New Flyer SR542 User manual

OPERATOR’S GUIDE
SR542
King County Dept.
of Transportation
D60HF 1998
542opfr.sec Page 1 Wednesday, November 4, 1998 8:05 AM

Copyright © 1998 New Flyer Industries Ltd. i
VEHICLE
IDENTIFICATION
NUMBERS
This operator’s guide is effective for only those transit vehicles
with the following Vehicle Identification Numbers:
SR500
SR542
Vehicle Identification Number Unit Number
5FYD2NS07WU018292 2300
5FYD2NS09WU018293 2301
Vehicle Identification Number Unit Number
5FYD2NS02WU019009 2302
5FYD2NS09WU019010 2303
5FYD2NS00WU019011 2304
5FYD2NS02WU019012 2305
5FYD2NS04WU019013 2306
5FYD2NS06WU019014 2307
5FYD2NS08WU019015 2308
5FYD2NS0XWU019016 2309
5FYD2NS01WU019017 2310
5FYD2NS03WU019018 2311
5FYD2NS05WU019019 2312
5FYD2NS01WU019020 2313
5FYD2NS03WU019021 2314
5FYD2NS05WU019022 2315
5FYD2NS07WU019023 2316
5FYD2NS09WU019024 2317
5FYD2NS00WU019025 2318
5FYD2NS02WU019026 2319

ii Copyright © 1998 New Flyer Industries Ltd.
SR542 continued
5FYD2NS04WU019027 2320
5FYD2NS06WU019028 2321
5FYD2NS08WU019029 2322
5FYD2NS04WU019030 2323
5FYD2NS06WU019031 2324
5FYD2NS08WU019032 2325
5FYD2NS0XWU019033 2326
5FYD2NS01WU019034 2327
5FYD2NS03WU019035 2328
5FYD2NS05WU019036 2329
5FYD2NS07WU019037 2330
5FYD2NS09WU019038 2331
5FYD2NS00WU019039 2332
5FYD2NS07WU019040 2333
5FYD2NS09WU019041 2334
5FYD2NS00WU019042 2335
5FYD2NS02WU019043 2336
5FYD2NS04WU019044 2337
5FYD2NS06WU019045 2338
5FYD2NS08WU019046 2339
5FYD2NS0XWU019047 2340
5FYD2NS01WU019048 2341
5FYD2NS03WU019049 2342
5FYD2NS0XWU019050 2343
5FYD2NS01WU019051 2344
5FYD2NS03WU019052 2345
5FYD2NS05WU019053 2346
5FYD2NS07WU019054 2347
5FYD2NS09WU019055 2348
5FYD2NS00WU019056 2349
5FYD2NS02WU019057 2350
5FYD2NS04WU019058 2351
5FYD2NS06WU019059 2352
5FYD2NS02WU019060 2353
Vehicle Identification Number Unit Number

Copyright © 1998 New Flyer Industries Ltd. iii
SR542 continued
5FYD2NS04WU019061 2354
5FYD2NS06WU019062 2355
5FYD2NS08WU019063 2356
5FYD2NS0XWU019064 2357
5FYD2NS01WU019065 2358
5FYD2NS03WU019066 2359
5FYD2NS05WU019067 2360
5FYD2NS07WU019068 2361
5FYD2NS09WU019069 2362
5FYD2NS05WU019070 2363
5FYD2NS07WU019071 2364
5FYD2NS09WU019072 2365
5FYD2NS00WU019073 2366
5FYD2NS02WU019074 2367
5FYD2NS04WU019075 2368
5FYD2NS06WU019076 2369
5FYD2NS08WU019077 2370
5FYD2NS0XWU019078 2371
5FYD2NS01WU019079 2372
5FYD2NS08WU019080 2373
5FYD2NS0XWU019081 2374
5FYD2NS01WU019082 2375
5FYD2NS03WU019083 2376
5FYD2NS05WU019084 2377
5FYD2NS07WU019085 2378
5FYD2NS09WU019086 2379
5FYD2NS00WU019087 2380
5FYD2NS02WU019088 2381
5FYD2NS04WU019089 2382
5FYD2NS00WU019090 2383
5FYD2NS02WU019091 2384
5FYD2NS04WU019092 2385
5FYD2NS06WU019093 2386
5FYD2NS08WU019094 2387
Vehicle Identification Number Unit Number

iv Copyright © 1998 New Flyer Industries Ltd.
SR542 continued
SR571
5FYD2NS0XWU019095 2388
5FYD2NS01WU019096 2389
5FYD2NS03WU019097 2390
5FYD2NS05WU019098 2391
5FYD2NS07WU019099 2392
5FYD2NS0XWU019100 2393
5FYD2NS01WU019101 2394
5FYD2NS03WU019102 2395
5FYD2NS05WU019103 2396
5FYD2NS07WU019104 2397
5FYD2NS09WU019105 2398
5FYD2NS00WU019106 2399
5FYD2NS02WU019107 2400
5FYD2NS04WU019108 2401
Vehicle Identification Number Unit Number
5FYD2NS0XXU019468 2402
5FYD2NS01XU019469 2403
5FYD2NS08XU019470 2404
5FYD2NS0XXU019471 2405
5FYD2NS01XU019472 2406
5FYD2NS03XU019473 2407
5FYD2NS05XU019474 2408
5FYD2NS07XU019475 2409
5FYD2NS09XU019476 2410
5FYD2NS00XU019477 2411
5FYD2NS02XU019478 2412
5FYD2NS04XU019479 2413
5FYD2NS00XU019480 2414
5FYD2NS02XU019481 2415
5FYD2NS04XU019482 2416
5FYD2NS06XU019483 2417
Vehicle Identification Number Unit Number

Copyright © 1998 New Flyer Industries Ltd. v
SR571 continued
5FYD2NS08XU019484 2418
5FYD2NS0XXU019485 2419
5FYD2NS01XU019486 2420
5FYD2NS03XU019487 2421
5FYD2NS05XU019488 2422
5FYD2NS07XU019489 2423
5FYD2NS03XU019490 2424
5FYD2NS05XU019491 2425
5FYD2NS07XU019492 2426
5FYD2NS09XU019493 2427
5FYD2NS00XU019494 2428
5FYD2NS02XU019495 2429
5FYD2NS04XU019496 2430
5FYD2NS06XU019497 2431
5FYD2NS08XU019498 2432
5FYD2NS0XXU019499 2433
5FYD2NS02XU019500 2434
5FYD2NS04XU019501 2435
5FYD2NS06XU019502 2436
5FYD2NS08XU019503 2437
5FYD2NS0XXU019504 2438
5FYD2NS01XU019505 2439
5FYD2NS03XU019506 2440
5FYD2NS05XU019507 2441
5FYD2NS07XU019508 2442
5FYD2NS09XU019509 2443
5FYD2NS05XU019510 2444
5FYD2NS07XU019511 2445
5FYD2NS09XU019512 2446
5FYD2NS00XU019513 2447
5FYD2NS02XU019514 2448
5FYD2NS04XU019515 2449
5FYD2NS06XU019516 2450
5FYD2NS08XU019517 2451
Vehicle Identification Number Unit Number

vi Copyright © 1998 New Flyer Industries Ltd.
SR571 continued
5FYD2NS0XXU019518 2452
5FYD2NS01XU019519 2453
5FYD2NS08XU019520 2454
5FYD2NS0XXU019521 2455
5FYD2NS01XU019522 2456
5FYD2NS03XU019523 2457
5FYD2NS05XU019524 2458
5FYD2NS07XU019525 2459
5FYD2NS09XU019526 2460
5FYD2NS00XU019527 2461
5FYD2NS02XU019528 2462
5FYD2NS04XU019529 2463
5FYD2NS00XU019530 2464
5FYD2NS02XU019531 2465
5FYD2NS04XU019532 2466
5FYD2NS06XU019533 2467
5FYD2NS08XU019534 2468
5FYD2NS0XXU019535 2469
5FYD2NS01XU019536 2470
5FYD2NS03XU019537 2471
5FYD2NS05XU019538 2472
5FYD2NS07XU019539 2473
5FYD2NS03XU019540 2474
5FYD2NS05XU019541 2475
5FYD2NS07XU019542 2476
5FYD2NS09XU019543 2477
5FYD2NS00XU019544 2478
5FYD2NS02XU019545 2479
5FYD2NS04XU019546 2480
5FYD2NS06XU019547 2481
5FYD2NS08XU019548 2482
5FYD2NS0XXU019549 2483
5FYD2NS06XU019550 2484
5FYD2NS08XU019551 2485
Vehicle Identification Number Unit Number

Copyright © 1998 New Flyer Industries Ltd. vii
SR571 continued
SR584
5FYD2NS0XXU019552 2486
5FYD2NS01XU019553 2487
5FYD2NS03XU019554 2488
5FYD2NS05XU019555 2489
5FYD2NS07XU019556 2490
5FYD2NS09XU019557 2491
5FYD2NS00XU019558 2492
5FYD2NS02XU019559 2493
5FYD2NS09XU019560 2494
5FYD2NS00XU019561 2495
5FYD2NS02XU019562 2496
5FYD2NS04XU019563 2497
5FYD2NS06XU019564 2498
5FYD2NS08XU019565 2499
Vehicle Identification Number Unit Number
5FYD2NS0XXU019566 2500
5FYD2NS01XU019567 2501
5FYD2NS06XU020374 2502
5FYD2NS08XU020375 2503
5FYD2NS0XXU020376 2504
5FYD2NS01XU020377 2505
5FYD2NS03XU020378 2506
5FYD2NS05XU020379 2507
5FYD2NS01XU020380 2508
5FYD2NS03XU020381 2509
5FYD2NS05XU020382 2510
5FYD2NS07XU020383 2511
5FYD2NS09XU020384 2512
5FYD2NS00XU020385 2513
5FYD2NS02XU020386 2514
5FYD2NS04XU020387 2515
Vehicle Identification Number Unit Number

viii Copyright © 1998 New Flyer Industries Ltd.
SR584 continued
5FYD2NS06XU020388 2516
5FYD2NS08XU020389 2517
5FYD2NS04XU020390 2518
5FYD2NS06XU020391 2519
5FYD2NS08XU020392 2520
5FYD2NS0XXU020393 2521
5FYD2NS01XU020394 2522
5FYD2NS03XU020395 2523
5FYD2NS05XU020396 2524
5FYD2NS07XU020397 2525
5FYD2NS09XU020398 2526
5FYD2NS00XU020399 2527
5FYD2NS03XU020400 2528
5FYD2NS05XU020401 2529
5FYD2NS07XU020402 2530
5FYD2NS09XU020403 2531
5FYD2NS00XU020404 2532
5FYD2NS02XU020405 2533
5FYD2NS04XU020406 2534
5FYD2NS06XU020407 2535
5FYD2NS08XU020408 2536
5FYD2NS0XXU020409 2537
5FYD2NS06XU020410 2538
5FYD2NS08XU020411 2539
5FYD2NS0XXU020412 2540
5FYD2NS01XU020413 2541
5FYD2NS03XU020414 2542
5FYD2NS05XU020415 2543
5FYD2NS07XU020416 2544
5FYD2NS09XU020417 2545
5FYD2NS00XU020418 2546
5FYD2NS02XU020419 2547
5FYD2NS09XU020420 2548
5FYD2NS00XU020421 2549
Vehicle Identification Number Unit Number

Copyright © 1998 New Flyer Industries Ltd. ix
SR584 continued
5FYD2NS02XU020422 2550
5FYD2NS04XU020423 2551
5FYD2NS06XU020424 2552
5FYD2NS08XU020425 2553
5FYD2NS0XXU020426 2554
5FYD2NS01XU020427 2555
5FYD2NS03XU020428 2556
5FYD2NS05XU020429 2557
5FYD2NS01XU020430 2558
5FYD2NS03XU020431 2559
5FYD2NS05XU020432 2560
5FYD2NS07XU020433 2561
5FYD2NS09XU020434 2562
5FYD2NS00XU020435 2563
5FYD2NS02XU020436 2564
5FYD2NS04XU020437 2565
5FYD2NS06XU020438 2566
5FYD2NS08XU020439 2567
5FYD2NS04XU020440 2568
5FYD2NS06XU020441 2569
5FYD2NS08XU020442 2570
5FYD2NS0XXU020443 2571
5FYD2NS01XU020444 2572
5FYD2NS03XU020445 2573
Vehicle Identification Number Unit Number

The information contained in this manual is updated periodically. While great care is taken in
compiling the information contained in this manual, New Flyer Industries Ltd. cannot assume
liability for losses of any nature arising from any errors and/or omissions.
The information and specifications contained throughout this manual are up to date at the time
of publication. New Flyer Industries Ltd. reserves the right to change the content of this manual
at anytime without notice.
Printed in Canada
xCopyright © 1998 New Flyer Industries Ltd.
Copyright © 1998 NEW FLYER INDUSTRIES LIMITED.
ALL RIGHTS RESERVED.
No part of this manual and/or data herein may be
reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopying, recording,
or information recording and retrieval systems, for any
purpose, without the express written permission of
New Flyer Industries Limited.
“New Flyer” is a tradename of “New Flyer Industries Limited”

 NOTE:
Effective with this publication, the National Highway Traffic Safety
Administration (NHTSA) has requested that the following statement
be provided for your information.
If the property believes that its vehicle has a defect which could
cause a crash or could cause injury or death, inform the National
Highway Traffic Safety Administration (NHTSA) in addition to
notifying New Flyer Industries Limited.
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 and New
Flyer Industries Limited.
To contact NHTSA either call the Auto Safety Hotline toll-free at
1-800-424-9393 (or 366-0123 in the Washington, DC area) or write
to: NHTSA, U.S. Department of Transportation, Washington, DC
20590. Other information about motor vehicle safety can be
obtained from the Hotline.
Copyright © 1998 New Flyer Industries Ltd. xi

Table of Contents
xii Copyright © 1998 New Flyer Industries Ltd.
INTRODUCTION .................................................................. 1
Vehicle Specifications....................................................... 2
Vehicle Identification......................................................... 5
Warnings & Cautions........................................................ 5
SAFETY INFORMATION ..................................................... 7
Safety Procedures ............................................................ 7
Safety Equipment ............................................................. 8
Emergency Exits............................................................... 8
The Interlock System...................................................... 11
Exit Door Sensitive Edges .............................................. 12
IMPORTANT ACCESS POINTS ........................................ 13
Side Console Components............................................. 13
Locker Control Switches................................................. 13
PLC Components ........................................................... 14
Fuel Filler Access Door .................................................. 14
Engine Access Doors ..................................................... 15
Wheelchair Lift Access Door .......................................... 15
Sander Access Doors..................................................... 16
Surge Tank Access Door................................................ 16
Articulated Joint Access Doors....................................... 16
Battery Access Door....................................................... 17
Quarter-Turn Latches ..................................................... 17
Towing Connections ....................................................... 18
TO ENTER THE VEHICLE................................................. 19
DRIVER’S CHECK LIST .................................................... 20
Exterior ........................................................................... 20
Interior ............................................................................ 21
DRIVER’S AREA................................................................ 29
Driver’s Window.............................................................. 29
Driver’s Seat ................................................................... 31

Copyright © 1998 New Flyer Industries Ltd. xiii
Steering Wheel & Horn................................................... 33
Public Address System .................................................. 34
Destination/Route Signs................................................. 36
Mirrors ............................................................................ 39
Roller Blinds ................................................................... 39
Fire Suppression System ............................................... 41
INSTRUMENTATION & CONTROLS ................................ 43
Instrument Panel ............................................................ 43
Driver’s Climate Controls................................................ 56
Side Console Switch Panel ............................................ 57
Foot Operated Controls.................................................. 65
Miscellaneous Controls .................................................. 66
VEHICLE OPERATION...................................................... 69
Pre-Start Checks & Adjustments.................................... 69
Transmission Operation ................................................. 69
Retarder Operation......................................................... 71
Anti-Lock Braking System Operation ............................. 72
Starting the Engine......................................................... 73
Day-Time Operation....................................................... 76
Night-Time Operation..................................................... 77
Pre-Trip Brake Test........................................................ 78
Moving the Vehicle......................................................... 79
Parking the Vehicle ........................................................ 80
Jump Start Connection................................................... 82
Operating the Vehicle in Reverse................................... 82
Engine Protection System .............................................. 82
Fire Suppression System Operation .............................. 83
Passenger Signal System .............................................. 85
WHEELCHAIR SYSTEM.................................................... 87
Wheelchair Lift................................................................ 87
Wheelchair Restraint System ......................................... 97
BIKE-RACK SYSTEM........................................................ 99
Loading Operation.......................................................... 99
Unloading Operation ...................................................... 99
NOTES ............................................................................. 100

xiv Copyright © 1998 New Flyer Industries Ltd.

INTRODUCTION
Copyright © 1998 New Flyer Industries Ltd. 1
1. INTRODUCTION
This manual describes the operating features and safety equip-
ment of the New Flyer D60HF Transit Vehicle. All personnel
involved in the operation of the vehicle should be acquainted with
this manual and should familiarize themselves with the D60HF,
before providing any public service. Knowing the contents of this
booklet and following its recommendations will help to assure safe
and trouble-free operation.
It is not the intention or responsibility of this manual to give
instruction in the use of common sense, basic skills and rules of
driving; therefore, it is assumed that you, the operator, are fully
qualified to operate a public transit vehicle.
This manual and any other supplied should be considered a
permanent part of the vehicle and remain with the vehicle at all
times. The information and specifications throughout this manual
are up to date at time of publication. New Flyer reserves the right
to change the content of this manual at any time without notice.
Any malfunction which interferes with the safe operation of the
vehicle should be reported immediately to the control center.
☞NOTE:
New Flyer urges you the driver to read this publication carefully,
as well as the following manuals which are readily available from
the respective manufacturer.
• Allison Transmission B500R Operator’s Manual SA2157H
• Cummins Operation and Maintenance Manual M11 Plus
Series Engines

INTRODUCTION
2Copyright © 1998 New Flyer Industries Ltd.
VEHICLE SPECIFICATIONS
D60 Foot High Floor Transit Vehicle
ENGINE & FUEL
Engine ........................................................................... Cummins M11E
Horsepower..............................................................315 HP- 1040 ft. lb.
Fuel.....................................................................................No. 2 Diesel
Fuel Capacity....................................................120 US Gallons, usable
TRANSMISSION
Allison World Transmission..........................................................B500R
Self-Contained Retarder ..................................... 100% Brake Activated
DIMENSIONS
Length (over bumpers).................................................. 60.7 ft. (18.5 m)
Width............................................................................... 8.5 ft. (2.57 m)
Height.............................................................................. 10.0 ft. (3.0 m)
Wheelbase Front............................................................. 16.8 ft. (5.1 m)
Wheelbase Rear............................................................. 25.7 ft. (7.8 m)
Turning Radius................................................................. 41 ft. (12.5 m)
Pivot Angle........................................................................................ 40°
Vehicle weight (approx.)......................................43,000 lbs (19,505 kg)
AXLES & SUSPENSION
Front Axle ...................................................................... Rockwell 17101
Front load-carrying capacity...................................14,600 lb. (6,620 kg)
Rear & Center Axle
....................................................... Rockwell 61053
Rear & Center load-carrying capacity................. 26,000 lb. (11,790 kg)
Final Drive Ratio ...........................................................................4.56:1
Suspension........................................... Air Springs & Shock Absorbers

INTRODUCTION
Copyright © 1998 New Flyer Industries Ltd. 3
DESTINATION & ROUTE SIGNS
Front Destination ....................................................Luminator Electronic
Side Destination
.....................................................Luminator Electronic
Street Side Route
.........................................................Transign Manual
Run Number
...........................................................Luminator Electronic
LIGHTING
Interior .....................................Transmatic – Fluorescent, 24 volt, top lit
HEATING SYSTEM
Heater Units......................... 2 Thermo King THU8.MB underfloor units
Auxiliary Heater
............................ Mobile Climate Control defroster unit
SEATING
Driver’s .......................................................................USSC 9110 ALX3
Passenger
..................................................... American Seating KC 548
Seating Capacity.................................................................................64
Wheelchair Stations...........................................2 (seats fold up & lock)
BRAKE SYSTEM
Mechanical Components........................Internal expanded S-Cam type
.......................................................................Automatic slack adjusters
Service Brake................................................................Full air operated
.............................................................................ABS & ATC controlled
Parking Brake .............................................Spring applied, air released
Emergency Brake...................................................Spring brake applied
.........................................................Brake treadle modulated to control
D60 Foot High Floor Transit Vehicle

INTRODUCTION
4Copyright © 1998 New Flyer Industries Ltd.
WINDOWS
General.................................. Black Anodized Frame – single top tip-in
..........................................................................................(bottom fixed)
..................................................... Glazing – laminated glass, 44% grey
Emergency Escape...................................................... All side windows
Driver’s Window......................2 Piece sliding – interior, exterior handle
DOORS
Entrance .........................Vapor slide glide – 34.0" between lift grabrails
Exits
....................................Vapor slide glide – 38.0" between grabrails
......................................................................Driver controlled operation
Controls............................................. 5 position opening-closing control
......................................................................Door manual control valve
SAFETY FEATURES
Emergency Escape Exits............................................. All side windows
.........................................................................................3 roof hatches
Fire Suppression System
........................................................... Amerex
Safety Triangles..............................................Right front wheelhousing
Fire Extinguisher............................................................5 lb. ABC rating
Exit Door......................................................Emergency release control
............................................................ Accelerator and brake interlocks
...................................................................................... Sensitive edges
D60 Foot High Floor Transit Vehicle

INTRODUCTION
Copyright © 1998 New Flyer Industries Ltd. 5
Vehicle Identification
The New Flyer vehicle identification plate is located in the driver’s
area, above and to the left of the driver’s seat. The plate lists the
Gross Vehicle Weight Ratings (GVWR), the Vehicle Identification
Number (VIN) and the Gross Axle Weight Ratings (GAWR) for all
axles.
Warnings & Cautions
Two types of headings are used in this guide to attract your atten-
tion. These notations will be highlighted with the icons below.
WARNING:
Used when an operating procedure or practice, if
not correctly followed, could result in personal
injury or loss of life.
CAUTION:
Used when an operating procedure or practice, if
not strictly observed, could result in damage to or
destruction of equipment.