Bluebird ALL AMERICAN User manual

Owner's Manual
ALL AMERICAN

1
Introduction ................................................................. 3
Forward ........................................................................ 4
Reporting Safety Defects ........................................... 4
Coach Identification ................................................... 4
Inspection..................................................................... 5
Operator's Compartment........................................... 7
Tilt & Telescoping Steering ........................................ 8
Instrument Panel & Controls .................................... 8
Switch Panel ................................................................ 9
Destination Signs ........................................................ 9
Seats & Seat Belts ...................................................... 10
Electrical Systems ..................................................... 13
Light Bulb Data ......................................................... 14
Doran Warning Light Monitor ................................ 15
Circuit Breakers ......................................................... 19
Mirrors & Mirror Adjustment ................................. 20
Emergency Equipment............................................. 22
Emergency Exit ......................................................... 24
Transpec Safety Vent ................................................ 24
Wheelchair Lifts ........................................................ 25
Stop Arms .................................................................. 25
Front Access ............................................................... 28
Access Doors ............................................................. 29
Body Tie Down.......................................................... 29
Towing or Pushing ................................................... 30
Doors .......................................................................... 30
Vandal Locks ............................................................. 34
Keeping Your Vehicle Looking New ...................... 35
Engine Access ............................................................ 36
Heaters ....................................................................... 38
Windows & Windshields ......................................... 45
Windshield Wipers ................................................... 49
Lower Side Panel Repair Procedure ...................... 50
Spare Tire Location & Removal .............................. 50
Tires, Wheels & Rims ............................................... 52
Jacking Instructions .................................................. 54
Engine Operating Instructions................................ 54
Noise Emissions Warranty ...................................... 56
Fuel & Lubricant Requirements ............................. 57
Compressed Natural Gas ........................................ 57
Manual Five Speed Transmission........................... 65
Allison Automatic Transmission ............................ 65
Two Speed Rear Axle Shift Control ........................ 70
Air Brakes .................................................................. 73
Hydraulic System ..................................................... 75
Hydraulic Clutch Controls &
Adjustment for Manual Transmissions ............ 77
Radiator Fans............................................................. 78
Shutters ...................................................................... 79
Cooling System ......................................................... 79
All American Pitman Arm....................................... 79
Front Axle Stop & Steering Gear
Automatic Poppet Adjustments ........................ 80
Wheelbearing Adjustments ..................................... 81
Rear Axle Vent ........................................................... 81
Ridewell Vehicle Air Suspension ............................ 82
Scheduled Maintenance ........................................... 86
Maintenance Service Keys ....................................... 89
Quick Reference Maintenance Charts.................... 90
Cummins Engine Maintenance Chart ................... 90
John Deere 8.1 CNG Engine Maint. Chart ............ 91
Suspension Maintenance Chart .............................. 92
Engine Belt Chart ...................................................... 92
Axle Maintenance Chart .......................................... 93
Brake Maintenance Chart ........................................ 94
Chassis Component Maintenance Chart ............... 95
Body Component Maintenance Chart ............. 96, 97
Wheelchair Lift Maintenance Chart ....................... 97
General Data .............................................................. 98
Index ........................................................................... 99
TABLE OF CONTENTS

2

3
INTRODUCTION
Thank you for selecting the Blue Bird All American. Your All American is the result of mass transporta-
tion developments, which have been ongoing since 1927. The design and construction of the All American
reflects Blue Bird’s concern for efficient, and above all, Safe Operation.
This manual has been prepared to acquaint you with various aspects of service, maintenance and opera-
tion. It explains the various features and controls which should be familiar to the operator before he/she
attempts to drive the unit and will help keep your Blue Bird All American in top operating condition and help
extend its service life.
Your Blue Bird All American may have all or some of the equipment described in this manual. Therefore,
you may find maintenance data for equipment not installed on your bus. Text, illustrations and specifications
in this manual are based on information available at the time of printing. We reserve the right to make
changes at any time without notice. To obtain maintenance and parts information, refer to Blue Bird Chassis
Maintenance Manual and Parts Catalog. You are encouraged to contact your Blue Bird distributor, if addi-
tional maintenance information or assistance is needed.
The complete line of Blue Bird Service Parts is available from your Blue Bird distributor. The use of origi-
nal Blue Bird replacement parts and components will help insure that the design features inherent in the All
American remain for the life of the vehicle.
Proper operation, service and maintenance is important to the safety and reliability of all motor vehicles.
The information contained herein is provided as a reference for systems and components that require peri-
odic service. The intervals given are manufacturer’s recommendations and should be considered maximum
intervals. Actual operating conditions must be considered and maintenance intervals adjusted accordingly.
Anytime a system does not perform satisfactorily, corrective service should be performed at once.
Familiarity with automobile operation and controls is not a prerequisite, but is assumed to be common
knowledge to all who will be operating this coach. Basically, control and operation of both are the same, but
some distinct differences must be recognized before operation of the coach is attempted.
Remember: The bus is 8 feet wide without outside mirrors and is 25 to 40 feet long. Therefore, it is 2 feet
wider and 2 to 3 times as long as the average automobile. The driver sits in front of the wide track front axle,
so the steering has a completely different feel. Acceleration will very likely be slower than that of an automo-
bile. The feel of the brakes may differ from that which is familiar to the new operator. This makes it very
important, from a safety standpoint, for him or her to become completely familiar with that function through
experience before attempting passenger transit. The operator will observe other differences, but after acquir-
ing basic familiarization and some practical experience, he will find the operation quickly becomes quite
natural, comfortable and far from difficult.
CAUTION: No one should attempt to operate this coach without a thorough knowledge of all instruments
and controls, without having had actual driving experience in this or a similar vehicle under supervision,
and without having the appropriate license or permit to operate it. Do not drive the coach until the space
in front, on the sides and in the rear is unobstructed. Most accidents occur because the operator did not
ensure that there was no one in the way before driving.
This manual should be read before the operator attempts to drive the unit.
This manual provides you with the most current maintenance and operation information. We welcome
your comments and suggestions regarding this manual. All correspondence should be directed to the Techni-
cal Services Department of Blue Bird Body Company, P.O. Box 937, Fort Valley, GA, 31030, Attn: TECHNICAL
SERVICES.

4
FOREWORD
This Operator’s Manual provides some general, as well as specific, information regarding safe operation
and maintenance of your Blue Bird bus. It does not address all items or situations that may arise and is not a
substitute for proper driver and mechanic training. The exercise of care, common sense and good driving and
working practices are required for safe operation.
If specific questions or concerns arise that are not adequately addressed in this manual, please contact
your Blue Bird distributor. The distributor will answer your questions or put you in contact with the proper
factory personnel.
Throughout this guide you will find CAUTIONS and WARNINGS. CAUTIONS are given to prevent
you from making an error which could damage the vehicle and possibly cause personal injury. WARNINGS
remind you to be especially careful to avoid personal injury.
Blue Bird Corporation offers many items as standard and optional equipment to meet state, federal and
local specifications and individual customer requirements. Properly selected equipment can help insure
reliable and safe transportation of passengers.
Some examples of this safety equipment are: stop arms, crossing guards, warning lights, warning light
monitors, mirrors, first aid kits, fire extinguishers, warning reflectors, fusees, directional and brake lights,
warning buzzers, vandal locks, emergency exits and seat belts.
It is the driver’s responsibility to insure that the safety items are in proper order. Equipment relating to
safety should be checked for operation on a daily basis. Safety equipment may vary due to state and federal
specifications, and individual customer requirements.
In addition, the driver/operator must insure that the loading area around the bus is clear of pedestrians
before stopping and that all unloaded passengers are a safe distance away from the bus before moving.
REPORTING SAFETY DEFECTS
If you believe your vehicle has a safety defect which could cause a crash or could cause injury or death,
you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to
notifying Blue Bird Corporation.
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. However, NHTSA cannot become
involved in individual problems between you, your dealer or Blue Bird Corporation.
To contact NHTSA you may either call the Auto Safety Hotline toll free at 1-800-424-9393 (or 366-0123 in
Washington, D.C. area), or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590.
You can also obtain other information about Motor Vehicle Safety from the hotline.
COACH IDENTIFICATION
The Vehicle Certification Plate certifies that the vehicle
conforms to all applicable Federal Motor Vehicle Safety Stan-
dards in effect at the date of manufacture. Do not remove or
deface this plate.
MANUFACTURED BY
BLUE BIRD BODY COMPANY
DATE OF MFR.
INC. VEH. MFG. BY DATE
SUITABLE TIRE - RIM CHOICE
GVWR
GAWR : FRONT
GAWR : REAR WITH TIRES
PSI COLD SINGLE
PSI COLD DUAL
WITH TIRES
RIMS, AT
RIMS, AT
THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL
MOTOR VEHICLE SAFETY STANDARDS IN EFFECT IN
CLASSIFICATION V.I.N.

5
The Body Serial and Service Number Plate is located on
the front upper inner panel above the windshield. Refer to
the data on this plate for registration purposes or for replace-
ment part information.
The Axle Record and Chassis Service Number Plate is
located on the front upper inner panel above the windshield.
Refer to the data on these plates for registration purposes or
for replacement part information.
INSPECTION
PRIOR TO PLACING THE NEW BUS IN SERVICE, PERFORM THE FOLLOWING:
• Check suspension u-bolt torque.
• Check Ridewell suspension torque.
• Check brake adjustment.
• Check body tie-down bolts torque.
DAILY INSPECTION
In order to keep your bus in the best operating condition from the standpoint of safety, convenience,
service and operating expense, it is recommended the following inspection procedures be followed on a daily
basis. Any malfunctions or defects should be corrected before the next trip. Report needed services to respon-
sible maintenance personnel.
• Check fuel level.
• Drain air tanks (cold weather).
• Check engine oil level.
• Check coolant level.
• Check automatic transmission fluid level.
Look outside the bus:
• Windshield, mirrors, front windows, head, tail, directional, and stop lights - wipe clean.
• Exhaust - tailpipe clear?
• Rear emergency door, open and close, check warning buzzer operation.
• Tire pressure and tread, OK? Lug nuts in place?
• Drain air brake tank.
• Look under bus - all clear?
• General outside appearance, clean for school bus identification?
• Mirrors - clean and adjusted?
BLUE BIRD
BODY CO.
FORT VALLEY, GEORGIA
BODY NO.
CAPACITY
MODEL YEAR
BODY SERVICE NO.
CHASSIS
SERIAL
FURNISH INFORMATION BELOW WHEN ORDERING AXLE PARTS
FRONT
AXLE
BRAKE
DRUM
REAR
AXLE
ENGINE
SERIAL
BRAKE LINING FMSI
NO.& FRICTION CODE
BRAKE LINING FMSI
NO.& FRICTION CODE
BRAKE
DRUM
REAR AXLE RATIO
CHASSIS SERVICE NO.

6
Look inside the bus:
• Seat, floor - housekeeping. Steps and aisle clear?
• Emergency exits open & close, rear door, windows.
• Emergency equipment.
• Fire extinguisher pressure.
• First aid kit.
• Driver’s area - windshield, windows clean?
• Mirrors - clean and adjusted?
• Emergency doors/windows unlocked and operate freely?
• Do buzzers activate when exits are not fully latched?
Starting the engine:
• Be sure parking brakes are on.
• Put in Neutral.
• With key on, check: Fuel gauge OK? Check brake warning buzzer or light, neutral safety switch.
• Start engine - look, listen for trouble signs, check gauges.
With the engine running, check (from driver’s seat):
• Mirrors, interior and stepwell lights, service door seal.
• Steering feel OK? Noise?
• Horn, defroster & heater blower, windshield wiper operation.
• Brakes - pedal height & feel, gauge reading OK? Parking brake release, reset.
Outside checks required before you drive away:
• Turn signals - right & left, front & rear - clean & flashing?
• Flasher warning lights - front & rear - clean & flashing?
• Stop arm (if used) - clean & working?
• Headlights hi-lo beams.
• Stoplights & taillights - clean & working?
• Hazard flasher working?
Final check as you move the bus:
• Seat belt fastened?
• Brakes - Stop & hold?
• Steering feel OK? Unusual noises? Bus under control- tracking straight?
• Brake to a stop. All gauges OK?
Remember: Safety on the road also depends on you. Observe weather and road condition and drive
accordingly. Be physically and mentally alert. When backing in vicinity of congestion or pedestrians use
outside monitor or director. Look around before driving away from where you are parked and observe all
traffic rules and regulations.
WEEKLY INSPECTION
• Drain air tanks (warm weather).
• Check tires.
• Inspect seat cushion attachments for tightness.
• Inspect seat belts and buckles.
• Check fuel water separator.
• Check windshield washer fluid level.

7
OPERATOR’S COMPARTMENT
1. Driver’s seat.
2. Switch panel.
3. Windshield wiper switch - op-
erates windshield wiper &
washer.
4. Driver’s window defroster - di-
rects air flowto driver’s window
5. Driver’s foot warmer, window
defroster control - controls flow
of air.
6. Horn button - sounds electric
horn.
7. Instrument panel.
8. Hazard signal switch - activates
emergency warning systems.
9. Parking brake - prevents unit
from rolling when parked.
10. Automatic transmission shift
control (range selector).
11. Driver’s fresh air controls - operates driver’s fresh air
vent.
12. Accelerator pedal - controls engine speed.
13. Brake pedal or air treadle - applies service brakes.
14. Dimmer switch - selects headlight high or low beam.
15. Tilt and telescoping lever.
16. Hand throttle - raises engine idle speed. (AAFE only)
WARNING: Do not use throttle lock as means of cruise
control. Always release throttle lock before putting
vehicle in motion.
17. High beam - indicates headlights on bright.
18. Low air - warning indicates air pressure
in system is low.
19. Blanks - for optional indicators.
20. Engine warning - indicates low oil pres-
sure or high water temperature.
21. Refill sander - warning, level of sand in
sanders is low.
22. Right turn indicator.
23. Left turn indicator.
NOT ILLUSTRATED
• Door control.
• Wig-Wag - low air pressure warning.
• Reservoir drain valve.
• Warning light monitor - indicates whether
warning lights are working.
• Inside mirror.
1
2
34 567
8
9
10
11
12
13
14
16
15
• Driver’s arm rest.
• Turn signal lever - operates turn signals.
• Fresh air control for front heaters - operates
fresh air vent.
• Fusee canister.
• Reflector flares and flags.
• PA system - used to address.
ENG
WARN LOW AIR REFILL SANDER
23 19 17 18 21 2220 19

8
TILT & TELESCOPING STEERING
To adjust steering wheel position, use the tilting lever located on
the left side of steering mounting bracket. Press lever downward to
unlock steering column. Move column to one of four positions and
release lever. To raise or lower the steering wheel position, pull up
on the tilting lever. This will enable you to raise or lower the steering
wheel to one of its seven positions.
INSTRUMENT PANEL & CONTROLS
INSTRUMENT PANEL WITH DUAL SCALE GAUGES
The speed indicator is measured in miles per hour and kilometers per hour. All temperature gauges are
measured in degrees Fahrenheit and degrees Celsius. All pressure gauges are measured in pounds per square
inch and kilopascals (kilo newtons per square meter).
1. Speedometer - indicates ve-
hicle speed.
2. Air pressure gauge, front -
indicates air system pressure.
3. Air pressure gauge, rear -
indicates air system pressure.
4. Tachometer with hourmeter
- indicates engine RPM.
5. Voltmeter - indicates electri-
cal system voltage.
6. Ammeter - indicates battery
charge and discharge, op-
tional.
7. Water temperature gauge -
indicates engine coolant tem-
perature.
8. Oil pressure gauge - indicates oil pressure.
9. Fuel gauge - indicates fuel supply.
10. Headlight switch - turns on headlights.
11. Dash light dimmer - dims lights in instruments.
12. Air Control Accelerator - increases engine RPM. (AARE only) (see ENGINE HIGH IDLE SWITCH)
13. Transmission Oil Temp Gauge - indicates transmission oil temperature.
WARNING: In the case of an air reserve failure, the low air pressure warning buzzer will sound and
warning light illuminate, giving an indication that trouble is evident and the respective air gauge located
on the dash will indicate which system has lost air pressure. The coach must not be operated under those
conditions, but must be repaired before continuing operation.
Tilt Lever
RPM X 1000
HOURS
0 0 0 0 0 0 0
MPH
Miles
0 0 0 0 0 0 0
FRONT AIR BRAKE
75 100
125
150
0
25
50
100-
0
+100
AMPS
160 200 240
TRANS
OIL
40 90 140
810 12 14 1618
VOLTS
OIL
0120
30 60
8
24
REAR AIR BRAKE
75 100
125
150
0
25
50
180 200 220
TEMP
40 90 125
ALIGN SEAT WITH
STEERING WHEEL
BEFORE OPERATING
VEHICLE
AIR
CONTROL
ACCEL
E1/2
F
FUEL
DASH
LIGHTS
12 591 47
10 13 6 211 3 8

9
SWITCH PANEL
1. Underseat Heater
2. Dome
3. Clearance Lamps
4. Warning Light Pilots
5. Manuals
6. Master
7. Heater Pump
8. Auxiliary Heater
9. Front Heater
10. Defroster
11. Fan
12. Wash/Wipe
13. Entrance Door
14. Exit Door
15. Pilot Light
DESTINATION SIGNS
Hinged Sign Front - Mounted on outside of front roof cap with internal control for changing sign. Peri-
odically lubricate hinges and lever assembly with lightweight lubricating oil.
Hinged Sign Rear - Mounted on outside of rear roof cap, manually changed from outside. Periodically
lubricate hinges with lightweight lubricating oil.
One Station Lighted Curtain - Replace bulbs as needed. May occasionally loosen and cause slack in the
curtain due to vibration. To tighten curtain, loosen bolts, pull curtain tight, retighten bolts.
Roller Destination Sign with Lighted Curtain - Replace bulbs as needed. May occasionally require same
adjustment as One Station Sign. Periodically lubricate roller gears with light grease, such as "White Lube,"
and hinges on access door with lightweight lubricating oil. To change sign, turn crank located on front upper
inner panel above windshield to desired destination.
Two Station Sign - Front lighted, sign material masonite with lettering on both sides. Lubricate interior
door hinge on front upper inner panel with lightweight lubricating oil.
Lighted “School Bus” Sign - Back lighted yellow plexiglass sign. Replace bulbs as needed. Lubricate
interior door hinge on front upper inner panel with lightweight lubricating oil.
NOTE: All maintenance procedures to be done at 6 months or 6,000 mile intervals, whichever occurs first.
BLANK BLANK BLANK DOME DOME DOME CL LAMPS WL PILOT WL PILOT WL MANUAL WL MASTER BLANK
BLUE BIRD
BODY COMPANY
FANFANBLANK BLANK BLANK BLANK BLANK
US HTR US HTR AUX HTR
HTR PUMP FRT HTR FRT HTR DEFROST EXIT DOOR ENT DOOR WASH/WIPE WASH/WIPE
LO HIPULL/ON PUSH/OFF
1
234 56
7
8910
11
12
13
14
15