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Grech Motors G28 Owner's Manual

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MOTORS
This label contains vital information used to identify your specific vehicle and the safety features
that must be understood and followed in order to operate this vehicle safely.
Your Grech Vehicle ID Number is:

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Summary of Contents for Grech Motors G28

  • Page 1 MOTORS This label contains vital information used to identify your specific vehicle and the safety features that must be understood and followed in order to operate this vehicle safely. Your Grech Vehicle ID Number is:...
  • Page 3 You have taken ownership of a true luxury vehicle which is in a class all its own. We are providing this manual to familiarize you with your new Grech Motors vehicle. This manual shall serve as a reference document for the operations and maintenance procedures that shall be required throughout the life of your vehicle.

  • Page 4: Table Of Contents

    PROAIR Control Panel Audio/Video PA Control Diesel Exhaust Fluid & Engine Brake Water Fill Tank & Water for Lavatory Lavatory Operations (if equipped) Factory Suspension Dump System Operation Auxiliary Battery Location E-450 Heated Mirror Operation Rear Step Operation GRECH MOTORS...
  • Page 5 Kelderman Suspension Preventative Maintenance Basic Troubleshooting E450 Vehicle Circuit Board Assembly F550 Vehicle Circuit Board Assembly Freightliner Vehicle Circuit Board Assembly Vehicle Wiring Diagrams Online @ WWW.GRECHMOTORS.COM Parts - Service - Warranty Vendor Reference Listing GRECH MOTORS Warranty Statement GRECH MOTORS...

  • Page 6: Pre-Trip Inspection (Suggested Minimum)

    Check condition of fire extinguisher, warning reflectors and first aid kit Check all doors, glass and windows for operation, cleanliness, and damage. Check all emergency exits for operation, warning devices, markings, to be free and clear Check interior lighting: for operation and damage GRECH MOTORS...
  • Page 7 Check belts for tension and wear Check operation of cameras, if applicable Check operation of PA system, if applicable Check operation of audio and video system, if applicable Check wheelchair lift for proper function or damage and securement station equipment GRECH MOTORS...

  • Page 8: General Vehicle Safety Warnings

    VEHICLE WITH THIS BUS. DISCONTINUE OPERATION OF THE VEHICLE, IF ANY PERSON STANDS IN THE BUS WHILE THE VEHICLE IS IN MOTION. DISCONTINUE OPERATION OF THE VEHICLE, IF A DOOR OR EMERGENCY EXIT SHOULD OPEN WHILE THE VEHICLE IS IN MOTION. GRECH MOTORS...
  • Page 9 Pressing the door control command button again (ref. pg 11 & 19) will allow the operator to resume the door closing process. If a problem persists, call the Grech Motors Service Department at 1-855-994-7324 GRECH MOTORS...

  • Page 10: Vapor Door Operational Safety Check List

    3. Next, the vehicle driver should attempt to close the passenger door by activating the Door Command Button. 4. If the passenger door contacts the obstruction and fails to stop once it makes contact, call the Grech Motors Service Department at and do not operate the vehicle.
  • Page 11 See Photo No. 1 on page 13. When the Emergency Release Lever is in the left position, the door can be opened with hand-pressure applied to push the door out Side Entry Door in the and away from the bus. locked Position GRECH MOTORS...

  • Page 12: Electric Door Emergency Release Lever

    The door should not move. If the door moves while the red-handle is in the right position, call the Grech Motors Service Department at and do not operate the vehicle.
  • Page 13 Electric Door Emergency Release Lever Emergency Exit Lever Decal Electric Door Release Lever- Exit Position Photo 1 CAUTION! LEVER MUST BE CHECKED DAILY, PRIOR TO VEHICLE OPERATION EMERGENCY USE ONLY Electric Door Release Lever- Closed Position Photo 2 GRECH MOTORS...

  • Page 14: Emergency Egress Window Operation

    The Emergency Egress Windows are a vital component in the vehicle’s emergency exit system. As such the vehicle driver should test the Emergency Egress Window Operation every day before putting the vehicle into service. To test the System, the vehicle driver should check the following items: GRECH MOTORS...
  • Page 15 Emergency Handle. Confirm that each Emergency Egress Window is equipped with the sticker designating that window as an emergency exit. If the Emergency Egress Window is missing the Emergency Exit designation sticker, call the Grech Motors Service Department at and do not operate the vehicle.

  • Page 16: Emergency Roof Hatch Exit

    Solutions containing, acetone, ether, lacquer thinner, or other solvents can destroy the high strength properties of many engineering plastics - AVOID these cleaners TURN HANDLE AS SHOWN ABOVE, THEN PUSH TO OPEN CAUTION! SEE MANUFACTURERS LITERATURE Check Exit Operation, Daily. FOR ADDITIONAL INFORMATION GRECH MOTORS...
  • Page 17 1. Ensure that each Emergency Roof Hatch is marked by an Emergency Exit sticker. Confirm that the Emergency Roof Hatch is equipped with the sticker designating the hatch as an emergency exit. If the Emergency Roof Hatch Exit is missing the Emergency Exit designation sticker, call the Grech Motors Service Department at and do not operate the vehicle.

  • Page 18: Dual Overhead Parcel Rack

    Overhead Parcel Rack Overhead Parcel Rack CAUTION! Do not overload Parcel Racks. Do not fasten parcels to retainer bars. Note: Maximum loading specification for both model parcel racks is either 20 Lbs. per foot or 5 Lbs per passenger. GRECH MOTORS...

  • Page 19: Drivers Overhead Control Panel For F-550 & Freightliner

    10 Climate Control Temperature (Setting Point) reading shows cabin temp 5 Interior Lights 11 Climate Control Mode Switch (Air - Heat - Off) 6 Exits (WARNING DEVICE) 12 Climate Control Fan Speed (High - to - Low) 7 Auxiliary GRECH MOTORS...

  • Page 20: Drivers Dash Control Panel For E-450

    5 Door Ajar (WARNING DEVICE) 11 Climate Control Mode Switch (Air - Heat - Off) 6 Rear Door Ajar (WARNING DEVICE) 12 Climate Control Fan Speed (High - to - Low) 7 Exits (WARNING DEVICE) GRECH MOTORS...

  • Page 21: Proair Control Panel

    Display will show current auto mode (A1 or A2) then switch to the other mode (A2 or A1) . Preset Operations Upon cycling of 12vdc supply, the unit will default to previous settings mode and blower speed. All output signals are negative voltage. GRECH MOTORS...

  • Page 22: Audio/Video Pa Control

    Tap to return to main menu. 7. PRESET BANK: Tap to tune to indicated preset channel. 8. CURRENT RADIO STATION 9. AUTO SCAN/PRESET SCAN: Tap to scan through currently stored Presets. Press and hold to scan and store strongest stations in your area. GRECH MOTORS...
  • Page 23 GPS satellite details. reverse. CAUTION: In the event of power loss, Navigation System must be reset to "Bus" mode in the settings menu. GRECH MOTORS...

  • Page 24: Diesel Exhaust Fluid & Engine Brake

    - on Freightliner only) and replenish the DEF fluid as The switch to turn it on/off is needed. It is never acceptable to run the vehicle out of DEF. below the transmission gear selector. EG Luggage Compartment Freightliner Gauge Ford Level Indicator Unlock Switch DEF Fill GRECH MOTORS...

  • Page 25: Water Fill Tank & Water For Lavatory

    Low Water Indicator Note: Never run the pump Note: Water pump will not dry. Damage to the pump operate when Low Water will occur. Indicator is iluminated. Pump Switch GRECH MOTORS...

  • Page 26: Lavatory Operations (If Equipped)

    OK to open the valve. Step 4 Close the valve, rinse the hose and return it to the storage compartment. You should also refill the fresh water tank as outlined in the Filling the Water Tank section. GRECH MOTORS...

  • Page 27: Factory Suspension Dump System Operation

    Note: This system will only operate when the ignition in the “on position” Note: The suspension will automatically raise to vehicle ride height when the rear luggage door is closed. GRECH MOTORS...

  • Page 28: Auxiliary Battery Location

    Auxiliary Battery location on F-550 & Freightliner On the F-550 the Charge Isolator Solenoid is Arrow indicates: approximate located under the vehicle next to the battery. location of Auxiliary Batteries on the drivers side of the vehicle GRECH MOTORS...

  • Page 29: E-450 Heated Mirror Operation

    The center posi- tion of the toggle defeats all mirror operations. When either the left or right mirror is engaged, the 4 arrow switches allow the mirror to move in 4 different directions for precise adjustment. GRECH MOTORS...

  • Page 30: Rear Step Operation

    REAR DOOR STEP DISABLE SWITCH allows you to enable or disable step operation. When the step is enabled, opening the rear door automatically extends the step. Note: See Manufacturers literature regarding periodic lubrication requirements. SEE MANUFACTURERS LITERATURE FOR ADDITIONAL INFORMATION GRECH MOTORS...

  • Page 31: Caution-Advisory Regarding Customer Vehicle Alterations

    IN ACCORDANCE WITH THE DESIGN PARAMETERS DETERMINED BY GRECH MOTORS ENGINEERING DEPARTMENT. THE ADDING, MOVING OR REMOVING OF THE ORIGINAL SEATING, IS STRICTLY PROHIBITED WITHOUT THE AUTHORIZATION OF GRECH MOTORS ENGINEERING DEPARTMENT. MODIFYING THE SEATING ARRANGEMENT OF YOUR VEHICLE WITHOUT...

  • Page 32: General Vehicle Dimensional Specifications

    115 in 115 in 115 in (with mirrors extended) Interior Height 78 in 77¾ in 77¾ in 77¾ in 77¾ in 77¾ in Interior Width 96 in 96 in 96 in 96 in 96 in 96 in 96 in GRECH MOTORS...

  • Page 33: Vehicle Id Labels

    Paint Code - This is the master number for the paint specification and color used on your vehicle. Tires, Rims - This indicates the required tire and rim sizes, and air capacities for your specific vehicle, for your maximum payload. GRECH MOTORS...

  • Page 34: Customer Assistance

    A reasonable time must be allowed to perform a repair These are some of the items that can be found online: after taking your vehicle to the authorized dealer. Repairs will be made using Grech Motors parts, or • U.S. dealer locator by Dealer Name,...
  • Page 35 • The vehicle’s current odometer reading. campaign. However, NHTSA cannot become involved in In some states, you must directly notify Grech Motors individual problems between you, your dealer, or Grech in writing before pursuing remedies under your state’s Motors.
  • Page 36 REPORTING SAFETY DEFECTS (CANADA ONLY) If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform Transport Canada. Transport Canada Contact Information Website http://www.tc.gc.ca/eng/roadsafety/menu.htm Phone 1–800–333–0510 GRECH MOTORS...

  • Page 37: Wheels And Tires

    Federal Regulations Part 575.104 (c)(2). U.S. Department of Transportation Tire quality grades: The U.S. Department of Transportation requires Grech Motors to give you the following information about tire grades exactly as the government has written it. Tire Quality Grades apply to new pneumatic passenger car tires.
  • Page 38 Federal Motor Vehicle Safety Standard No. 139. Grades B and A represent higher levels of performance on the laboratory test wheel than the minimum required by law. GRECH MOTORS...
  • Page 39 35 psi [37 psi (2.5 bar) for Metric 1 mile (1.6 kilometers). tires]. Increasing the inflation pressure beyond this pressure will not increase the tire’s load carrying capability. GRECH MOTORS...
  • Page 40 DOT Tire Identification Number for safety standard Area between the bead area and the tread. certification and in case of a recall. *Tread area of the tire: Area of the perimeter of the tire that contacts the road when mounted on the vehicle. GRECH MOTORS...
  • Page 41 Note: You may not find this information on all tires Note: If your tire size does not begin with a letter this because it is not required by federal law. may mean it is designated by either the European GRECH MOTORS...
  • Page 42 106 mph (171 km/h) 168 mph (270 km/h) 112 mph (180 km/h) 186 mph (299 km/h) I. M+S or M/S: Mud and Snow, or 118 mph (190 km/h) AT: All Terrain, or AS: All Season. GRECH MOTORS...
  • Page 43 150 would wear 1½ times as well on the government edge that meets the door-latch post, next to the course as a tire graded 100. driver’s seating position), or Tire Label located on GRECH MOTORS...
  • Page 44 D. Maximum Load Single lb (kg) at psi (kPa) cold: Indicates the maximum load and tire pressure when the tire is used as a single; defined as two tires (total) on the rear axle. Information on T Type Tires GRECH MOTORS...
  • Page 45 D. D: Indicates a diagonal type tire. R: Indicates a radial type tire. E. 16: Indicates the wheel or rim diameter in inches. If you change your wheel size, you will have to purchase new tires to match the new wheel diameter. GRECH MOTORS...
  • Page 46 Wheels and Tires gauge, as automatic service station gauges may be Location of the Tire Label inaccurate. Grech Motors recommends the use of a You will find a Tire Label containing tire inflation digital or dial-type tire pressure gauge rather than a pressure by tire size and other important information stick-type tire pressure gauge.
  • Page 47 Wheels and Tires Always inflate your tires to the Grech Motors a bump or dip in the road that does not dampen out recommended inflation pressure even if it is less than by itself. Shimmy may result from significant under-...
  • Page 48 Note: Some spare tires operate at a higher inflation Note: If you have to drive a distance to get air for pressure than the other tires. For T type mini-spare GRECH MOTORS...
  • Page 49 WARNING See Proper Tire Inflation Technique in the An inflated tire and rim can be very diagram on the next page. dangerous if improperly used, serviced or maintained. To reduce the risk of GRECH MOTORS...
  • Page 50 Inspecting Your Tires and Wheel Valve Stems Periodically inspect the tire treads for uneven or excessive wear and remove objects such as stones, nails or glass that may be wedged in the tread GRECH MOTORS...
  • Page 51 (2 millimeters). accelerate the aging process and may require tires to When the tire tread wears down to the same height GRECH MOTORS...
  • Page 52 U.S. index, speed rating and type as those DOT Tire Identification Number for safety standard originally provided by Grech Motors. certification and in case of a recall. The recommended tire and wheel size may be found...
  • Page 53 For a mounting pressure more than 20 psi (1.38 bar) replacement tires and wheels, you should not greater than the maximum pressure, a Grech Motors exceed the maximum pressure indicated on the dealer or other tire service professional should do the sidewall of the tire to set the beads without additional mounting.
  • Page 54 *Do not run over curbs or hit the tire against a curb cause damage to your tires. If your vehicle seems to when parking pull to one side when you’re driving, the wheels may be out of alignment. Have an authorized dealer check Highway Hazards the wheel alignment periodically. GRECH MOTORS...
  • Page 55 If you have a dissimilar spare wheel and tire assembly it is GRECH MOTORS...
  • Page 56 Ford. Use of Follow these guidelines when using snow tires and any tire or wheel not recommended by chains: Grech Motors can affect the safety and • If possible, avoid fully loading your vehicle performance of your vehicle, which could result in •...
  • Page 57 • Remove the tire chains when they are no longer needed. Do not use tire chains on dry roads. If you have any questions regarding snow chains or cables, please contact your authorized dealer. GRECH MOTORS...

  • Page 58: Load Carrying Capacities

    The payload listed on the Payload Information Label dealer plus any aftermarket equipment. is the maximum payload for the vehicle as built by the assembly plant. Payload - is the combined weight of cargo and passengers that the vehicle is carrying. The GRECH MOTORS...
  • Page 59 The label above is an example of the label on your placed on each axle (front and rear) including vehicle vehicle which specifies the proper tire loading limits curb weight and all payload. which must be followed to insure the safe operation of your vehicle. GRECH MOTORS...
  • Page 60 1. Locate the statement “The combined weight of injury. occupants and cargo should never exceed XXX kg or XXX lb.” on your vehicle’s placard. 2. Determine the combined weight of the driver and passengers that will be riding in your vehicle. GRECH MOTORS...
  • Page 61 100-pound load capacity: (45-kilogram) bags of cement. Do you have enough load capacity to transport the cement to your home? *Suppose your vehicle has a 1400-pound If you and your friend each weigh 220 pounds (99 GRECH MOTORS...
  • Page 62 Weight Rating specified for your vehicle on the Safety Compliance Certification Label. The label shall be affixed to either the door hinge pillar, door-latch post, or the door edge that meets the door-latch post, next to the driver’s seating position. GRECH MOTORS...

  • Page 63: Ultra Ride Air Suspension

    • Check lower control arm, sway bar, and lateral control rod (panhard bar) bushings for wear. Replace if necessary. Attention: Only Used on F550 • Check and re-torque all fasteners (refer to Torque Table) Check Annually: • Check shock absorbers for oil leaks and function GRECH MOTORS...

  • Page 64: Firestone Ride Rite Air Spring

    Check your vehicle owner’s manual or data plate on driver’s side door for maximum loads listed for your vehicle. When inflating your Air Helper Springs, add air pressure in small amounts, checking pressure frequently during inflation. The air spring requires much less air volume than a tire and, therefore, inflates much quicker. GRECH MOTORS...

  • Page 65: Kelderman Suspension

    CHECK AFTER THE FIRST 1000 MILES: 1. Recheck & tighten any loose fasteners. 2. Check for any loose or worn components. CHECK AFTER EVERY 30,000 MILES: 1. Check trailing arm bushings and pan hard bar bushings for wear; replace if worn. GRECH MOTORS...

  • Page 66: Preventative Maintenance

    Additionally, the intervals given by Grech Motors on the following pages, are recommen- dations only, and should be considered as maximum intervals. It should be noted that maintenance inspection and service operations of shorter duration are always preferable to longer durations.
  • Page 67 ► inspect tires for wear and inspect tread depth ► inspect torque specifications on Ultra Ride Suspension System (if equipped) ► lube door seals with silicon spray, check for proper sealing ► check the torque of all door hardware on Vapor door systems GRECH MOTORS...
  • Page 68 AT 30,000 MILES/3600 HOURS DO THE FOLLOWING: ► lube door seals with silicon spray, check for proper sealing ► re-inspect torque specifications on Ultra Ride Suspension System (if equipped) ► check the torque of all door hardware on Vapor door systems GRECH MOTORS...
  • Page 69 ► check the torque of all door hardware on Vapor door systems NOTE: at 100,000 MILES re-implement the initial 5000 mile maintenance routine and follow each mileage milestone as you did in the beginning. Example 100,000 miles, 115,000 miles, 120,000 miles etc... GRECH MOTORS...

  • Page 70: Basic Troubleshooting

    GRECH MOTORS can recommend one near you. REAR A/C BLOWER INOPERATIVE Check to make sure all fuses are good. If the rear A/C is still not work- ing, call the Service Department at GRECH MOTORS.
  • Page 71 BACK-UP ALARM INOPERATIVE Check to make sure reverse lights are coming on, if not, check the fuse located in the FORD fuse panels. SIDE ENTRY DOOR AJAR ALARM Check to make sure the side door lock is engaged properly. GRECH MOTORS...
  • Page 72 Basic Troubleshooting Guide PROBLEM POSSIBLE SOLUTIONS GRECH MOTORS...

  • Page 73: E450 Vehicle Circuit Board Assembly

    E-450 Vehicle Circuit Board Assembly The Circuit Board Assembly above is shown horizontal for the purpose of this manual. GRECH MOTORS...
  • Page 74 1. Solenoid 250A 12V DC 8. Timer, 5 Min Lights 2. Relay Block 9. Mounting Bracket - Solenoid 3. Relay Sockets 10. Clamp, Tube Clip 4. Fuse Blocks 5. PAC Video Amplifier 6. A/C Thermostat & Relay Board 7. Electrical Panel Board GRECH MOTORS...

  • Page 75: F550 Vehicle Circuit Board Assembly

    F-550 Vehicle Circuit Board Assembly The Circuit Board Assembly above is shown horizontal for the purpose of this manual. GRECH MOTORS...
  • Page 76 F-550 Vehicle Circuit Board Diagram Fuse Legend-enlarged 1. Solenoid 250A 12V DC 8. Mega Fuse 2. Relay Block 9. Clamp, Tube Clip 3. Relay Sockets 4. Fuse Blocks 5. PAC Video Amplifier 6. Mounting Bracket - Solenoid 7. Electrical Panel Board GRECH MOTORS...

  • Page 77: Freightliner Vehicle Circuit Board Assembly

    Freightliner Vehicle Circuit Board Assembly The Circuit Board Assembly above is shown horizontal for the purpose of this manual. GRECH MOTORS...
  • Page 78 Freightliner Vehicle Circuit Board Diagram Fuse Legend-enlarged 1. Solenoid 250A 12V DC 9. Clamp, Tube Clip 2. Relay Block 3. Relay Sockets 4. Fuse Blocks 5. PAC Video Amplifier 7. Electrical Panel Board 8. Timer, 5 Min. Lights GRECH MOTORS...

  • Page 79: Vehicle Wiring Diagrams Online @ Www.grechmotors.com

    Main Wiring Diagrams All Vehicle Main Wiring Diagrams can be found online at WWW.GRECHMOTORS.COM/diagrams/wiring GRECH MOTORS...

  • Page 80: Parts - Service - Warranty

    All other Non-Warranty parts needs can be handled by contacting the Grech Motors Parts Department, directly at 1-855-994-7324. In order to expedite your parts order, please have your Grech Motors serial number, which starts with G-######, and is located on the drivers door jamb of all our vehicles.
  • Page 81 PARTS - SERVICE - WARRANTY If there is any doubt as to whether or not a repair is related to the Grech Motors Warranty, call the Grech Motors Service Department at 1-855-994-7324, this may save you time wasted at a chassis dealer or another shop, for a problem appropriately solved by contacting Grech Motors Service Department.
  • Page 82 1. Repair is done at the Grech Motors Service Department, in Riverside, California 2. Repair is done at a Grech Motors authorized service facility near you. 3. Repair is done at a shop of your choice, with prior approval of the Grech Motors Service Department.
  • Page 83 If method 3 is used, simply pay for the work and mail a copy of the invoice along with the Grech Motors repair authorization number (R.A.N), and include your Grech Motors vehicle ID number, which is found on the vehicle ID tag on the drivers door jamb. This will insure your claim(s) can be processed without any problems.

  • Page 84: Vendor Reference Listing

    1 Year, Unlimited Miles PREMIER AUTO PRODUCTS 1-856-231-1800 2 Years, Unlimited Miles VALEO THERMAL BUS SYSTEMS 1-574-264-2190 XT265 2 Years, Unlimited Miles (ROOF HATCH) ProAir 1-800-338-8544 X 118 3 Years, 100,000 Miles, whichever occurs first 1-877-726-4617 2 Years GRECH MOTORS...

  • Page 85: Grech Motors Warranty Statement

    five (5) years or 100,000 miles, whichever comes first, from the date of purchase by the original retail customer. In the event of a Warranty claim, Grech Motors reserves the right to replace or repair the defective part.
  • Page 86 Grech Motors shall have no liability for any defect or damage caused by the original owner’s use of parts or services which are not authorized by Grech Motors or for any parts or paint which have been subject to misuse, neglect or accidents, or have been subject to external mechanical or chemical influences, especially stone chips, airborne rust or industrial fall-out.
  • Page 87 It is the policy of Grech Motors, to incorporate product improvements to our products whenever possible or practical to do so. We reserve the right to make changes and or improvements at any time without incurring any obligation to make such changes on previously sold products. Additionally, the information and specifications contained within this manual are current at time of printing.

This manual is also suitable for:

G33G45 m2Eg40G33dG36G40 m2

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