GILLIG LOW FLOOR User manual

1
Service Manual
Hampton Roads Transit
Chassis Numbers: 77621–77660
Coach Numbers: 2000–2039
Customer Name
Click here to go to the Table of Contents
Click here to go to the Index
Click here to go to the Maintenance Schedule

2
Foreword
Foreword
This manual has been prepared to provide the transit operator with maintenance information for the Gil-
lig Low Floor coach. Information has been provided in an easy-to-read format featuring system descrip-
tions and specic procedures for performing the required maintenance.
Four Gillig manuals are supplied for the Low Floor coach: the Driver’s Handbook, Service Manual,
Parts Manual, and the Electrical Schematics Manual. The manuals package also includes vendor-sup-
plied manuals for the engine, transmission, axles, wheels, air conditioning, and other specialized or
customer-ordered equipment and options. The Gillig manuals interface with, and sometimes overlap, the
information in the vendor manuals.
This Service Manual is produced specically for the coaches whose serial numbers are designated on the
cover of the manual. The customized services outlined may not be appropriate for other Gillig coaches,
which are not included in the listing for this manual. Please do not use this manual as a basis for servic-
ing other Gillig coaches in your eet.
We have made every effort to provide accurate, complete, and useful publications for our customers. We
welcome comments and suggestions for improvements to these publications. If you have a suggestion,
please include it, along with the specic page reference, in a letter or telephone call to the Publications
Department at Gillig.
Additional copies of this or any other Gillig publication may be purchased by contacting the Gillig Parts
Department at [phone].
ALL RIGHTS RESERVED. NO PART OF THIS MANUAL
MAY BE REPRODUCED IN ANY FORM OR BY ANY
MEANS WITHOUT THE PRIOR WRITTEN PERMISSION
OF GILLIG CORPORATION.
© 2006 GILLIG CORPORATION

3Table of Contents
Specications ......................................................... 11
Weights and Measurements.................................................................................. 11
Torque Information................................................................................................. 12
Torque Values—Bolts and Nuts........................................................................... 12
Axle & Suspension Torque Values....................................................................... 14
Wheel Nut Torque Values .................................................................................... 15
Fluid Specications................................................................................................ 16
Chapter 1– General Information............................19
Introduction............................................................................................................. 19
Important Safety Information ................................................................................ 19
Bus Operation......................................................................................................... 22
Jacking and Towing ............................................................................................... 29
Supporting the Coach on Jack Stands ................................................................ 30
Towing Instructions .............................................................................................. 31
Driveshaft Removal ............................................................................................. 34
Axle Shaft Removal............................................................................................. 35
Welding Precautions .............................................................................................. 36
Warranty Information ............................................................................................. 37
Chapter 2– Preventive Maintenance.....................41
Adjusting Maintenance Intervals .......................................................................... 41
Daily Maintenance .................................................................................................. 42
Lubrication Points .................................................................................................. 43
Maintenance Schedule........................................................................................... 45
Table of Contents

4
Table of Contents
Chapter 3– Engine..................................................59
Engine Oil................................................................................................................ 59
Checking the Oil Level......................................................................................... 60
Probalyzer Sampling System .............................................................................. 61
Changing the Oil.................................................................................................. 61
Engine Oil Filter...................................................................................................... 62
Oil Pressure Gauges and Senders........................................................................ 64
Throttle .................................................................................................................... 64
Spinner II Oil Filter ................................................................................................. 65
Fuel System ............................................................................................................ 70
Fuel Specications................................................................................................. 75
Fuel Tank ................................................................................................................. 76
Engine Cooling ....................................................................................................... 79
Radiator ................................................................................................................... 86
Surge Tank .............................................................................................................. 89
Air Intake System ................................................................................................... 90
Exhaust System...................................................................................................... 93
Engine Removal & Installation.............................................................................. 98
Drive Belts............................................................................................................. 104
Engine Diagnostics .............................................................................................. 109
Chapter 4– Transmission/Driveline/Rear Axle... 111
Transmission ........................................................................................................ 111
Operation............................................................................................................... 112
Transmission Fluid............................................................................................... 114
Checking Transmission Fluid Level ................................................................... 116
Davco Transmission Fluid Level Gauge ............................................................ 119
Fluid and Filter Change Intervals....................................................................... 123
Fluid and Filter Change ..................................................................................... 124
Exterior Inspection and Cleaning ....................................................................... 125
Transmission Fluid Cooler .................................................................................. 125
Transmission Replacement ................................................................................. 126
Driveline ................................................................................................................ 130
Drive Axle .............................................................................................................. 134

5Table of Contents
Chapter 5– Suspension .......................................139
General Information ............................................................................................. 139
Air Springs ............................................................................................................ 140
Shock Absorbers.................................................................................................. 143
Ride Height Adjustment....................................................................................... 146
Front Suspension ................................................................................................. 149
Rear Suspension .................................................................................................. 151
Rear Axle Alignment .......................................................................................... 156
Suspension Troubleshooting .............................................................................. 157
Front Axle.............................................................................................................. 159
Axle Overhaul ....................................................................................................... 162
Steering Linkage................................................................................................... 163
Front End Alignment ............................................................................................ 168
Front Axle Troubleshooting................................................................................ 172
Steering Column................................................................................................... 174
Chapter 6– Air System .........................................183
Air System Operation........................................................................................... 183
Suspension Air System Operation ..................................................................... 186
Kneeling System Operation................................................................................. 188
Door Control Operation ...................................................................................... 190
Air Compressor .................................................................................................... 193
Maintenance ...................................................................................................... 195
Compressor Removal and Installation............................................................... 197
Performance Testing ......................................................................................... 199
Troubleshooting................................................................................................. 200
Air Governor (Bendix D-2) ................................................................................... 203
Preventive Maintenance .................................................................................... 203
Air Reservoirs ....................................................................................................... 208
Valves and Pressure Switches............................................................................ 209
Safety Valve....................................................................................................... 209
Check Valves..................................................................................................... 211
Air Lines............................................................................................................. 213

6
Table of Contents
Brake System Operation...................................................................................... 215
Brake Valves ......................................................................................................... 215
Brake Valve (Bendix E-10R).............................................................................. 215
Preventive Maintenance ............................................................................... 218
Retarder Brake Valve Adjustment Procedure ............................................... 224
Relay Valve (Bendix R-12DC) ........................................................................... 226
Brake Relay Valve (Bendix R-14) ...................................................................... 233
Quick Release Valve (Bendix QR-1) ................................................................. 238
Spring Brake Valve (Bendix SR-1) .................................................................... 240
Parking Brake Control Valve (Bendix PP-1) ...................................................... 245
Brake Interlock Solenoid Valve.......................................................................... 246
Air Dryer (Bendix AD-9) .......................................................................................247
Regular Scheduled Maintenance ...................................................................... 247
Rebuilding the Air Dryer..................................................................................... 249
Air Dryer Troubleshooting.................................................................................. 254
Air System Condenser/Separator ....................................................................... 257
Chapter 7– Brakes & Wheels...............................261
Hazardous Material Warning ............................................................................... 261
Brake System........................................................................................................ 263
Maintenance.......................................................................................................... 264
System Tests......................................................................................................... 266
Parking Brake ....................................................................................................... 267
Brake Chambers ................................................................................................... 267
Rear Brake Chamber Maintenance................................................................... 268
Spring Brake Manual Release........................................................................... 269
Removal and Installation of Rear Brake Chambers .......................................... 270
Verifying Brake Adjustment................................................................................. 272
Automatic Slack Adjusters................................................................................. 272
Automatic Brake Adjuster Checking Procedures............................................... 277
Troubleshooting Brakes ...................................................................................... 279
Anti-Lock Braking System Operation................................................................. 281
Front and Rear Wheel Hub Assemblies ............................................................. 283

7Table of Contents
Wheels and Tires.................................................................................................. 288
Mounting and Demounting Safety Precautions ................................................. 288
Vehicle Operation Safety Precautions ............................................................... 289
Wheel Maintenance........................................................................................... 289
Wheel Nut Torque.............................................................................................. 292
Wheel Installation ................................................................................................. 293
Tire Maintenance .................................................................................................. 295
Wheel and Tire Balancing.................................................................................. 300
Chapter 8– Hydraulic System..............................303
System Operation................................................................................................. 304
Fan Motor Circuit Valves...................................................................................... 306
Spool Valve ....................................................................................................... 306
PWM Fan Control System ................................................................................ 308
Hydraulic Fan Motor............................................................................................. 309
Troubleshooting the Fan Motor Circuit .............................................................. 310
Fan Motor Removal ........................................................................................... 312
Fan Motor Inspection and Repair ...................................................................... 313
Hydraulic Pump .................................................................................................... 315
Hydraulic Fluid................................................................................................... 315
Hydraulic Pump Removal ................................................................................. 316
Hydraulic Pump Overhaul.................................................................................. 317
Hydraulic System Reservoir................................................................................ 318
Hydraulic System Cooler..................................................................................... 320
Pressure Gauges and Testing ............................................................................. 320
Bleeding/Filling Power Steering Hydraulic System .......................................... 324
Steering System ................................................................................................... 326
Diagnosis of Problems....................................................................................... 331
Hydraulic / Steering System Troubleshooting................................................... 332

8
Table of Contents
Chapter 9– Electrical System..............................339
Battery ................................................................................................................... 339
Battery Maintenance.......................................................................................... 339
Battery Disconnect Switch................................................................................. 341
Disconnecting/Removing the Batteries.............................................................. 342
Replacing Batteries ........................................................................................... 343
Battery Inspection.............................................................................................. 344
Electrolyte Maintenance .................................................................................... 346
Battery Testing................................................................................................... 347
Charging the Battery.......................................................................................... 350
Battery Capacity Ratings................................................................................... 352
Common Causes of Battery Failure .................................................................. 352
Jump Starting with a Booster Battery ................................................................ 353
Battery Equalizer .................................................................................................. 356
Equalizer Troubleshooting................................................................................. 358
Equalizer Replacement ..................................................................................... 359
EM70D Electrical System Monitor ..................................................................... 361
Charging System .................................................................................................. 363
Alternator ........................................................................................................... 363
On-Vehicle Charging System Checks ............................................................... 366
Alternator Repair ............................................................................................... 369
Alternator Cable/Fuse Installation Procedure.................................................... 371
Starting System .................................................................................................... 373
Multiplexing System............................................................................................. 382
Multiplex System Connections .......................................................................... 388
Troubleshooting................................................................................................. 389
Module LED’s .................................................................................................... 391
Diagnosis........................................................................................................... 392
Welding Precautions.......................................................................................... 394
Electrical Panels ................................................................................................... 395
SAE J1939 Interface ............................................................................................. 398
Rear Run Box........................................................................................................ 400
Electric Horns ....................................................................................................... 401

9Table of Contents
Fire Detection System.......................................................................................... 403
Fire Suppression System .................................................................................... 405
Interior Lighting .................................................................................................... 406
Exterior Lighting Equipment ............................................................................... 411
Marker, Clearance, and Identication Lights ..................................................... 415
Speedometer......................................................................................................... 416
Wheelchair Ramp ................................................................................................. 417
Electrical Connectors........................................................................................... 419
Wiring Harnesses, Junctions, and Connectors................................................. 426
Chapter 10– Heating / Air Conditioning .............429
Passenger Heating and Air Conditioning........................................................... 429
System Control ..................................................................................................... 432
Driver’s Heater and Defroster System................................................................ 433
Booster Pump ....................................................................................................... 433
Auxiliary Coolant Heater (Optional).................................................................... 441
Chapter 11– Body and Interior ............................443
Underbody............................................................................................................. 443
Corrosion Protection.......................................................................................... 443
Exterior .................................................................................................................. 445
Side Framing and Skins .................................................................................... 445
Cobolt/Gusset Connections.......................................................................... 445
Cobolt/Gusset Repair ................................................................................... 447
Windshield Wipers ............................................................................................... 455
Access Doors........................................................................................................ 458
Body Repair and Painting.................................................................................... 459
Interior ................................................................................................................... 463
Passenger Doors .................................................................................................. 465
Front Doors ........................................................................................................... 468
Rear doors............................................................................................................. 472
Door Repair ........................................................................................................... 478

10
Table of Contents
Windows................................................................................................................ 479
Windshield ......................................................................................................... 479
Driver’s Side Window ........................................................................................ 481
Window Removal............................................................................................... 482
Emergency Egress Windows............................................................................. 483
Driver’s Seat.......................................................................................................... 485
Passenger Seating ............................................................................................... 496
Index ......................................................................499

11 Specications
Specications
The specications provided in this publication are based on information available at the time it was
written and are subject to change at any time due to manufacturer revisions. These specications are
intended as general guidelines for servicing components on the vehicle. In all cases where services are
performed, it is the responsibility of the service personnel to be sure that they have the most current in-
formation available before performing the job. If there are any questions regarding the values supplied in
this specications listing, contact the Gillig Service Department before performing intended service.
WEIGHTS AND MEASUREMENTS
Weight
Vehicle Weight: 25,000 lbs (varies depending on installed components)
Gross Maximum Vehicle Weight: 39,600 lbs
Heights
Height with standard tires: 122" (including exhaust pipe)
Floor height with standard tires (at aisle): 15.75"
Headroom (minimum): 76.5"
Wheelbase 279"
Internal Noise Level
Normal Operating Conditions: 80 dBA (max.)

12
Specications
TORQUE INFORMATION
Torque Values—Bolts and Nuts
Whenever possible, torque at the nut. Unless otherwise noted in the specic application on which
you are working, standard S.A.E. torque values are to be applied when servicing the coach. Check how
many threads per inch the capscrew contains and determine if the capscrew has an S.A.E. grading of 5
or 8 (see Figure S-1). A grade 5 capscrew is often distinguished by
three radial lines on its head, while a grade 8 capscrew may have
six radial lines on its head. Grade 8 capscrews are made stronger
and are able to handle more torque. Different manufacturers use
different markings to designate the grade of nuts and bolts. Make
sure replacement nuts and bolts are the correct grade by contacting
your Gillig Parts representative or the maker of the component that
you’re servicing.
Always use specic torque values for the component being serviced,
if such are stated in up-to-date text or illustrations regarding that
component. For example, when servicing the engine, refer to the engine
manufacturer’s manual, which accompanies this manual. If specic
torque values are not given in this manual or in accompanying OEM
manuals, use the most up-to-date standard S.A.E. torque values.
Always use bolts and nuts with the same torque values and strength,
made of the same material, and treated/plated with the same material
as those being replaced. Damage to parts and systems can be caused
by using bolts and nuts with the wrong specications. Always obtain
replacement bolts and nuts through your Gillig Parts representative!
Coated/Plated Hardware
Determining the correct torque value for nuts and bolts on your bus is imperative for passenger safety
and long equipment life. All bolts coated/plated with cadmium, zinc, yellow zinc dichromate, etc.
are considered lubricated. Specially coated/plated nuts and bolts require considerable adjustment in
torque application. Some nuts and bolts on your bus are coated/plated, and some may in addition be
lubricated with Never-Seez®, an anti-seizing product. When using an anti-seizing product, the torque
applied to a nut or bolt will need to be signicantly decreased to avoid damaging parts due to overtight-
ening. Contact your Gillig Service representative before using any anti-seize product. Because there
can be so many torque value variables, it is extremely important that you adhere to torque values given
in OEM documentation and provided in this manual, and heed the Notice and Caution above.
Figure S-1, Capscrew Grading
5 8

Specications
13
Torque with Crowfoot Wrench
If a nut is situated so that it’s difcult to get a torque wrench and socket on it, a crowfoot wrench can be
used. The following calculation can be used for any torque and for any fastener.
When using a crowfoot wrench, you must adjust the torque setting on
your torque wrench following the formula below. Otherwise you will
over-torque and possibly break fasteners.
Refer to Figure S-2 below. Add Distance A (the distance from the center of the torque wrench grip to the
center of the torque wrench drive) to Distance B (the distance of the center of the torque wrench drive to
the center of the crows foot socket). Divide the Gillig-specied torque value by this sum. Now multiply
the result by Distance A. The new torque, which you will set on your torque wrench, should be less
than the Gillig-specied torque.
For example, if the wrench is 10" long, the crows foot is 2" long, and you want 120 ft-lb of torque, you
would set the wrench for 100 ft-lb.
To utilize the formula shown in Figure S-2 below, note the following:
Fastener Torque = the torque specied in the Gillig Service Manual for the fastener. In our example,
the torque value is 120 ft-lb.
Set Torque = the torque you set on your torque wrench when using the crowfoot. In our example, this
comes out to 100 ft-lb.
Distance A (in our example) = 10"
Distance B (in our example) = 2"
120 divided by 12 = 10
10 x10 = 100 (ft-lb)
Figure S-2, Crowfoot Wrench Torque Formula
Fastener
Distance = B
Torque Wrench Distance = A
Set Torque = x A
Fastener Torque
A+B

14
Specications
Axle & Suspension Torque Values
*Tighten nut to given specication, then continue to tighten until
slot in nut lines up with hole.
Steering Linkage (Without Anti-Seize)
Description Size Torque Range
ft-lb N-m
Pitman Arm Bolt 3/4" - 16 230–290 312–393
Drag Link to Pitman Arm Nut 200–250* 271–339*
Drag Link to Steering Arm Nut 200–250* 271–339*
Steering Gear Mounting Bolts 7/8" - 14 490–510 664–692
Steering Gear Mounting Bolts 3/4"- 16 290–310 393–420
Refer to the Meritor Maintenance Manual 2 included with your bus for
front axle torque values.
Front Suspension (Without Anti-Seize)
Description Size Torque Range
ft-lb N-m
Torque Rod Bolts 5/8" - 18 170–190 231–258
Torque Rod Clamp Nuts 5/8" - 18 135–165 183–224
Shock Mounting Nuts 3/4" - 10 170–190 231–258

Specications
15
Axle & Suspension Torque Values (Continued)
Wheel Nut Torque Values
See “Wheel Installation” in the Brakes and Wheels chapter of this manual.
Rear Suspension
Rear Axle
Description Size Minimum Torque
ft-lb N-m
Breather Vent 3/8" - 18 20 minimum 27 minimum
Drain Plug 3/4" - 14 35 minimum 47 minimum
Description Size Bolt / Stud
Coating Grade Nut Coating Grade
Torque Range
(ft-lbs) with
Anti-Seize
Torque Range
(ft-lbs) w/o
Anti-Seize
Upper and Lower
Torque Rods to Chassis 5/8-18 Phos & Oil 8 Cadmium TS w/ Wax C 115 ± 5 145 ± 5
Upper Torque Rods to
Axle Bracket 5/8-18 Phos & Oil 8 N/A N/A 200 ± 5 265 ± 5
Lower Torque Rods to
H Frame 1-14 Phos & Oil N/A Cadmium TS w/ Wax C 400 ± 5 475 ± 5
Upper Torque Rod
Clamp Bolt 5/8-18 Zinc 8 Nylock-
Zinc 8
150 ± 15 115 ± 5
Axle to H Frame
Connection 7/8-14 Phos & Oil 8 Cadmium TS w/ Wax C 310 ± 5 400 ± 5
Shock Absorber Bolt 3/4-16 Zinc 8 Nylock-
Zinc 8
110 110
1/2-13 Zinc N/A Cadmium
TS w/ Wax B
35 ± 5 35 ± 5
Air Bag Mounting Nut
3/4-16 Zinc N/A Cadmium
TS w/ Wax A
35 ± 5 35 ± 5

16
Specications
FLUID SPECIFICATIONS
For acceptable substitutions and uids for unusual operating conditions, consult the appropriate section
of this manual or the OEM (Original Equipment Manufacturer) manuals supplied with the coach.
Fluid capacity values given are accurate within 10% and should be used as a guideline only. When
adding coolant, oil, transmission uid, and hydraulic uid, refer to instructions given in this manual and
in manufacturer manuals supplied with the coach. Always use dipsticks, sight glasses, etc. to determine
the correct uid levels.
Maximum uid capacities are given for initial ll purposes only. When
doing actual uid changes, uid requirements will be less due to uids
remaining in the system. Use dipsticks, sight glasses, etc. to determine
the correct uid levels.
Engine Oil 20 qt / 19 L High, 16 qt / 15 L Low
All Seasons, above 14°F 15W-40, API Category CI-4
For winter and arctic conditions see “Oil Viscosity” in Chapter 3– Engine.
Engine Coolant
15 gal / 57 L (dry ll, including hoses, heater coils, transmission cooler, etc.)
(do not mix types) Ethylene Glycol, 50% concentration
Propylene Glycol, 50% concentration
Coolant must meet ASTM 6210 specications and Cummins 14603 specications.
Transmission Fluid 29.6 qt / 28 L initial dry ll (hoses, transmission cooler, etc.)
26.4 qt / 25 L rell
Use the correct uid type! To preclude voiding your warranty by using the wrong type of
transmission uid, please refer to “Transmission Fluid” in the Transmission chapter!
Differential / Rear Axle Oil 22 qt / 20.8 L
Fill Meritor axles with Meritor-specied lubricants only. Using non-approved lubricants will
void Meritor’s warranty. Damage to axle components also can result. Refer to “Approved
Rear Drive Axle Lubricants” on the Meritor Web site: www.arvinmeritor.com.
See specications table on the following page.

17 Specications
Differential / Rear Axle Oil (Continued)
Gear Oil Type API Spec. SAE Viscosity Meritor Spec. SAE Spec. Outside Temperature
Standard-Drain
Lubricants
Petroleum with EP
additives
GL-5
85W/140 O76-A
SAE J2360
Tested and
Approved
Above +10°F (–12°C)
80W/140 O76-B Above –15°F (–26°C)
80W/90 O76-D Above –15°F (–26°C)
75W/90 O76-E Above –40°F (–40°C)
75W O76-J From –40°F (–40°C) to +35°F (+2°C)
75W/140 O76-L Above –40°F (–40°C)
Extended-Drain
Lubricants
Petroleum with
Extended-Drain Base
Oils and EP additives
GL-5
75W/90, 80W/90,
80W/140 or
75W/140
O76-Q, O76-R
SAE J2360
Tested and
Approved
Depends on viscosity. Refer to the
viscosity grades listed above.
Petroleum with Semi-
Synthetic Base Oils
and EP additives
80W/90 O76-P Above –15°F (–26°C)
Fully Synthetic Base
Oil and EP additives
75W/140 O76-M Above –40°F (–40°C)
Fully Synthetic Base
Oil and EP additives
75W/90 O76-N Above –40°F (–40°C)
Hydraulic Fluid 14.4 qt / 13.6 L (including reservoir, hydraulic lines, and
hydraulic system components)
15W-40, API Category CI-4 Engine Oil
A/C Compressor Oil See compressor manufacturer’s recommendations.
Front Wheel Bearing Grease Lithium 12-Hydroxy Stearate, NLGI Grade 1 or 2
Steering & Brake Component Grease 6% Lithium 12-Hydroxy Stearate, NLGI Grade 1
8% Lithium 12-Hydroxy Stearate, NLGI Grade 2
U-Joint & Driveshaft Slip Spline Grease NLGI E.P. Grade 2 Lubricating Grease

Specications 18

General Information
19
Chapter 1– General Information
INTRODUCTION
This manual contains operation and maintenance information for the Gillig Low Floor Bus. The
information pertains to standard installed equipment, common optional equipment, and features. All
information and data in this manual are based on the latest product information available at the time of
publication. The Gillig Corporation reserves the right to make product changes at any time.
Service Bulletins and manual revisions may be published to supplement, supersede, or augment the
information in this manual. The bulletins should be placed in the appropriate places in the manual for
future reference.
IMPORTANT SAFETY INFORMATION
It is your responsibility to be completely familiar with the WARNINGS, CAUTIONS, and NOTICES
described in this Service Manual. These highlighted messages advise against the use of specic service
methods or procedures which can result in personal injury, damage to the equipment, or unsafe operating
conditions. It is important to understand that these messages do not cover every possible situation. Gillig
Corporation could not possibly know and evaluate every single service method, nor could they advise
the service trade of all possible consequences of each method. Accordingly, anyone who uses a service
procedure or tool which is not recommended by Gillig Corporation does so at his or her own risk!
WARNING, CAUTION, and NOTICE messages appear at appropriate places of the manual in special
print. It is critical to the safety of service personnel and to the safe and proper function of the coach that
these messages are carefully observed, especially while undertaking any of the procedures presented in
this manual. WARNINGS, CAUTIONS, and NOTICES appear as follows:
Appears when an operating or service procedure, if not correctly
followed, could result in personal injury or fatality
Appears when an operating or service procedure, if not strictly observed,
could result in damage to the equipment.
Highlights an operating or service procedure which is essential for
proper operation, maintenance, or repair.

General Information 20
Most accidents involving bus operation and maintenance are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before the accident occurs.
Improper operation, lubrication, or maintenance of the coach can be dangerous and could result in injury
or death. Do not perform any lubrication or maintenance on the coach until you read and understand the
instructions in this manual or in the manufacturer-prepared operations and maintenance manuals pro-
vided for the engine, transmission, and other subsystems.
• Do not burn discarded Teon seals; toxic gases are produced.
• Never dry bearings by spinning them with compressed air. Spinning
a bearing without lubrication can damage the bearing or cause it to
disintegrate.
• Attach a “Do Not Operate” tag to the start switches and controls at the
driver’s area and the rear control panel before servicing or repairing
the engine or transmission or attached components.
• Disconnect all batteries before servicing the electrical system.
• Stay clear of all moving parts and do not wear loose clothing or jewelry
while servicing the bus.
• Relieve all pressure in air, hydraulic, oil, fuel, or coolant lines before
any lines, ttings, or related items are disconnected or removed.
• All fuels, most lubricants, and some coolants are ammable and must
be handled with caution.
• Keep all fuels and lubricants in properly marked containers and store
away from all unauthorized persons.
• Store all oily rags or other ammable material in a protective container
and keep the container in a safe place.
• Do not bend or strike high pressure lines. Do not install bent or
damaged lines, tubes, or hoses.
• Disconnect the batteries and I/O system components when arc-welding
anywhere on the coach; this helps to protect sensitive electronics. See
“Welding Precautions” later in this section.
• In some cases, the auxiliary coolant heater (optional) will operate
even with the ignition turned off. This may create a re or exhaust gas
hazard in an enclosed space. Always make sure the coolant heater has
not been unintentionally left on when you leave the bus.