Thomas SAF-T-LINER EFX Operator's Manual
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Thomas SAF-T-LINER EFX Operator's Manual

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INER
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M
PERATOR
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ANUAL

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Summary of Contents for Thomas SAF-T-LINER EFX

  • Page 1 -T-L ® INER PERATOR ANUAL...
  • Page 2 20590, or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov, in addition to notifying THOMAS BUILT BUSES, INC. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.

  • Page 3: Table Of Contents

    ABLE ONTENTS ECTION ........... . .1 NTRODUCTION EPA10 E .
  • Page 4 INER ® -T-L EFX O PERATOR ANUAL Page ii...

  • Page 5: Introduction

    This manual has been prepared to acquaint you with and illustrations will pertain to optional equipment. the necessary information for the proper operation of Thomas Built Buses, Inc. reserves the right to make your Thomas Bus body and chassis. changes at any time without notice.

  • Page 6: Proposition 65 Warning

    _______ NOTICE Your Thomas Built Bus has been manufactured in Thomas Built Buses will not be responsible for any strict compliance with all the applicable Federal Motor change or modification occurring to the vehicle after Vehicle Safety Standards (FMVSS) and Canadian its purchase that violates these FMVSS and Canadian Motor Vehicle Safety Standards (CMVSS).
  • Page 7 EHICLE ODIFICATION ISCLAIMER OLICY Thomas Built Buses, Inc. is not responsible for any • steering, braking, or suspension alteration other direct or indirect consequence of any modification or than original specification alteration made to its products by anyone other than •...

  • Page 8: Vehicle Identification

    Identification Number When are attached to the inside roof liner above the driver's concerning the chassis of a Thomas product. window or on the front bulkhead. 2. Order Number - The first five-digit number in the Body Identification number. The Certification Plate certifies compliance with all 3.
  • Page 9 NTRODUCTION EHICLE MISSION ONTROL NFORMATION ABEL Page 1.5...

  • Page 10: Vehicle Loading

    PERATOR ANUAL EHICLE OADING The Thomas vehicle is designed to provide excellent Vehicle warranty is void on any vehicle which has service if not loaded in excess of either the Gross been subject to misuse. Overloading the vehicle is Vehicle Weight Rating (GVWR) or the maximum front misuse.
  • Page 11 ELIVERY NSPECTION EHICLE Each new Thomas bus has been inspected before delivery. Every precaution has been taken to provide the user with a complete and trouble-free bus. There are certain steps that must be taken to continue the assurance of a trouble-free bus.
  • Page 12 INER ® -T-L EFX O PERATOR ANUAL IRST HIRTY In addition to the Delivery Inspection, a one-time These are areas that should receive attention on any preventive maintenance inspection should be new vehicle. performed after the first thirty days of operation. •...
  • Page 13 (FMVSS) EDERAL OTOR EHICLE AFETY TANDARDS EFINITIONS...
  • Page 14 INER ® -T-L EFX O PERATOR ANUAL Page 1.10...

  • Page 15: Epa10 Exhaust System

    Active regeneration can occur automatically any To meet EPA guidelines, diesel engines installed in time the vehicle is moving. The exhaust gas Thomas Built Buses, Inc. chassis for domicile in temperature could reach 1500°F (800°C), which is Canada and the USA use an Aftertreatment System...

  • Page 16: Ats Warning Lamps

    INER ® -T-L EFX O PERATOR ANUAL ATS W ARNING AMPS The Malfunction Indicator Lamp (MIL) illuminates to A slow, 10-second flashing of the Heat Exhaust indicate a fault that affects the emissions. Figure 1 System Temperature (HEST) lamp alerts the driver that a parked regen is in progress, but the exhaust Warning lamps in the driver’s message center alert temperatures are still relatively cool.
  • Page 17 EPA10 E XHAUST YSTEM CONT ATS P ARKED EGENERATION IGURE IGURE IGURE 3.1 After the parked regen has run for 20 to 40 NOTICE minutes, the regen cycle is completed. The engine idle speed will drop to normal, and the The driver must remain with the vehicle during the vehicle may be driven normally.
  • Page 18 INER ® -T-L EFX O PERATOR ANUAL ATS D (DPF) M IESEL ARTICULATE ILTER AINTENANCE Eventually ash will accumulate in the DPF and the filter will require servicing. DPF servicing must be performed by an authorized technician, following the engine manufacturer’s instructions. A record must be maintained for warranty purposes, that includes: •...

  • Page 19: Filling Requirements

    EPA10 E XHAUST YSTEM DEF T OCATION AND ILLING EQUIREMENTS The tank is located on the right side, rearward of the The School Bus has a 10-gallon tank capacity. DEF front entrance door. The DEF tank has a 19 mm filler consumption approximately fuel...
  • Page 20 INER ® -T-L EFX O PERATOR ANUAL CONTINUED / DEF G AUGE • Between 25% and 50% full, two bars are • Between 10% and 25% full, one bar is illuminated green. Figure 7 illuminated green. Figure 8 IGURE IGURE DEF W ARNINGS AND NGINE...
  • Page 21 EPA10 E XHAUST YSTEM CONT DEF W ARNINGS AND NGINE ERATES DEF T —W DEF L —W MPTY ARNING GNORED ARNING AND EVEL ARNING AND INOR NGINE ERATE AJOR NGINE ERATE When the DEF level drops to 2.5%, the DEF warning After the DEF tank registers empty, if the DEF is not lamp in the gauge is illuminated flashing (amber), one bar of the DEF-level lightbar flashes red and the...
  • Page 22 INER ® -T-L EFX O PERATOR ANUAL CONT DEF W ARNINGS AND NGINE ERATES will occur. After driving 20 hours or 1000 miles (1600 km) without remedy, the STOP engine lamp will illuminate, and a major engine derate will occur as soon as the electronic sensors indicate a safe situation After the DEF tank is refilled with DEF, and the...
  • Page 23 Replace parts that show leakage, wear, or damage, with genuine Freightliner/Thomas parts. EPA10 E (ATS) T XHAUST YSTEM...
  • Page 24 INER ® -T-L EFX O PERATOR ANUAL NSPECTION Check the DPF exterior surface for dents or NOTICE other damage. A dent over 3 inches (76 mm) in diameter and 1/4-inch (6-mm) deep could The Environmental Protection Agency’s 2010 cause internal damage to the DPF, causing it regulations mandate lowered exhaust emissions, to malfunction.
  • Page 25 EPA10 E XHAUST YSTEM NSPECTION 1 - C ATD S IGURE UMMINS ENSOR OCATIONS DOC I SCR I NLET EMPERATURE ENSOR NLET EMPERATURE ENSOR DOC O SCR T UTLET EMPERATURE ENSOR EMPERATURE ENSOR DPF O UTLET EMPERATURE ENSOR UTLET ENSOR DPF T 10.
  • Page 26 Tighten to 30 lbf-ft (41 M-m) if needed. Do not instructions, or take the vehicle to an authorized overtighten. Freightliner or Thomas Built Bus service facility Check for leaks around the clamps that for repair. attach the ATD in the ATS, and around the clamps that retain the DPF in the ATD.
  • Page 27 EPA10 E XHAUST YSTEM NSPECTION CONT Check all sensors attached to the ATD for damage to the DPF, causing it to malfunction. leaks or damaged wires. No leaks are Check for heat discoloration on the surface of allowed. the ATD. Heat discoloration may indicate Check the DPF exterior surface for dents or internal damage;...
  • Page 28 Thomas Built Buses dealer, an independent outlet, or the vehicle owner or operator. The vehicle owner is responsible for determining the suitability of replacement components to maintain compliance with federal and local jurisdictional regulations.
  • Page 29 Criteria Pollutant Standards and Greenhouse Gas Emissions/Fuel Consumption Standards Model year 2007 and later vehicles and/or engines domiciled in the U.S. or Canada are designed to meet Emission and Fuel Efficiency Standards of the U.S. (Federal) Environmental Protection Agency (EPA), the National Highway Traffic Safety Administration (NHTSA), Emission Regulations under the Canada Motor Vehicle Safety Act in Canada, and the California Air Resources Board (CARB) effective as per the applicable emission model year.
  • Page 30 INER ® -T-L EFX O PERATOR ANUAL Page 2.14...

  • Page 31: Operator ' S Compartment

    PERATOR OMPARTMENT This section provides the operator with important It is important to carefully read and understand the operational and general information. The following following pages before operating the vehicle. A proper divides the Operator's Compartment into four major understanding of component location, function, and parts.
  • Page 32 INER ® -T-L EFX O PERATOR ANUAL RIVER Located on the dash at the driver’s window and directs air from the defrosters to the driver's side glass. LECTRONIC EATER EFROSTER The heater control panel enables the operator to control the dash heating system by adjusting the temperature setting and the fan speed.

  • Page 33: Air Pressure Gauge

    PERATOR OMPARTMENT RESSURE AUGE The air pressure gauge indicates the levels of air pressure in the primary or rear axle brake system CAUTION CAUTION (green needle). (An optional secondary or front axle brake system, red needle, is available.) If you have If one needle suddenly drops pressure and stays dual air pressure gauges, they should indicate the below 65 psi (448 kPa), the other system can still...
  • Page 34 INER ® -T-L EFX O PERATOR ANUAL 3000 PTS T RANSMISSION HIFTER WITH PTIONAL RANSMISSION USHBUTTON When *(D) Drive is selected, the transmission will initially engage the lowest gear programmed for the (D) Drive position, usually (1) First gear. As the speed increases, it will automatically upshift.
  • Page 35 PERATOR OMPARTMENT 3000 PTS T RANSMISSION HIFTER PTIONAL RANSMISSION USHBUTTON CONT The Display Mode button allows the driver to enable a NOTICE secondary shift schedule. *(R) Reverse or (D) Drive position may be To access the Diagnostic Codes, press the up and prevented when a damaging or undesirable range down arrows at the same time.
  • Page 36 INER ® -T-L EFX O PERATOR ANUAL 2500 PTS T RANSMISSION HIFTER WITH PTIONAL RANSMISSION EVER ( D ) Overdrive - For most highway driving. (D) Drive - For most city driving. (2) Second - For driving slowly in heavy city traffic or on mountain roads where more precise speed control is desirable, and for climbing and descending long grades.
  • Page 37 PERATOR OMPARTMENT EPA10 I NSTRUMENT LUSTER IESEL ACHOMETER PTIONAL IGHT IGNAL AINTENANCE ASTEN ARNING (MPH & M IGNAL PEEDOMETER ETRIC & G XHAUST YSTEM EMPERATURE RANSMISSION NDICATOR AUGE HECK NGINE AINTENANCE & G NGINE OOLANT NDICATOR AUGE ALFUNCTION NDICATOR RUISE ONTROL APG (A RANSMISSION...
  • Page 38 INER ® -T-L EFX O PERATOR ANUAL CONT EPA10 I NSTRUMENT LUSTER Tachometer - Indicates engine speed in 12. A.B.S. Warning - The warning lamp blinks once, revolutions per minute (rpm). then goes OFF and stays OFF, unless the Maintenance Intervals Indicator (Yellow) - Will system detects a problem.
  • Page 39 PERATOR OMPARTMENT CONT EPA10 I NSTRUMENT LUSTER 22. High Coolant Temperature Gauge (Red) - The 27. Diesel Exhaust Fluid (DEF) Gauge - Refer to warning light (thermometer icon) and emergency EPA10 Exhaust System section for operation. buzzer activate whenever coolant 28.
  • Page 40 INER ® -T-L EFX O PERATOR ANUAL ISPLAY ESSAGE CREEN PERATING XAMPLE FOR AINTENANCE The maintenance menu shall contain three sub The maintenance intervals menu allows the driver to menus. These three sub menus are maintenance set the change intervals of the Engine Oil and Engine intervals, transmission oil life remaining, and Air Filter.
  • Page 41 PERATOR OMPARTMENT ) (CONT'D) ISPLAY ESSAGE CREEN PERATING XAMPLE FOR AINTENANCE Screen 3 Auxiliary Screens -Maintenance..Engine Oil To set the interval for engine oil changes, use the down button to scroll to ENGINE OIL in the maintenance menu. to select ENGINE OIL, press the Right button. Screen 4 Auxiliary Screens -Maintenance..Engine Oil...

  • Page 42: Cruise Controls

    INER ® -T-L EFX O PERATOR ANUAL DPF (D IESEL ARTICULATE ILTER ANUAL EGEN WITCH The DPF Regen Switch located on the dash, may Omit Exhaust System Regeneration Switch have three selectable positions: (shorting connector) is installed under the left dash next to the diagnostic port that performs this •...

  • Page 43: Headlight Switch

    PERATOR OMPARTMENT ANEL IMMER WITCH Enables the driver to dim or brighten the light on the dash panel by sliding the button to the desired brightness. EADLIGHT WITCH The headlight switch is a three position switch that controls the main lighting circuit. Position 1, lower position is the OFF position.
  • Page 44 INER ® -T-L EFX O PERATOR ANUAL IGHT IGHT ARNING Eight-light warning system controls the amber and red warning lights mounted on the four corners of the exterior of the vehicle. These lights are activated at various times by the driver as necessary. This system requirements vary from state to state.
  • Page 45 PERATOR OMPARTMENT INDSHIELD IPER ASHER ONTROL AND NDICATOR Electric windshield wiper/washer is standard. The To activate the windshield washers, press the wiper electric windshield wiper/washer controls the wipers. knob. The washers will operate on both wet arms. Wet The wiper knob is located on the lower right dash. The arms provide for the washer fluid to be plumbed to the wiper control is a multi-position switch, which operates spray tips located on the wiper blades at the pivot...
  • Page 46 INER ® -T-L EFX O PERATOR ANUAL GNITION WITCH WITH ESTART EATURE The ignition switch is a four position key switch that Once the switch is turned to Position 4 and released, controls the cold ignition circuits. The four positions it must be returned to Position 1 before attempting to are as follows: restart the engine.
  • Page 47 PERATOR OMPARTMENT , LO/HI, O ASSENGER EATER WITCH The underseat heater fan switches enable the vehicle operator to control the fan speed of the underseat heaters. The fans operate at either Low, High speed or Off. IRROR ONTROL WITCHES Controls remote adjustment for both upper flat and lower convex mirrors (left side and right side) independently.
  • Page 48 INER ® -T-L EFX O PERATOR ANUAL , ON-OFF OOSTER The booster pump switch energizes an auxiliary coolant booster pump to circulate coolant to the heaters when engine is idling or when stop and go driving conditions reduce coolant flow due to low engine rpm.
  • Page 49 PERATOR OMPARTMENT ECONDARY ESERVE RAIN Momentary switch that allows the driver to activate the solenoid drain valve located on the secondary reservoir. ESERVE RAIN Momentary switch that allows the driver to activate the solenoid drain valve located on the wet tank reservoir. RIMARY ESERVE RAIN...
  • Page 50 INER ® -T-L EFX O PERATOR ANUAL ONSOLE WITCH ANEL The Side Console Switch Panel contains the controls layout of your side console switch panel may differ for bus heaters and defrosters, destination sign lights, slightly due to vehicle specifications and selected and other standard and optional body group controls.
  • Page 51 PERATOR OMPARTMENT , 12-V UXILIARY OWER UTLET Supplies a 12-volt power supply source for driver add- on accessories, such as cellular phones and two way radios. Located on the switch cabinet, the outlet is wired directly to the battery with a 10 amp in-line fuse. WITCH LANKS Blank panels are used to fill in openings in the switch...
  • Page 52 INER ® -T-L EFX O PERATOR ANUAL EFROSTER WITCH Enables the defroster fan for windshield cleaning. The fans run at either low or high speed. Momentary switch that activates the air horn mounted beneath the driver's vestibule floor. When switch is released, it returns to the off position. ID M ARKER IGHTS...
  • Page 53 PERATOR OMPARTMENT ’ , ON-OFF (O RIVER IGHT WITCH The driver's dome light switch enables the vehicle operator to energize the dome light above the operator's compartment. NTERIOR IGHT WITCHES The interior light switches energize all the vehicle interior dome lights except the one directly above the driver.
  • Page 54 INER ® -T-L EFX O PERATOR ANUAL UTSIDE PEAKER WITCH Outside speaker horn mounted beneath front area of bus. Located on left side rear of the inner bumper. Enables the outside speaker horn. UGGAGE OMPARTMENT IGHT WITCH Located on the side panel, enables driver to activate the light in the luggage compartment.
  • Page 55 PERATOR OMPARTMENT , ON-OFF (O IGHTS WITCH Controlled by the vehicle operator and activates fog lights for better visibility in inclement weather. ROSSING EACTIVATION WITCH Switch deactivates the crossing control arm after warning lights have been activated. MERGENCY IGHT WITCH Turns on lights mounted above the emergency door and/or rear pushout hatch.
  • Page 56 INER ® -T-L EFX O PERATOR ANUAL ONDITIONING ASTER WITCH The air conditioning switch enables the bus operator to energize or de-energize the air conditioning system. A/C A WITCH In A/C position, air conditioning system operates and cold air is available. In vent position, air conditioning system is off and outside air is available.

  • Page 57: Warning Buzzer

    PERATOR OMPARTMENT ARNING UZZER Mounted on the driver's switch cabinet to alert the driver when the emergency exit is opened. IRROR EFROSTER WITCH The mirror defroster switch energizes the defroster strips in the exterior mirrors. ESTINATION WITCH The destination sign switch energizes the vehicle destination sign light.
  • Page 58 INER ® -T-L EFX O PERATOR ANUAL ICROPHONE When a remote mounted microphone is ordered. Hole will be plugged when not ordered. ANDER WITCH Switch located in the driver's area, enables vehicle operator to energize the wheel sanders that mount forward of the rear wheels.
  • Page 59 PERATOR OMPARTMENT UXILIARY ESERVE RAIN Momentary switch that allows the driver to activate the solenoid drain valve located on the auxiliary reservoir. , ON-OFF (O HIME Vehicle operator has the option of having the chime switch ON or OFF. If the operator chooses to have the chime OFF, a Passenger "Stop Request"...
  • Page 60 INER ® -T-L EFX O PERATOR ANUAL RAKE YDRAULIC RAKES The driveline parking brake is designed to hold the To properly adjust the driveline park brake: vehicle securely in a parked position. This is Park the bus on level ground. accomplished by locking the driveline in place Chock the vehicle wheels.
  • Page 61 PERATOR OMPARTMENT CONT RAKE YDRAULIC RAKES Use a pull scale graduated in pounds and 10. Discontinue adjusting the knob when the scale attach it to the brake handle one inch from the is reading a force of 120 +/- 2 pounds to apply end of the lever.

  • Page 62: Operator ' S Compartment

    INER ® -T-L EFX O PERATOR ANUAL PERATOR OMPARTMENT ONTROLS The following pages provide information on the enable the operator to perform a variety of tasks controls in the operator's compartment. The design, without moving from the driver's seat. location, and mounting position of these controls IGNAL EVER IMMER...

  • Page 63: Power Steering

    PERATOR OMPARTMENT OWER TEERING Power steering uses energy from your engine to NOTICE assist you in steering the vehicle. When the engine is off, or if the power system becomes inoperative, the After any severe impact such as striking large vehicle can still be manually steered, but requires potholes, inadvertent sliding into curbs on icy increased driver effort.

  • Page 64: Brake Pedal

    INER ® -T-L EFX O PERATOR ANUAL LECTRONIC CCELERATOR EDAL The accelerator pedal is an electric rheostat type control that sends a gradually increased current to the engine to control engine rpm and vehicle speed. RAKE EDAL YDRAULIC The brake pedal controls the application of the vehicle service brake.

  • Page 65: Sun Visor

    PERATOR OMPARTMENT ISOR Six inches x 30" plastic with finished edge mounted to Never use an abrasive cleaner. Keep mounting windshield header. brackets tight. Optional sun visor is available in three versions: A plexiglass 6" x 30" with aluminum legs mounted over the driver's window and/or over the right side of windshield.
  • Page 66 INER ® -T-L EFX O PERATOR ANUAL EFROSTER The defroster fans are used to help clear the windshield and driver's window for better visibility. The fans run at either low or high speed. The fans must be cleaned and the fasteners tightened occasionally. Doran Monitor, Exterior 4 or 8 Light (Opt.) The Doran exterior light monitoring system (4, 8, 12, 16) monitors the condition of those exterior vehicle...

  • Page 67: Driver's Seat

    PERATOR OMPARTMENT RIVER The driver's seat is designed to accommodate a following adjustments enable the seat to be moved for variety of driver builds and seating preferences. The maximum driver comfort: ECHANICAL Backrest Tilt - Rotate the knob for infinite to adjust height.
  • Page 68 INER ® -T-L EFX O PERATOR ANUAL Backrest Tilt - Rotate knob for infinite selection Lumbar Adjustment - Push rocker up to inflate of settings. lumbar. Push rocker down to deflate lumbar. Cushion Height Front - Lift handle, pull up and Optional Triple Chamber Air Lumbar - Lower, forward.
  • Page 69 PERATOR OMPARTMENT RIVER WITH EDESTAL Backrest Tilt - Rotate the knob for infinite Seat Height Adjustment - Rotate the four (4) selection of settings. knobs on the box pedestal (two on each side) to Cushion Height Front - Lift handle, pull up and loosen and select slot for desired height.

  • Page 70: Driver ' S Seat Belt

    INER ® -T-L EFX O PERATOR ANUAL RIVER The driver's seat belt should be worn at all times when Application - Hold buckle in one hand and pull operating the vehicle. connector belt across pelvic region (hip bone). Prior to adjusting or fastening the seat belt, adjust the Make sure neither belt is twisted.
  • Page 71 PERATOR OMPARTMENT CONT RIVER Release - The seat belts contain a push button Inspection - Inspect the seat belts and tether belts as located on the buckle. To release the belt push in on follows. the button and the latch will disconnect from the 1.
  • Page 72 INER ® -T-L EFX O PERATOR ANUAL NGINE CCESS OORS PPER CCESS OWER CCESS OOR FOR EASE OF CHECKING ENGINE OIL LEVEL TRANSMISSION FLUID LEVEL POWER STEERING FLUID RESERVOIR Page 3.42...

  • Page 73: Daily Checklist

    PERATING THE EHICLE This section provides the operator with important understanding of component location, function, and operational information. The following pages contain operation is important to the safe operation of the helpful driving tips, information for daily operation, and vehicle and the protection of all passengers. procedures for operation in emergency or inclement weather conditions.

  • Page 74: Engine Compartment

    INER ® -T-L EFX O PERATOR ANUAL NGINE OMPARTMENT ERVICE CAUTION CAUTION Do not service the engine until the transmission gear shift selector lever is in "N" (Neutral) and the parking brake is engaged. Unless the particular procedure requires you to run the engine while working in the engine compartment, you should always turn off the ignition and remove the key, avoiding the...

  • Page 75: Final Check

    PERATING THE EHICLE INAL HECK • Adjust driver's seat and steering wheel. • Verify parking brake is applied and check • Start engine; look and listen for signs of trouble. operation of doors, emergency escape hatches • Check all gauges and warning lights. and emergency exits.

  • Page 76: Normal Starting

    INER ® -T-L EFX O PERATOR ANUAL ORMAL TARTING It is important that the vehicle operator be familiar 3. Turn ignition key ON. with all operating controls and indicators before 4. Wait until the Instrument Cluster performs self- attempting to operate the vehicle. check, then start.

  • Page 77: Block Heaters

    PERATING THE EHICLE LOCK EATERS Block heaters are heating elements installed in the An optional weather proof plug-in receptacle is engine water jacket to aid in cold starting by keeping mounted in the exterior panel above the front bumper. the engine coolant warm while the engine is not Make sure that cover stays closed to prevent damage operating.

  • Page 78: Main Circuit Breaker

    INER ® -T-L EFX O PERATOR ANUAL NGINE DLING YSTEM Idling the vehicle's diesel engine in cold temperatures will not result in desired engine temperature. Actually, CAUTION CAUTION a diesel engine cools down when left idling. The vehicle operator should activate the fast idle feature. Avoid extended or unnecessary idling.

  • Page 79: Driving Tips

    PERATING THE EHICLE RIVING UTOMATIC RANSMISSIONS The vehicle operator should use care when accelerating or downshifting on slippery road CAUTION CAUTION surfaces. Sudden acceleration or engine braking, caused by shifting to a lower gear range, can result in Do not coast the vehicle in neutral. Severe a loss of vehicle control.
  • Page 80 INER ® -T-L EFX O PERATOR ANUAL ARKING When parking the vehicle, use the following within the chamber, allowing the spring to set the sequence: brakes. 1. Shift transmission lever to “Neutral” or “Park” In the event the air system is below 60 psi, the parking with engine running.

  • Page 81: Battery Care

    PERATING THE EHICLE ATTERY AINTENANCE ATTERY Inspect the battery cables for wear, and replace as needed. Clean the cable connector WARNING terminals with a wire brush: Batteries release explosive gas as a by-product of 1.1 Clean and tighten the battery ground cable, their chemical activity.
  • Page 82 INER ® -T-L EFX O PERATOR ANUAL Emergency Starting With Jumper Cables When using jumper cables, follow the instructions 3. Connect the positive (+) jumper cable to the below. positive terminal on the discharged battery. See Jumper Connections diagram on next page. 4.
  • Page 83 PERATING THE EHICLE REVERSE ISCONNECT JUMPER CABLES IN THE ORDER THAT THEY WERE CONNECTED A. D D. N ISCHARGED ATTERY EGATIVE UMPER ABLE B. N E. B EGATIVE ROUND OOSTER ATTERY C. P OSITIVE UMPER ABLE 1. 1 ONNECTION OSITIVE UMPER ABLE TO ISCHARGED...

  • Page 84: Battery Replacement

    INER ® -T-L EFX O PERATOR ANUAL ATTERY EPLACEMENT CAUTION CAUTION Wiring batteries backwards can cause serious damage to the electrical system. WARNING Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.

  • Page 85: Tire Inflation

    PERATING THE EHICLE NFLATION RESSURE CAUTION CAUTION Over or underinflated tires can affect vehicle handling. Pressure can fall suddenly, resulting in loss of vehicle control. Do not drive over posted speed limits or at excessive speeds. This vehicle is not equipped with high speed capability tires and should never be operated in excess of 74 mph (119 kph) for even a short time.
  • Page 86 INER ® -T-L EFX O PERATOR ANUAL HASSIS ACKING OINTS CAUTION CAUTION Do not raise vehicle using a bumper jack. Use only jack (or equivalent) supplied by vehicle manufacturer with your vehicle. Position jack only at prescribed jacking points. If you must raise the vehicle for servicing, use adequate jack stands.
  • Page 87 CAUTION CAUTION followed when towing the vehicle. Thomas Built Buses recommends that when an Proper equipment must be used to prevent damage to EFX requires towing, that it be towed from the vehicles during the towing procedure. Use a safety front whenever possible.
  • Page 88 INER ® -T-L EFX O PERATOR ANUAL RONT OWING HEELS ROUND This is the preferred way of towing. The vehicle may be towed on all wheels provided the steering is NOTICE operating normally. Remember that the power steering will not have power assist, and the air brakes If the unit is to be towed more than 10 miles the are disabled.
  • Page 89 PERATING THE EHICLE RONT OWING RONT HEELS ROUND Proper equipment must be used to prevent damage to the vehicle during the towing procedure. Connect the NOTICE towing equipment to the main structural parts of the vehicle chassis. The chain should be hooked around This is to prevent the possibility of the emergency the front axle outboard of the springs.

  • Page 90: Out Of Fuel

    INER ® -T-L EFX O PERATOR ANUAL FTER OWING After towing the vehicle, block the rear wheels, before disconnecting the towing vehicle. Check and fill Remove the covers from the hub openings and install rear axle with oil as described in the lubrication chart. the axle shafts.

  • Page 91: Operating The Vehicle

    PERATING THE EHICLE ILLING CAUTION CAUTION Handle fuel with care; it is highly flammable. Do not refuel the vehicle while smoking or when near open flames or sparks. Always stop engine before refueling vehicle. Fill fuel tank outdoors. Prevent fires by keeping vehicle clean of accumulated trash, grease and other debris.
  • Page 92 INER ® -T-L EFX O PERATOR ANUAL XTENDED EHICLE TORAGE Any time vehicle will be out of use over an extended 4. Remove and clean battery. Store in a cool, dry period of time (60 days or more), the following steps place, and keep it charged.
  • Page 93 PERATING THE EHICLE EMOTE ANUAL RAIN ALVES Manual Drain valves allows the driver to drain the air tanks without reaching under the unit. The access door is located left side of the unit behind the battery box. OPEN CLOSE PRIMARY SECONDARY ACCESSORY SPECIAL...
  • Page 94 INER ® -T-L EFX O PERATOR ANUAL Page 4.22...

  • Page 95: Emergency Equipment

    A proper understanding of component location, function and Safety equipment on the Thomas vehicle varies operation is important to the competent operation of according to local, state, Federal, and operator the vehicle and the protection of all passengers.
  • Page 96 INER ® -T-L EFX O PERATOR ANUAL MERGENCY INDOW XITS The vehicle's emergency push-out windows also function as emergency exits. To open the windows in emergency situations, follow the instructions that are clearly displayed on the window frame. NOTICE The vehicle should not be driven if an emergency exit buzzer is sounding.
  • Page 97 MERGENCY QUIPMENT MERGENCY SCAPE ATCH The vehicle may contain an emergency roof escape hatch. The location of the hatch is subject to vehicle build specifications according to Federal or State Regulations variations. On vehicles equipped with an emergency roof escape hatch, opening instructions are clearly displayed on the hatch cover.
  • Page 98 INER ® -T-L EFX O PERATOR ANUAL UTTER Seat belt cutting knife used for the purpose of cutting seat belt and wheelchair securement belts in emergency situations. Located with other safety equipment. XTINGUISHER The fire extinguisher should be inspected monthly to verify that it contains sufficient charge.
  • Page 99 MERGENCY QUIPMENT ) (O USEES LARES Three 30 minute fusees in a cylindrical container mounted with easy access by the driver. Operator should be familiar with the proper use of the fusees. Fire axes are maintained with the bus for use in case of emergency.
  • Page 100 INER ® -T-L EFX O PERATOR ANUAL AFETY QUIPMENT OXES AND CCESSORY OMPARTMENT Located over windshield with glass lettered "Emergency Equipment Inside". May be equipped with lock and buzzer, if so desired. Hinge must be lubricated occasionally. AINTENANCE ROCEDURE EHR OFFERED AS PTION 1.
  • Page 101 MERGENCY QUIPMENT AINTENANCE NTERVALS EHR OFFERED AS OPTION If the vehicle is in daily use, Hehr recommends maintenance every time the bus is washed, or monthly, which ever is shorter. Proportionately longer periods may be used if the vehicle is not used every day or if it is operated only in a clean dry environment.
  • Page 102 INER ® -T-L EFX O PERATOR ANUAL Page 5.8...

  • Page 103: General Information

    ENERAL NFORMATION UTWARD PENING There are two (2) adjustments for the standard The adjustments are pre-set and should not require outward opening entrance doors: adjustment for many years under normal use. However, should it become necessary to readjust, use Door opening adjustment the following procedures.
  • Page 104 INER ® -T-L EFX O PERATOR ANUAL ANUAL PENING DJUSTMENT 5. Do not exceed the door opening.dimension of 28 1/2". This also controls the sequence of the front and rear doors closing. The rear door leaf must come in first allowing the front door leaf to overlap the rear leaf, and seal the door and stepwell opening.

  • Page 105: Door Maintenance

    ENERAL NFORMATION AINTENANCE The door hinge fasteners should be tightened periodically to ensure proper door operation. CAUTION CAUTION It is very important that drain holes in the bottom of the Care should be used when operating doors while outward opening door leaves be cleaned every thirty making adjustments.
  • Page 106 INER ® -T-L EFX O PERATOR ANUAL PERATED LOSURE DJUSTMENT 1. Bleed air from system by activating the 5. Adjust Flow Control Valves by tightening emergency air release rocker switch located clockwise until snug; back off 1 1/2 turns, above the door. counterclockwise for initial adjustment of Check that air is absent by moving door control opening...
  • Page 107 ENERAL NFORMATION Page 6.5...
  • Page 108 INER ® -T-L EFX O PERATOR ANUAL MERGENCY An emergency door is usually located on the street side of the vehicle. The opening hardware for the emergency door is protected to prevent accidental opening. Instructions for opening the emergency door are clearly displayed on the door face.
  • Page 109 6. Reseal sash, inside and outside using silicone, securely anchored on both sides to the one piece bow Thomas Part #01013370 or equivalent. This will frames with four (4) clips, two (2) on either side of the ensure that moisture does not enter the side of window.

  • Page 110: Glass Replacement

    2.a To replace the lower stationary glass, loosen the rubber seal available from your Thomas Dealer. center screw on each end of the center rail. 5. Check the new glass to be installed. Sharp Remove the screw on each end of the lower rail.
  • Page 111 4. Inspect new or replacement glass and install rubber seal around outer edge. All glass used by Thomas meets FMVSS 205 requirements. Use of OM glass is recommended when replacing any glass on the bus.

  • Page 112: Windshield Replacement

    INER ® -T-L EFX O PERATOR ANUAL INDSHIELD EPLACEMENT The windshield is installed by a bonded process. This requires no maintenance by the operator. If problems arise requiring the replacement of the windshield, the vehicle should be taken to a professional glass installer.
  • Page 113 ENERAL NFORMATION HOMAS EATS AND ARRIERS All seats and barriers used in the manufacture of bus materials on the after-market for minor cuts and seat bodies must meet many federal requirements. One cover repair. Torn seams in the cushion or back requirement commonly overlooked is the seat back covers can be easily repaired by removing the covers, foam for impact energy absorption.
  • Page 114 EATS If your bus is equipped with passenger seats other • Transportation Seating than Thomas, you can contact them direct for P. O. Box 595 information on care and maintenance. Below is a list Montezuma, GA 31063 of these manufacturers.
  • Page 115 (full of fuel) with 120 lb. per and maintenance staff; these guidelines are provided seating position for all seats on the vehicle by Thomas Built Buses to assist owners and and 150 lb. for driver and each wheelchair operators to help insure safe and compliant seating position should not be greater than the GAWR arrangements.
  • Page 116 INER ® -T-L EFX O PERATOR ANUAL RACK EATING ENERAL NSTALLATION AND EMOVAL UIDELINES H = H-P OINT ORIZONTAL H = H-P OINT ERTICAL SBT = S HICKNESS OINT OINT ONTINUED ON NEXT PAGE Page 6.14...
  • Page 117 *Each seat has a unique absolute minimum knee room spacing per FMVSS 222. Generally this minimum is less than recommended. Most states require a minimum knee room of 24". It is also recommended by Thomas Built Buses that a minimum knee room of 24" be maintained. If you require a knee room of less than 24", contact Thomas Built Buses to get the seats absolute minimum spacing.
  • Page 118 INER ® -T-L EFX O PERATOR ANUAL RACK EATING ENERAL NSTALLATION AND EMOVAL UIDELINES 6. All seats in a school bus should have another clear opening of the emergency exit such that seat or a barrier installed immediately in front an ellipsoid with major axis of 50 centimeters above minimum seat spacing and below and minor axis of 33 centimeters, keeping a...
  • Page 119 ENERAL NFORMATION RACK EATING ENERAL NSTALLATION AND EMOVAL UIDELINES 9. Wheelchair anchorages should allow passage of the ellipsoid in front of the torso or behind the shoulder belt attachment as shown below. USHOUTS NOT PERMISSIBLE IN THIS AREA MERGENCY MERGENCY LLIPSOID This is typically achieved by the position of a 10.
  • Page 120 INER ® -T-L EFX O PERATOR ANUAL RACK EATING ENERAL NSTALLATION AND EMOVAL UIDELINES 11. Wheelchair anchorages should be kept well away from the exit aisle to side emergency exit doors. No anchorages are allowed within 12” of the centerline of the exit aisle. LOOR LINE HEELCHAIR NCHORAGES...
  • Page 121 ENERAL NFORMATION RACK EATING ENERAL NSTALLATION AND EMOVAL UIDELINES 12. The rear exit door deserves special attention (10,000 lb). For vehicles with a GVWR of less in a school bus. Fully tracked units with than 45336 opening should removable seats adjacent to the rear exit door accommodate a volume of 152 mm deep x must allow enough clear area in the door 558 mm wide x 1143 mm high.
  • Page 122 INER ® -T-L EFX O PERATOR ANUAL RACK EATING ENERAL NSTALLATION AND EMOVAL UIDELINES 13. Wheelchair anchorages should be excluded from this area. IMENSIONS IN MILLIMETERS PENING 1143 GVWR >4536 kg LOOR LINE <=4536 kg HEELCHAIR ANCHORAGES ‐ N MERGENCY HEELCHAIR NCHORAGES WITHIN THE SHADED REGION Page 6.20...
  • Page 123 19. Again, Thomas Built Buses is dedicated to manual. helping our customers operate our products 15. Seats equipped with ISO Latch infant carrier...
  • Page 124 INER ® -T-L EFX O PERATOR ANUAL MPACT inches high, 22 inches wide, and six inches deep. NOTICE Disregarding the GVWR of School buses: In case Refer to FMVSS 217 for additional Information. of a side emergency exit door, an opening of at least 114 centimeters high and 61 centimeters wide is School buses with a GVWR of more than 10,000 required.
  • Page 125 ENERAL NFORMATION MPACT However, a seat bottom may be located within the area as described if the seat bottom pivots and automatically assumes and retains a vertical position when not in use, so that no portion of the seat bottom is within the area as described above.
  • Page 126 INER ® -T-L EFX O PERATOR ANUAL MPACT No portion of a seat or restraining barrier located forward of the area described above and between the door opening and a longitudinal vertical plane passing through the longitudinal centerline of the bus shall extend rearward of a vertical transverse plane tangent to the forward most portion of a latch mechanism on the door.
  • Page 127 H point. Also the same as seat contact Thomas Built Buses. spacing minus the seat back thickness. Seat spacing: The distance measured from the same point on two adjacent seats.
  • Page 128 INER ® -T-L EFX O PERATOR ANUAL RACK DENTIFICATION When installing a track mounted seat, it is important that you know what seat you are installing. You must be able to identify each seat being installed to maintain the proper seat spacing. A seat can be identified by following these three steps: 1.
  • Page 129 ENERAL NFORMATION RACK DENTIFICATION The SynTec seat can be seen below. All SynTec seats 39” seat will have an approximate seat cushion width will be similar in shape. Another difference between of 39”. The 39” seat will not have three lap and the two is the SynTec frame.
  • Page 130 ISO latch, and lap belts. The following pictures show each individual option with each make of seat. If you are unsure or can not find the option in this manual, please contact Thomas Built Bus for assistance. IMMI L...
  • Page 131 ENERAL NFORMATION RACK DENTIFICATION IMMI L IMMI FLEX S NUMBER OF BELTS MAY VARY ISO S NUMBER OF BELTS MAY VARY NUMBER OF LATCHES MAY VARY Page 6.29...
  • Page 132 Seats must conform to the contradicts federal regulation please disregard and allowable knee room spacing for each contact Thomas Built Bus. particular seat. Please refer to the knee room section of the manual. If you are unsure of the •...
  • Page 133 ENERAL NFORMATION NSTALLING RACK EATING ETAIL ASHER ETAIL IMMI Seat Track Installation Page 6.31...
  • Page 134 Thomas Built point. A good place to measure the seat spacing is the Buses for proper seat spacing.
  • Page 135 ENERAL NFORMATION HEELCHAIR ESTRAINTS General information NOTICE If this unit is equipped with wheelchair placements, each wheelchair placement will have two or four track Refer to the operation instructions supplied with segments in the floor and one track segment above the restraint system for proper use and safety the window.
  • Page 136 INER ® -T-L EFX O PERATOR ANUAL HEELCHAIR ESTRAINTS Securing the Occupant Window Handle Clearance The occupant must be secured with an upper torso All emergency window release handles must have a belt occupant tiedown and pelvic belt occupant two-inch minimum clearance to allow unobstructed tiedown.
  • Page 137 IEDOWN Several combinations of wheelchair securement For information on the proper use and care of the systems are available through Thomas. Each one has specific setup on your vehicle, consult the unique characteristics while accomplishing the same manufacturer's Instruction Guide supplied with the goal.
  • Page 138 INER ® -T-L EFX O PERATOR ANUAL LECTRIC ROSSING All stop arms and crossing arms, air or electric, draw Stop arms/crossing arms are most commonly from the on-board chassis air or electrical system. The operated by a manual switch mounted in the switch connection to the chassis system should never be panel.

  • Page 139: Front Bumper

    ENERAL NFORMATION PARE ARRIER The spare tire carrier on the vehicle is located in the To re-install the tire onto the carrier, use the following rear overhang of chassis on the right side. procedure: 1. Load tire onto carrier bracket. Use the following procedure to remove the spare tire 2.
  • Page 140 INER ® -T-L EFX O PERATOR ANUAL & H ACKING EAVY ACKING LARM The backing horn or heavy duty backing alarm is mounted at the rear underbody and signals automatically when chassis transmission is placed in reverse. It is wired into the back up lights. ESTRICTION NDICATOR The restriction indicator is a progressive locking type,...
  • Page 141 ENERAL NFORMATION B2001-19-000 ASSENGER DVISORY YSTEM CTIVATION PTION Alarm system that requires the driver to deactivate it • Time to alarm: N/A. by walking through the interior of the bus to turn it off • Type of Alarm: Chassis Horn. and verify that no passengers are still aboard.
  • Page 142 INER ® -T-L EFX O PERATOR ANUAL CR2A - O B2001-20-000 HILD EMINDER YSTEM ODEL PTION Alarm system that requires the driver to deactivate it • Time to alarm: 60 seconds. by walking through the interior of the bus to turn it off •...
  • Page 143 ENERAL NFORMATION - B2001-21-000 ASSENGER DVISORY YSTEM CTIVATION Alarm system that requires the driver to deactivate it • System Activation: When red warning lamps by walking through the interior of the bus to turn it off are used for first time. and verify that no passengers are still aboard.
  • Page 144 INER ® -T-L EFX O PERATOR ANUAL - B2001-22-000 HILD EMINDER YSTEM Alarm system that requires the driver to deactivate it • Type of Alarm: Chassis horn. by walking through the interior of the bus to turn it off • System Activation: 10 minutes after the bus is and verify that no passengers are still aboard.
  • Page 145 ENERAL NFORMATION - B2001-23-000 HILD EMINDER YSTEM Alarm system that requires the driver to deactivate it • System Activation: When red warning lamps by walking through the interior of the bus to turn it off are used for first time. and verify that no passengers are still aboard.
  • Page 146 INER ® -T-L EFX O PERATOR ANUAL - B2001-24-000 ASSENGER DVISORY YSTEM UZZER CTIVATION Alarm system that requires the driver to deactivate it • Location Deactivation Switch: Rear by walking through the interior of the bus to turn it off bulkhead.
  • Page 147 ENERAL NFORMATION ) - B2001-26-000 ASSENGER DVISORY YSTEM CTIVATION HECK Alarm system that requires the driver to deactivate it • Time to alarm: 60 seconds. by walking through the interior of the bus to turn it off • Type of Alarm: Chassis Horn. and verify that no passengers are still aboard.
  • Page 148 INER ® -T-L EFX O PERATOR ANUAL - B2001-28-000 ASSENGER DVISORY YSTEM UZZER CTIVATION Alarm system that requires the driver to deactivate it • Type of Alarm: Buzzer and Chassis Horn. by walking through the interior of the bus to turn it off •...
  • Page 149 ENERAL NFORMATION EP2 - B2001-29-000 HILD EMINDER YSTEM Alarm system that requires the driver to deactivate it • Confirmation of Deactivation: Interior lamps by walking through the interior of the bus to turn it off flash when deactivated. and verify that no passengers are still aboard. •...
  • Page 150 INER ® -T-L EFX O PERATOR ANUAL Page 6.48...

  • Page 151: Electrical Circuit Protection

    AINTENANCE This section provides the operator with important The following are minimum preventive maintenance information about vehicle maintenance. Proper inspections that should be performed as shown on the vehicle maintenance is essential to ensuring vehicle forms or more often as operational and climatic reliability and dependability.
  • Page 152 EFX O PERATOR ANUAL OUCH Retouch damaged areas as soon as possible to develop into a major expense. Your Thomas dealer benefit vehicle appearance and control corrosion. may be your paint source. Exposed metal quickly corrodes and repair may ASHING...

  • Page 153: Floor Covering

    AINTENANCE LOOR OVERING Cleanliness is important to you and your passengers, Wax floor occasionally for best appearance and floor and will give you longer floor life. Allowing dirt and life. The use of a non-skid type floor wax is suggested. other abrasive materials to accumulate on the floor will shorten the life of the vehicle floor covering.
  • Page 154 INER ® -T-L EFX O PERATOR ANUAL LOOR NDERNEATH Accumulations of mud, snow and road salts should be underside of the floor of all foreign elements annually removed with a high pressure hose. Follow this and re-undercoat if chemical action is apparent, or procedure at intervals of 30 days to 6 months, separation of undercoat to body floor is visible.

  • Page 155: Tires - General Information

    AINTENANCE IRES ENERAL NFORMATION Tire size and inflation pressures are recorded on the checked. Otherwise, check pressure every few vehicle certification plate. For greater riding comfort, weeks. Check spare tire regularly. prolonged tire life, and to reduce wear and tear on the vehicle, the tires should be inflated as specified.
  • Page 156 INER ® -T-L EFX O PERATOR ANUAL HANGING IRES CAUTION CAUTION WARNING To avoid personal injury and/or property and To minimize the risk of personal injury, do not put equipment damage, call for expert tire service. any portion of your body under the vehicle while the vehicle is supported by a jack.
  • Page 157 AINTENANCE CONTINUED HANGING IRES Use the following procedure for changing the outside Place automatic transmission vehicles in rear axle tire. A qualified tire service center should be NEUTRAL. contacted to change an inside rear axle tire due to the Shut down engine. safety hazards involved.

  • Page 158: Tightening Wheel Nuts

    INER ® -T-L EFX O PERATOR ANUAL IGHTENING HEEL Before tightening the wheel nuts, the following points Torque all wheel nuts to 450-525 ft/lbs. (608- should be understood: 7098 Nm). NOTICE CAUTION CAUTION Stud Pilot Wheels - Lug nuts on the right side of The presence of rust streaks emanating from the the vehicle have right-hand (turn clockwise to lug nuts is evidence of the lug nuts not being...
  • Page 159 AINTENANCE & M HEEL NSPECTION AINTENANCE Installing wheels without good metal-to-metal contact at the wheel mounting surface can cause CAUTION CAUTION the wheel lug nuts to loosen and could allow the Whenever a wheel is removed and then wheel to come off while the vehicle is in motion, reinstalled, always remove any corrosion that causing loss of control.

  • Page 160: Headlight Aiming

    INER ® -T-L EFX O PERATOR ANUAL EADLIGHT IMING Preliminary Checks horizontal dial should be set at zero. Before checking or adjusting the headlight aim, do the Check to see that the split image target lines following: are visible in the viewing port. If necessary, •...
  • Page 161 AINTENANCE CONTINUED EADLIGHT IMING Figure 1 - Headlight Adjustment with Hoppy Tool Adjusting Headlight Aim NOTE: Because of the various headlight assembly options offered, the location of adjustment screws on the vehicle’s headlight assembly may vary from what is shown here. Figure 2 & 3 Figure 2 Continued on next pages Page 7.11...
  • Page 162 INER ® -T-L EFX O PERATOR ANUAL CONTINUED EADLIGHT IMING Figure 3 Headlight Aiming Headlight adjustment knobs are located on back side of headlight. These can be reached from underneath the chassis above the front bumper. Figure 4 - Headlight Adjusting Knobs ERTICAL EADLIGHT ARIATION...

  • Page 163: Lubrication Charts

    The following information has been extracted from the supplied with the Thomas Maintenance Manual service manuals manufacturers providing should be studied as they contain additional components for Thomas Built Buses. All manuals lubrication and maintenance information. NGINE APACITY AND LASSIFICATION UMMINS NGINE...
  • Page 164 INER ® -T-L EFX O PERATOR ANUAL NGINE IL AND ILTER HANGE NTERVAL UMMINS NGINE ILEAGE NTERVAL NTERVAL ISB 200-260 6,000 miles (9600km) 6 months or 500 hours NGINE ISCOSITY HART (SAE) UMMINS NGINE MBIENT EMPERATURE ISCOSITY to 120 F (-17 to 49 5w/40 or 15W/40 to 118...
  • Page 165 AINTENANCE ERVICE NSPECTION OINTS Item No. Description Air Filter Automatic Slack Adjusters (Air Brakes) Brakes Engine Coolant Reservoir Driveshafts - U-Joint & Slip Yokes Engine - Belts Engine - Oil Filter Engine - Oil Fill Tube Engine - Fan Front Axle - Wheel Bearings, King Pins, Bushings, &...

  • Page 166: Brake System

    INER ® -T-L EFX O PERATOR ANUAL UBRICATED HEEL EARINGS Use only gear type oil. For extreme cold weather use SAE 80W and for hot climates use SAE 140. • Base stock from solvent refined, high viscosity- index petroleum oil Oil lubricated bearing in lieu of grease packed wheel •...
  • Page 167 AINTENANCE UTOMATIC LACK DJUSTERS WARNING Manually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits is likely masking a mechanical problem. Adjustment is not repairing. Before adjusting an automatic slack adjuster, troubleshoot the foundation brake system and inspect it for worn or damaged components.
  • Page 168 INER ® -T-L EFX O PERATOR ANUAL RANSMISSION LUID UTOMATIC RANSMISSIONS The following procedure should be used when Overfilling - results in oil breakdown due to excessive checking the transmission fluid in the automatic heat and aeration from the churning action of the transmission: gears.
  • Page 169 AINTENANCE RANSMISSION UBRICANT LLISON RANSMISSION APACITY ECOMMENDED UBRICANT 2500 PTS 20 Qts.* Dexron III or C-4 3000 PTS 29 Qts.* Dexron III or C-4 *Dry fill, not including coolers and external filter. RANSMISSION IL AND ILTER HANGE HART LLISON RANSMISSION ILEAGE NTERVAL NTERVAL...
  • Page 170 INER ® -T-L EFX O PERATOR ANUAL LUID Check the lubricant every 3000 miles (4800km) or Drain and refill axle housing at 25,000 miles once a month. (40000km) or 12 months, whichever occurs first. Check the lubricant level in the rear axle according to Draining the rear axle is best accomplished the following sequence: immediately after the vehicle has completed a trip.
  • Page 171 AINTENANCE HECK IFFERENTIAL EVEL Check the lubricant every 3000 miles (4800km) or once a month. NOTICE Check the gear oil level in the rear axle according to Dana Axle has removed the Lower Drain plug. The the following sequence: drain and fill plug are located on the lower right side of With the vehicle on level ground, remove the the drive axle.

  • Page 172: Coolant Level

    INER ® -T-L EFX O PERATOR ANUAL OOLANT EVEL Check the cooling system daily, such as during fuel If you have to add coolant more than four times a year, stops. You do not need to remove the radiator cap to see your dealer for a cooling system check.
  • Page 173 AINTENANCE NTIFREEZE Your bus is equipped with a 50/50 solution of Alliance pre-charged antifreeze, part OWI ALA003, is antifreeze and water. The antifreeze is an SCA pre- recommended. charged, heavy duty coolant/antifreeze which is a blend of ethylene glycol, and a specially formulated NOTICE inhibitor package designed for heavy duty cooling system applications.

  • Page 174: Cooling System

    INER ® -T-L EFX O PERATOR ANUAL OOLING YSTEM The cooling system in the vehicle contains To flush the system: approximately 52 U.S. quarts (49.2L). The antifreeze 1. Place a large container under the radiator. is an SCA pre-charged, heavy duty coolant/antifreeze 2.
  • Page 175 AINTENANCE CONTINUED OOLING YSTEM If the system is dirty, showing mineral build up, scale, • The use of a permanent antifreeze with a high rust or oil, use a heavy duty radiator cleaner following silicate content should be avoided to prevent the engine manufacturer's directions.
  • Page 176 INER ® -T-L EFX O PERATOR ANUAL CONTINUED OOLING YSTEM NOTICE CAUTION CAUTION During filling, air must be vented from the engine Refer to the Engine Manufacturer's Service coolant passages. (Some engines are equipped literature for approved coolant. with a vent to allow the air to escape.) The system must be filled slowly to prevent air locks.

  • Page 177: Air Cleaner

    AINTENANCE LEANER The air cleaner is located in the forward section ahead Replacement is simple: of the stepwell. An elastic seal is attached to the top • Secure the vehicle. inlet adapter, sealing the area where the air cleaner • remove the four fasteners from the bottom, contacts the incoming air plenum.
  • Page 178 INER ® -T-L EFX O PERATOR ANUAL ABLE PERATED RAIN ALVES Cable operated Berg drain valves mounted on all air reservoir tanks. Remote mounted cables are located on the right side of the body. To drain the tanks, pull on cables below the side sheet. Tanks should be drained daily.

  • Page 179: Drive Belt Replacement And Adjustment

    AINTENANCE RIVE EPLACEMENT AND DJUSTMENT NOTICE Belts must be cool when tension is checked. Disconnect the negative cable from the battery when replacing belt. Check belts for wear, cracks, and other damage. Replace the belt if it is frayed or has pieces of material missing.
  • Page 180 INER ® -T-L EFX O PERATOR ANUAL UMMINS NGINE PERATING PECIFICATIONS 10-30 *Oil Pressure - psi *(kPa) (69-207) **Coolant Temperature - F -212 **(C) -100 Engine Idle RPM Rated Speed RPM 2500 (governed) Charging Voltage 13-14 Volts *Lower oil pressure is normal at idling speed. Higher than normal oil pressure at start-up with engine cold is acceptable.
  • Page 181 AINTENANCE ENERAL EHICLE PECIFICATIONS NOTICE All height dimensions are based on an average of measurements taken. All measurements are based on 11R22.5 Tires (41 1/2" outside diameter). TANDARD 1 Height 1 Height Body Window Body Length Body Turning F/Axle R/Axle Wheelbase Model Section...
  • Page 182 AGE INTENTIONALLY LEFT BLANK...
  • Page 183 Form #1 & C RIVER AILY NSPECTION ONDITION EPORT Bus Number _____________________________ Date/Time___________________________ Location ____________________________ Mileage_________________________________ AINTENANCE EPARTMENT Not OK Fill fuel tank - Gallons/Liters ____ .........____ _______ Check engine oil level - Quarts/Liters added ____ .
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  • Page 185: Maintenance Inspection

    Form #2 REVENTIVE AINTENANCE NSPECTION 4,000 Miles (6,400 Km) - 60 Days (whichever occurs first) Unit Number__________________________ Check = OK Mileage ______________________________ X = Attention Required Repair Order #________________________ R = Repair Date/Time ____________________________ N/A = Not Applicable Location______________________________ Not OK Check driver's reports for problems previously reported .
  • Page 186 Form #2 REVENTIVE AINTENANCE NSPECTION CONTINUED Not OK Check coolant level, Freeze protection_____% and SCA levels_____ppm or units . . .____ _______ Important: Check with Engine Manufacturer for their SCA recommendations and maintenance schedule. Check Hydraulic fluid level ..........____ _______ Grease rear suspension ____ Drive shaft ____ Brake mechanism ____ .
  • Page 187 Form #3 REVENTIVE AINTENANCE NSPECTION 45,000 Miles, 75,000 Km - Annual Check = OK Unit Number__________________________ X = Attention Required Mileage ______________________________ R = Repair Repair Order #________________________ N/A = Not Applicable Date/Time ____________________________ Location______________________________ Not OK Steam clean engine compartment, if necessary ......____ _______ Perform #1 Inspection .
  • Page 188 Form #3 REVENTIVE AINTENANCE NSPECTION CONTINUED Not OK Drain automatic transmission - drop pan. Replace internal filter ....____ _______ 32.1 Renew transmission filter ......... .____ _______ 32.2 Refill with ATF Dexron 111 or equal .
  • Page 189 Form #4 AINTENANCE ENERAL AINTENANCE ECORDS The maintenance service record is for your services performed on your vehicle. This record log convenience. Record the services performed on your should remain with the vehicle at all times. vehicle in the record log. You should retain copies of your receipts for the services.
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  • Page 192 Post Office Box 2450 High Point, NC 27261 (336) 889-4871 www.thomasbus.com ©2015 Thomas Built Buses, Inc. All rights reserved. No portion of this catalog may be reproduced by any means without express permission from the copyright holder. Part #TBB 176060 rev. 2021.1.26...

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