GILLIG LOW FLOOR User manual

1
Service Manual
Hampton Roads Transit
Chassis Numbers: 77621–77660
Coach Numbers: 2000–2039
Customer Name
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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