspension Chapter of your Components service manual. Every 6 Months or 12,000 Miles Brakes Lubricate Air Brakes Cam Shaft Housing NLGI #2 EP multipurpose grease rated GC-LB or equivalent.
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Y FE DRIVER HANDBOOK Every 12 Months or 12,000 Miles Axle & Suspension, Front Inspect & Adjust AirTek Suspension Ride Shock Length, eye-to-eye: 17.25" +/- 0.25" Height Inspect & Torque SofTek Spring See Diagram & Appendices in Suspension Chapter of your Suspension Components service manual.
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CARE & MAINTENANCE Every 12 Months or 90,000 Miles Fuel System Inspect DEF Tank Check for dents, or external impact damage. Inspect DEF Tank Lines Check for hose integrity. Every 12 Months or 100,000 Miles Axle & Suspension, Rear Replace Rear Axle Synthetic Lubricant Viscosity depends upon operating climate.
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Y FE DRIVER HANDBOOK As required at overhaul Transmission Replace Transmission Internal Filter As Specified by Engine Manufacturer Cooling System Replace Coolant See your Engine Operator's Manual. Use only premixed coolant(s) approved by the engine manufacturer. Never mix different types or brands of coolant. Engine Replace Oil &...
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