MCI Motor Coach Industries Manuals PDF - Bus & Coach Manuals PDF, Wiring Diagrams, Fault Codes
J4500 OPERATORS MANUAL TABLE OF CONTENTS SUBJECT PAGE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Daily Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Switches, Warning Lights and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Steering Column and Floor-Mounted Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Operating Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Wheelchair Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Engine Operation, Fuel and Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Emergency Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Heating and Air Conditioning (HVAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Audio and Video System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 INTRODUCTION Typical illustrations may be used, therefore minor illustration differences may exist when compared to actual parts or other publications COACH APPLICABILITY This manual supports the MCI J4500 Coach. TO THE DRIVER This manual has been prepared to provide you with the information you need to operate the MCI J4500 Series Coach. The specifications and information throughout this manual are subject to change without notice. CERTIFICATION PLATE The certification plate (Figure 1.) is mounted beside the driver's seat, and certifies compliance with all applicable Federal Motor Vehicle Safety Standards in effect on the date of manufacture. It also lists the date the coach was built, the GVWR, GAWR's, rim size, tire pressures, coach model and coach serial number. EMISSION CONTROL DECAL The emission control decal (Figure 2.) is affixed to the lower panel next to the driver's seat, beside the certification plate shown in Report immediately any problem or malfunction that interferes with the operation of the coach, particularly if safety may be affected. The term "Optional" in this manual pertains to all equipment and features other than basic. MCI SERVICE NUMBER: 1-800-241-2947 This manual is a permanent part of this vehicle. It must stay with the coach if the coach is sold. PUBLICATION DATE: July 2015 EFFECTIVE WITH UNIT NUMBER 67310 MCI PUBLICATION PART #.: 03-26-1035B Figure 2. COACH NAMEPLATE The nameplate (Figure 3.) is mounted in the engine compartment at the rear of the coach. The vehicle identification number (VIN), model year and date of manufacture are shown on this plate. Figure 1. July 2015 Figure 3. 1 VEHICLE IDENTIFICATION NUMBER (VIN) The nameplate and the certification plate both contain the seventeen-character vehicle identification number (VIN).The numbers correspond to the items in the following list. 1. The first three characters identify the manufacturing company: 1M8 = MCI Inc. (U.S.) 2MG = MCI Ltd. (Canada) 2. The fourth character identifies the coach model: 3 = J4500 Intercity 3. The fifth character identifies the series: J = J-Series 4. The sixth character identifies the type of coach: M = Intercity (MCI) P = Incomplete Vehicle 5. The seventh character identifies the type of engine: B = Cummins ISX 8 = Detroit Diesel DD13 6. The eighth character identifies the type of brakes: A = Air Brake Intercity 7. The ninth character is the check number. 8. The tenth character identifies the year: G = 2016 9. The eleventh character identifies the manufacturing location: W = Winnipeg, Manitoba 10. The twelfth through seventeenth characters is the coach's unit number. 2 July 2015 INTERNATIONAL SYMBOLS Some of the following international symbols may be on controls and components of this coach (Figure 4.). 1. Parking Brake 2. Anti-Lock Brakes 3. Stop Engine 4. Check Engine 5. Do Not Shift 6. Retarder Hot 7. Protect Eyes By Shielding 8. ECAS Stop 9. Suspension Recover 10. Entrance Door Open 11. Entrance Door Close 12. Fog Lights 13. Window & Aisle Lights 14. Aisle Lights 15. Drivers Light 16. Step Lights 17. Reading Lights 18. Blinds Up 19. Blinds Down 20. Master Power 21. Engine Start 22. Fast idle 23. Engine Brake 24. Retarder 25. Baggage Doors Unlock July 2015 Figure 4. 26. Baggage Doors Lock 27. Kneel 28. Spark Could Explode Battery 29. Avoid Sparks Or Flames 30. Drivers Area HVAC 31. Lights Or High Beam 32. Clearance Lamps 33. Turn Signals 34. Hazard Warning 35. Engine Oil Pressure 36. Engine Oil Temp 37. Engine Coolant Temp 38. Windshield Wipers 39. Acid Cause Burn 40. Caution Possible Injury 41. Lighter 42. Battery Charging System 43. Horn 44. Air Pressure 45. Fasten Seat Belt 46. Ventilating Fan 47. Windshield Defrost 48. Windshield Washer 49. Passenger Area HVAC 3 THIS PAGE INTENTIONALLY LEFT BLANK 4 July 2015 DAILY INSPECTIONS The following checks are in addition to the Federal Motor Carrier Safety Administration requirements, not instead of them. EXTERIOR INSPECTION 1. Ensure that all windows, mirrors and lights are clean and unobstructed. 2. Ensure that all side windows are closed. A protrusion of 1/4" (6mm) or more indicates that a window in not properly latched. 3. Check that the coach exterior is clear of debris, and that all service doors are secure. 4. Check the tire pressure and inspect the tires for damage. Check that the wheel nuts are tight and inspect the wheels for damage. 5. Look under the coach for fluid leaks, animals or obstructions. Check behind the coach. 6. Check the engine oil level, coolant level, condition of belts and power steering fluid level. 7. Check the engine compartment to ensure that there are no loose or unsecured objects. 8. Check the windshield washer reservoir and fill if required. INTERIOR COMPONENTS CHECKLIST 1. Ensure that the door(s), hatches and emergency exit windows open, close, seal and latch properly. 2. Ensure that the parcel rack doors are latched. 3. Inspect the seats and floor for debris. Clean if necessary. 4. Ensure that the interior and step-well lights work. 5. Ensure that the lavatory door, windows and wheelchair access door (if equipped) are closed and latched. 6. Ensure that emergency equipment and contents are in place and properly stowed. 7. Activate the entertainment control module and verify the operation of the driver's and cordless microphones (if equipped). Adjust output volume if necessary. 9. Ensure that the engine compartment remote control box ENGINE ENABLE switch is ON and the STARTER CONTROL switch is set to FRONT. 10. Turn ON the main electrical switch. Before starting ensure that the fast idle is OFF and the parking brake is applied. Ensure that there is ample distance ahead of and behind the coach in case it moves unexpectedly during starting. DO NOT rev the engine while starting. July 2015 5 The following checks are in addition to the Federal Motor Carrier Safety Administration requirements, not instead of them. OPERATIONAL CHECKLIST 1. While the engine is running, look for oil or coolant leaks and listen for air leaks. 2. While the engine is running, check the alternator lights on the remote control box in the engine compartment. The lights should be OFF. 7. Position the inside and outside mirrors, adjust the driver's seat and fasten the seat belt. 8. Ensure that the tilt steering column is locked. 9. Ensure that the defroster, heater, horn, windshield wipers and washers all function. Be very careful when the engine is running and the engine door is open. If it is necessary to have the engine running for certain inspections or checks, keep a safe distance from moving belts, pulleys, shafts or fans. Keep hands and limbs away from moving belts and pulleys and also hot areas such as exhaust and turbocharger components and coolant lines. Do not wear loose, baggy or frayed clothing when working near any moving parts such as pulleys, belts, shafts or fans. 3. Close and secure all baggage and service doors. 4. Ensure that all exterior lights are working. 5. If the coach is equipped with a wheelchair lift, check the lift operation. For more information refer to the vendor manual. 6. After the HVAC system has stabilized (10 to 15 minutes), listen for abnormal noises in the compressor and fan motors; check the compressor oil level and check the refrigerant level. Ensure that the self-test has been performed successfully and that there are no errors or alarms indicated. Do not move the coach until the front and rear air gauges both read at least 100 psi. 10. Apply the service brakes, release the park brake, then release the service brakes. 11. Apply and hold the brakes and observe the pressure drop. It should not drop by more than 3 psi in 1 minute. 12. Move the coach slowly and bring it to a stop to ensure that the brakes stop and hold the coach. 13. Ensure that brake pedal operation feels normal. 14. Ensure that all gauges stay in normal range. 15. Move the coach a short distance at low speed and check the steering. Ensure that the coach is under full control and handling properly. The steering wheel must turn smoothly without any unusual noises. 6 July 2015 DRIVER'S SEAT BELT MIRRORS Driver's Seat Belt Adjustment Inside Rear-view Mirrors (Optional) The inside rear-view mirrors can be manually adjusted up, down or sideways. Using the restraint system can lessen the severity of injury in an accident or sudden maneuver. While seated straight and well back into the seat, adjust the belt as necessary. To unfasten the belt, push the release button. If a belt jams, you may be able to release it by working the belt in and out until the belt rewinds far enough to unlock. If the belt remains jammed or other restraint system parts do not work properly, report the condition to service personnel promptly. Seat Belt Inspection Every 30 days, check the belt, buckle, latch plate, retractor and guide loops for proper operation. Check for loose or damaged parts. Keep sharp edges and sharp objects away from belts and other parts of the restraint system. Keep the belts clean and dry. Replace belts if the webbing appears frayed, cut or damaged. Replace belts that have been involved in an accident. Have parts replaced if there are any questions as to their condition. Clean seat belts with mild soap and lukewarm water only; do not bleach or dye. Exterior Rear-view Mirrors Exterior mirrors have separate upper and lower segments. The convex upper portion is for wideangle view. Adjust the exterior mirrors so that you can see the side of the coach in part of the mirror. This helps determine the relationship of the coach to objects seen in the mirror. The roadside and curbside mirror controls are on the lower LH console switch panel. Use the switch in the center of each mirror control to select the upper or lower mirror. Move the switch to the left to adjust the lower mirror and to the right to adjust the upper mirror. Defrost the mirrors using the mirror heat switch located below the mirror controls. July 2015 7 PRE-TRIP INSPECTION, INTERIOR / EXTERIOR LIGHTING Before the Pre-Trip Inspection function is enabled, these functions must be met: · Position the Master Power switch to the "ON" position, · Select "NEUTRAL" on the transmission Shift Pad selector, · Set the Park Brake, · Position the Reading Light test switch to the "ON" position. · Apply and hold a service brake application of 60 psi, Only after these conditions are met, the Pre-Trip Inspection function is enabled, automatically activating all interior / exterior coach lighting and dash tell-tale lights and buzzer will activate for two (2) minutes. ANTI-THEFT PRECAUTIONS 1. Do not leave the coach unattended with the engine running. 2. Park in a lighted spot when possible. 3. Fully close all windows and doors. 4. Keep valuable items out of sight. 5. Lock out the battery disconnect switch The back-up lights do not illuminate during the Pre-Trip Inspection. The Pre-Trip Inspection function can be canceled by positioning the Reading Light test switch to "OFF", or positioning the Hazard switch to "ON". 8 July 2015 SWITCHES, WARNING LIGHTS AND GAUGES Figure 5. Driver Area 1. Instrument Panel, refer to Page 20 2. LH / RH Tell-Tale Cluster, refer to Pages 10-13 3. LH Switch Panel, refer to Pages 15 4. RH Switch Panel, refer to Pages 16 5. Lower, LH Console Switch Panel, Page 17 6. HVAC Display, refer to Page 15 July 2015 9 TELL-TALE LAMPS Tell-tales indicate various conditions by lighting. In general, yellow indicates system status and red indicates a fault or warning. Tell-tales are located in RH and LH clusters, in the instrument cluster. Some tell-tales are accompanied by a buzzer or bell. At system start-up, tell-tales light briefly to show that the LEDs work. LEFT-HAND TELL-TALE CLUSTER (Figure 6.) Figure 6. ACTIA LH Tell-tale Cluster Left Turn Indicator (Green) Regeneration (DPF) (Yellow) - Tell-tale illuminates when a regeneration is required. Tell-tale is OFF during Regen. Wait to Start (Yellow) - This tell-tale will illuminate when the grid heater is ON (pre-heat function). Check Engine (Yellow) - Engine fault. Refer to vendor manual. Stop Engine (Red) - Engine is powering down or stopped. Low Coolant (Yellow) - Tell-tale indicates a low engine coolant level. Do not run engine until condition is corrected. Not Generating (Red) - Tell-tale indicates that one or both alternators are not functioning. High Exhaust Temperatures (HET) (Yellow) - Tell-tale will illuminate when the coach is moving less than 5 mph (approx.) and the exhaust outlet temperature exceeds the predetermined level. Diesel Exhaust Fluid (DEF) (Yellow) - Telltale illuminates indicating the DEF level is low. Correct by refilling the DEF tank. DEF tell-tale flashes indicating the DEF level has fallen below a critical level. Correct by refilling the DEF tank. DEF tell-tale flashes and Check Engine illuminates indicating the DEF level is critically low and power loss will occur. Normal engine power will be restored by refilling the DEF tank. DEF tell-tale flashes and Check Engine and Stop Engine illuminates indicating the DEF tank has been run dry. Engine will De-rate and limit speed to 5 MPH. Normal engine power and coach speed will restored by refilling the DEF tank. 10 July 2015 MIL (Yellow) - Malfunction Indicator Tell tale Lamp (on DD13 engines ONLY). Telltale indicates a failure of an emission system component. Blank Water in Fuel (Yellow) - Tell-tale indicates water in the fuel filter. Park Brake Applied (Red) Trailer Park (Red) - Tell-tale is disabled. ABS (Yellow) - Tell-tale indicates anti-lock braking system malfunction. Electronic Stability Control / Automatic Traction Control (Yellow) - Tell-tale indicates an Electronic Stability Control (ESC) or an Automatic Traction Control (ATC) event. Brake Lights (Green) - Tell-tale illuminates throughout the service brake application. Engine Brake (Yellow) - Tell-tale indicates the engine brake is activated. Check Transmission (Yellow) - Move the coach to a safe location and turn OFF ignition. DO NOT change gear. Stop Transmission (Red) - Tell-tale is disabled. Retarder Temperature (Red) - Tell-tale illuminates when retarder oil temperature is above 168 degrees Celsius for more than ten (10) seconds. Brake Wear (Yellow) - Tell-tale is disabled. Fuel Filter Restriction (Yellow) Indicates the fuel filter has been clogged. Tag Lock Fault (Red) - Tell-tale illuminates when coach speed reaches 15 mph and the tag cylinder does not lock. Tell tale is OFF when coach speed returns to 10 mph. No Hill Start (Yellow) - Tell-tale is disabled. July 2015 11 RIGHT-HAND TELL-TALE CLUSTER (Figure 7.) Figure 7. ACTIA RH Tell-tale Cluster Driver Seat Belt (Red) - Tell-tale lights when park brake is released and the driver's seat belt is not buckled. Check Info (Yellow) - Tell-tale indicates message on alphanumeric display of speedometer. Refer to next page for further information. High Ride (Red) - Tell-tale will illuminate and a buzzer sounds when the coach is in transition and is maintained in HIGH RIDE. Low Ride (Red) - Tell-tale flashes when the coach is in transition to and is maintained in LOW RIDE. Low Fuel (Yellow) Cruise Enabled (Green) - Tell-tale indicates that the cruise control is activated. High Beams (Blue) - Hi-beam tell-tale will illuminate when the main headlamps are on HIGH intensity. Right Turn Indicator (Green) Ride Fault (Red) - Tell-tale illuminates when a fault has occurred in the MDSS. Report problem to maintenance personnel. Kneel (Red) - Tell-tale flashes and a buzzer sounds when the coach is kneeling or recovering. When kneel is reached, the lamp stays on and the buzzer stops. Tag Unload (Red) - Tell-tale Illuminates when the tag axle is unloaded. Rear Rise (Red) - Tell-tale illuminates and a buzzer sounds when the Rear Rise switched is pressed. WCL Door Open (Red) - Tell-tale will illuminate indicating door ajar or unlocked condition. 12 July 2015 WCL Interlock (Red) - Tell-tale illuminates when the wheelchair lift interlock is activated. The wheelchair interlock system, when activated, disables the transmission shift and throttle, sets the park brake solenoid, and begins engine fast idle. Front Door Open (Red) - Tell-tale light illuminates when the entrance door is open. WCL Stop Request (Blue) - Illuminates when a passenger in the wheelchair area presses the stop button. Stop Request (Yellow) - Tell-tale lights when a passenger presses the stop request button. Aux. Heat (Yellow) - Illuminates when the auxiliary heater has been activated. Fire Alarm (Red) - Illuminates when the temperature sensors sense heat from a fire in the engine compartment. Emergency Lights (Yellow) - Tell-tale is disabled. Dock Lights (Blue) - Tell-tale is disabled. Check Lube (Yellow) - Tell-tale is disabled. Back-up Alarm Off (Yellow)- Tell-tale is disabled. Lavatory Emergency (Yellow)- Tell-tale illuminates when a passenger presses the emergency button in the lavatory. CHECK INFO TELL-TALE The CHECK INFO tell-tale illumination indicates that a message regarding additional tell-tale information is displayed on the alphanumeric display of speedometer. Dependant of the message displayed, a buzzer may accompany the message. Move the coach to a safe parking area to view the message displayed on the alphanumeric display of speedometer. After the message has been recorded, the operator can press the TRIP button (RH side of the speedometer, refer to Figure 8.) to dismiss the message. The CHECK INFO tell-tale will remain illuminated, but the message will not appear in the alphanumeric display of speedometer until the system re-broadcasts the signal. The tell-tale information displayed on the alphanumeric display of speedometer are Lavatory Emergency (displayed as LAVTORY), Baggage Lights (BAG LTS), Low Ride (LOWRIDE), Digital Wheel End Sensor (WHL END) and Fire Alarm. Service Lights (Yellow) - Tell-tale indicates engine compartment. light is ON. Bike Rack (Yellow) - Tell-tale is disabled. Figure 8. Speedometer Alphanumeric display July 2015 13 Figure 9. 4 in 1 Gauge 4 IN 1 GAUGE TELL-TALES (Figure 9.) 1. Front Air PSI 3. Water Temperature The low air warning tell-tale illuminates when the air pressure drops below the pre-determined level. In the event of a low air warning, stop the coach and determine the cause of air loss before proceeding. 2. Rear Air PSI The low air warning tell-tale illuminates when the air pressure drops below the pre-determined level. In the event of a low air warning, stop the coach and determine the cause of air loss before proceeding. The tell-tale illuminates when the coolant temperature is above normal. Obtain service as soon as possible. 4. Oil Pressure The tell-tale illuminates when the oil pressure is too low. Low air pressure will illuminate the LOW AIR lamp and a buzzer will sound, indicating that the air pressure is too low. Stop coach and determine reason for pressure loss. DO NOT operate the coach under 100 psi air pressure. 14 July 2015 5. Override - Press to override an emergency engine shutdown for 30 seconds. Press as often as necessary to move coach to safe parking. This switch allows the operator to override an emergency shutdown due to an engine malfunction. Pressing the switch allows the operator to run the engine for an additional 30 seconds so that the operator can move the coach to a safe parking area. Figure 10. - LH Switch Panel LEFT-HAND SWITCH PANEL (Figure 10.) 1. Fog Lights Switch 2. Mirror Heat Switch - Press this switch to clear the mirrors of fog and frost. 3. Parcel Rack Blower Switch - The PARCEL RACK switch turns the parcel rack blowers ON and OFF 4. Auxiliary Heater Switch - When the engine is OFF, the engine can be preheated by pushing the AUXILIARY HEATER switch forward, which activates a 90 minute timer in the Proheat unit. When the Proheat burner is ON, the HEATER ON telltale lights. To turn the Proheat OFF, push the switch back. It will purge for 2 to 3 minutes. If the coach is started during preheating, the temperatureDependant control overrides the timer. In a driving situation, the override switch should be utilized only to safely move the coach to a safe parking area. The engine overrule feature is not intended to provide a"limp home" capability. This feature should not be utilized to extend coach driving to a garage or other destination, as engine damage may result from over-extension of the safety feature limitations. 6. Master Power Switch - Pressing this switch to the ON (upper) position will enable all of the multiplex modules and turn on the coach's electrical system. 7. Engine Start Switch - Used to start the coach using the rocker switch ignition. To START the coach using the rocker switch ignition, place the master power switch in the ON (upper) position. Press the upper portion of the engine start momentary-on spring return switch to engage the starter. Release the switch once the coach has started. Allow the coach to idle for 30 seconds. To STOP the engine, place the master power switch in the OFF (lower) position. July 2015 15 Figure 11. RH Switch Panel RIGHT-HAND SWITCH PANEL (Figure 11.) 1. Interior Light 2. Reading Lights - Turns reading lights ON and OFF. 3. Blank Switch 8. Entrance Door Open/Close - Press and hold the upper half of the switch to open the door. Press and hold the lower half of the switch to close the door. Door movement stops if the switch is released. 4. Baggage Bay Lights - Turns the baggage bay lights ON and OFF. The baggage bay lights have a timer feature that automatically shuts OFF the lights after 30 minutes, if the switch is left in the ON position. 5. LH Baggage Lock - Locks and unlocks the lefthand baggage doors. 6. RH Baggage Lock - Locks and unlocks the right-hand baggage doors. 9. Panel Lights 10. Driver's Light - Turns lights on in the driver's compartment. 11. Step-well Lights - When this switch is ON, the step-well lights turn ON whenever the entrance door opens. 12. Blue LED Light 13. Blank Switch 7. Kneeling - With the park brake applied, the transmission in Neutral and the entrance door closed, press and hold the KNEEL half of the switch to lower the front of the coach 5" (127 mm). 14. Hazard/Warning Lights - Flashes all front, rear and side-mounted turn signal lights and both telltales simultaneously. 16 July 2015 Figure 12. Lower LH Console Switch Panel LOWER LH CONSOLE SWITCH PANEL (Figure 12.) 1. Cup Holder 2. Headlight Switch 3. Mirror Controls - Adjust the RH and LH exterior mirror heads (upper and lower). 4. 110 Volt 5. Tag Lock / Auto Switch Press the upper half, LOCK, of the momentary switch to lock the tag cylinder. The CHECK INFO tell tale flashes and the alphanumeric display on the speedometer will display TAG LOCK. When coach speed reaches 15 mph, the alphanumeric display on the speedometer will stop displaying the TAG LOCK message. When coach speed reaches 10 mph and lower, the tag cylinder will remain locked and the alphanumeric display on the speedometer will display the TAG LOCK message. The tag cylinder can only be unlocked by pressing the lower half, AUTO, of the momentary switch or by cycling the ignition. 6. Mud/Snow - On extra soft surfaces (snow, mud or gravel), press the MUD/SNOW switch to increase traction by slightly increasing permissible wheel spin. The LOW TRACTION or ESC / ATC telltale will blink continuously when MUD/SNOW is active. Press the switch again to turn off MUD/SNOW. (Turning off the ignition also resets the MUD/SNOW feature.) 7. Fast Idle - Place the transmission in Neutral, apply the parking brakes and turn FAST IDLE on to increase engine idle speed for engine warm-up, air pressure build-up or A/C operation when the coach is parked. Return the switch to normal when fast idle is not required. 8. Tag Axle Unload - Press to unload the tag axle to improve traction on the drive axle. Press again to transfer the load back to the tag axle. Only unload the tag axle in low traction situations. July 2015 17 LOWER LH CONSOLE SWITCH PANEL Cont'd 9. Rear Rise 10. Level Control Switch - Press the UPPER half of the switch to raise the front and rear suspension to the High Ride parameter height. Press the LOWER half to lower the front and rear suspension to Low Ride parameter height. 11. Normal Ride / Recover - Press switch to change front and rear suspension to Normal Ride height. 12. LH Blind Switch 13. RH Blind Switch 14. 12-Volt Power Source 15. Automatic Transmission Control 16. Wheelchair Master Switch (Optional) 17. Emergency Park Brake Release 18. Front Service Compartment Door Release Figure 13. 18 July 2015 Regeneration Switch The regeneration toggle switch is located in the rear, side service compartment (Figure 14.). PARKING BRAKES The coach has air-operated spring parking brakes. The PARKING BRAKE control is a black, button located under the LH switch panel (Figure 15.). To avoid serious personal injury or property damage, ensure that no persons or objects are at or within two feet of the exhaust outlet at any time during a regeneration. Ensure that exhaust and outlet are clear of any trash, grasses, or other vegetation or debris. Use extreme caution during a stationary regeneration, as exhaust gas tail pipe outlet temperatures can exceed 900 degrees F (482 degrees C). Stationary regenerations are to be performed outdoors only. DO NOT leave the coach unattended during a stationary regeneration. DO NOT perform inside a garage or maintenance facility. DO NOT attach an exhaust extraction hose to the exhaust outlet. Do not leave the coach without applying the parking brake. Figure 15. Parking Brake Knob Normal Park Brake Operation 1. Stop the coach, put the transmission in neutral. 2. Pull the park brake knob out (Figure 15.) to set the park brake. The valve will latch in this position. 3. Ensure that the air pressure gauge shows 100 psi (689 Pa) or more. 4. Push the park brake knob fully in to release the brakes. The valve will latch in this position. Emergency Park Brake Release In an emergency, where there is no pressure or low pressure in the air system, the parking brake can be released by pushing and holding down the Emergency Park Brake Release. Figure 14. Regen Switch Park Brake Interlocks The parking brake is interlocked with and affects the operation of kneeling and cl as follows: · Kneeling - The park brake must be applied to kneel. Releasing the park brake cancels kneeling and returns the coach to normal ride height. · Wheelchair Lift - The park brake is interlocked by the wheelchair lift key switch. The park brake must be set before turning the wheelchair lift master key switch on. Opening the wheelchair lift doors also sets the parking brake. The park brake emergency release air tank has only enough air to release the parking brake three times. The Emergency Park Brake Release is a green, circular button located on the lower LH console switch panel (Figure 16.). Figure 16. Emerg. Park Brake Release July 2015 19 Figure 17. J4500 Instrument Panel INSTRUMENT PANEL/GAUGES(Figure 17.) 1. Speedometer - The speedometer, which features an alphanumeric message display, reads the forward speed of the coach in miles per hour or kilometers per hour. The speedometer features a MODE and TRIP button allow the driver to select, set/ reset displays and scroll through active system warning messages, when the coach is at a complete stop. The MODE button is utilized to select the mode of operation for the message display and to clear priority messages. The TRIP button is utilized to change what is displayed on the lower line of the alphanumeric message display. The following settings can be selected on the main screen by utilizing the MODE and/or TRIP buttons (Figure 18.): - Imperial / Metric Units, 2. 4-in-1 Gauge: Front Air Pressure - The secondary air pressure gauge reads front brake air reservoir pressure in pounds per square inch or kilo-pascals. If the pressure is low during start-up, the LED lights and a buzzer sounds. The alarms stop when the pressure builds up to operating level. Do not operate the coach under 100 psi (690 kPa). Rear Air Pressure - The primary air pressure gauge reads rear brake air reservoir pressure in pounds per square inch or kilo-pascals. If the pressure is low during start-up, the LED lights and a buzzer sounds. The alarms stop when the pressure builds up to operating level. Do not operate the coach under 100 psi (690 kPa). - Contrast Adjust, - Display Language (English, Spanish or French) - Diagnostics Menu. If a low air warning activates during driving, stop the coach immediately and find the cause of the air loss. If brake reservoir pressure drops significantly, the parking brakes apply automatically. Figure 18. 20 July 2015 4-in-1 Gauge: (cont'd) Oil Pressure - The oil pressure gauge reads engine oil pressure in pounds per square inch or kilo Pascals. Oil pressure should be between 50 - 70 psi (345 - 483 kPa). The LED lights when the oil pressure is too low. Coolant Temperature - The coolant temperature gauge reads engine coolant temperature in degrees Fahrenheit or Celsius. The normal operating range is 160-226F (71-108C). The LED lights when the temperature is above normal. Obtain service as soon as possible. 3. 3-in-1 Gauge: Fuel - The fuel gauge reads the fuel level in the tank. Diesel Exhaust Fluid (DEF) - The DEF gauge reads the fluid level in the tank. Engine Tachometer - The engine tachometer reads engine revolutions per minute. 4. Voltmeter - The voltmeter reads the condition of the 24-volt electrical system. The gauge is calibrated in volts. The needle should be from 27 to 29 volts. If below 27 volts, the batteries are undercharging. If above 29 volts, the batteries are overcharging. Have the system checked if over- or undercharging. The LED lights when voltage is too low. 5. Transmission Temperature 6. Plug 7. Vent 8. SmarTire SmartWave Full Function Display The SmartWave tire monitor system provides tire pressure deviation alert, low pressure warning and high temperature alert for all tire positions. SmartWave display functions: 1. ALARM tell-tale light to alert driver. 2. Display screen shows alert icons, tire location and numerical unit of pressure or temperature. 3. Control buttons to scroll through display. July 2015 21 Bendix Wingman System (Optional) Figure 19. The Driver is always responsible for the control and the safe operation of the vehicle at all times. The Bendix Wingman Advanced (or ACB) system does not replace the need for a skilled, alert professional driver, reacting appropriately and in a timely manner, and using safe driving practices. Any audible and/or visual alert by the system means that your vehicle is too close to the vehicle ahead, immediately act to potentially avoid, or lessen the severity of, a collision. Improper use of the Bendix Wingman Advanced (or ACB) system can result in a collision causing property damage, serious injuries, or death. Active Cruise with Braking (ACB) The Wingman system (Figure 19.) is engaged by turning cruise control ON and setting the vehicle speed. The system helps maintain a set distance between the operated vehicle and a detected vehicle ahead. To disengage the system, turn the cruise control OFF or press the brake pedal. The Wingman Advanced (or ACB) system is automatically ready when the cruise control is set. However, cruise control must be used only in the same conditions that are normally recommended for ordinary cruise control. As noted below, there are certain situations when cruise control should NOT be used. Do not use cruise control in the following conditions or situations: · Inclement weather (rain, snow, fog, ice or other severe weather conditions) · Dense Traffic · Sharp curves and winding roads · Entrance or exit ramps · Downhill grades · Construction zones · Smaller forward vehicles - Smaller vehicles, such as motorcycles, may be difficult for the radar to identify. It is the driver's responsibility to be aware of these types of vehicles and to slow down if necessary. Any vehicle trouble code that disables vehicle cruise control will also cause a diagnostic trouble code in Wingman Advanced (or ACB). The Wingman system will not operate until the DTC is cleared. Collision Mitigation (Advanced) Audible and visual alerts are provided to the operator through a Driver Interface Unit (DIU). All the alerts are always active regardless whether cruise control is engaged or not. Any alert means your vehicle is too close to another vehicle or object. These alerts will change as the distance between the two vehicles decreases alerting the operator of the impending hazard. As the distance closes, the system will automatically intervene and slow the vehicle. 22 July 2015 The radar system only senses metallic objects. Non-metallic or limited metallic objects such as people, animals, RVs, motorcycles, horse drawn buggies, logging vehicles, or cross- traffic will not trigger the system. Due to inherent limitations of radar technology, the collision mitigation technology on rare occasions may not detect moving vehicles or stationary objects in your vehicle's lane of travel. Road curvature may impact the radar's ability to track vehicles ahead in the same lane. Operator alerts, warnings, or brake interventions may not occur. In addition, the system may react to moving vehicles not in your vehicle's lane of travel. Operator alerts, warnings, or brake interventions may occur. Figure 20. Bendix Wingman Driver Interface Unit (DIU) 1. Three Red LEDs 2. UP Button 3. OK Button 4. Down Button 5. Orange LED 6. Blue LED 7. Three Yellow LEDs 8. LCD Display Following Distance Alert (FDA) A FDA is generated through the DIU using vehicle speed, forward vehicle speed, distance and driving scenarios. These alerts indicate that the time between your vehicle and the detected forward vehicle ahead is less than one and a half (1.5) seconds and decreasing. Once the audible alert is heard, the driver should increase the distance between their vehicle and the vehicle ahead until the audible alert stops. Single, Yellow Illuminated LED The forward vehicle is within a 1.5 seconds range and traveling at the same speed or slower. The screen will visually show the distance between the vehicles, closing. Two, Yellow Illuminated LEDs The forward vehicle is much too close and traveling at the same speed or slower. The screen will visually show the vehicles slightly closer to each other. All Three, Yellow Illuminated LEDs This is the closest and most urgent Following Distance Alert. The forward vehicle is in this zone and traveling at the same speed or slower. The screen will visually show the distance between the vehicles as very close. All Three, Red Illuminated LEDs This alert is the most severe warning. A loud solid tone is generated, and the screen will flash. The system will automatically slow down the vehicle. The operator must apply additional braking to maintain a safe distance from the vehicle ahead. If a collision is likely to occur, and the collision mitigation feature activates the brakes, the tone of the alert will change and the screen will flash between two displays. This alert indicates that a collision with the detected forward vehicle is likely and the driver must immediately act to potentially avoid, or lessen the severity of a collision. July 2015 23 Stationary Object Alert (SOA) This alert does not provide any automatic intervention at all, active braking or vehicle deceleration. Operator must take appropriate braking and/or avoidance measures. This alert indicates that a collision with a stationary object is likely and the operator must immediately act to potentially avoid, or lessen the severity of, a collision. System will provide up to a three (3) second alert when approaching a detected, sizable, metallic stationary object in vehicle's current lane of travel. Two Yellow Illuminated LEDs The radar detects a sizable, non-moving, metallic object in the vehicle's path of travel. Brake Overuse Alert This alert is provided when the system is intervening and using the brakes excessively. Brake overuse can lead to overheating and a potential loss of braking performance (brake fade). Using cruise control on downhill runs will cause this alert. Do not use cruise control on downhill grades. Blinking Blue LEDs When brake overuse is detected, a text message and audible alert/alarm is generated and the DIU blue LED will illuminate. The operator has 15 seconds to take action (turn cruise control OFF or apply the brakes). Solid Blue LEDs If the operator doesn't take action within 15 seconds, the system will shut off and a DTC (Diagnostic Trouble Code) will be generated. All intervention features of the system will remain off until the next ignition cycle. If the operator does intervene within the 15 seconds, the system will remain unavailable for 20 minutes. After 20 minutes the displayed ACB Braking Overuse message will disappear and the blue LED will turn off. All three types of alerts (FDA, IA, and SOA) will continue to be provided during the brake overuse alert. False Alerts In certain unusual traffic or roadway conditions, Wingman Advanced (or ACB) may issue a false alert. While eliminating all false alerts is not possible, if false alerts occur too frequently (more than twice a day), this may indicate sensor misalignment. Service the system at the earliest opportunity. Front Bumper Radar Sensor The sensor relaying information to the DIU is located on the front bumper of the coach (Figure 21.). Figure 21. Radar sensor inspection for obstruction/ damage must be monitored routinely. 24 July 2015 STEERING COLUMN & FLOOR-MOUNTED CONTROLS STEERING COLUMN Figure 22. Steering Wheel Ensure that the column is firmly locked before driving. Do not adjust the steering column while driving; steering control could be lost. The tilt and telescoping steering column is basic. It has a molded polyurethane steering wheel with fingertip cruise control and Jake brake. The tilt/telescoping control lever is on the LH side of the steering column (Figure 23.). Pull on the adjustment lever and tilt the steering wheel to the desired position. Push on the adjustment lever and raise or lower the assembly as necessary. Release the lever to lock. Ensure that the column is securely latched. Figure 23. July 2015 25 "SMART STICK" CONTROLS The "Smart Stick" (Figure 24.), on the LH side of the steering column, controls the turn signals, air horn, headlamp dimmer, windshield washer and windshield wipers. Turn Signals Move the lever up for right turns, and down for left turns. The corresponding telltale will flash. Air Horn Press the button on the end of the turn signal lever to activate the air horn. Headlamp Dimmer Pull the turn signal lever forward and release it to change from one setting to another. The HIGH BEAM telltale lights when the headlights are on high beam. Windshield Washers Push the sleeve towards the steering column. Activating the washer turns the wipers ON for four seconds on low speed. Windshield Wipers There are four rotary positions that operate the wipers: OFF, intermittent, low speed and high speed. 1. Windshield Washer 2. Windshield Washer 3. Turn Signals 4. Air Horn 26 Figure 24. July 2015 CRUISE CONTROL Do not use cruise control in heavy traffic, on icy roads or in any other driving condition that does not permit a constant speed. Setting Vehicle Speed Press the ON switch to turn on the cruise control. Accelerate to the desired speed, press the Set switch, then release the accelerator pedal. The CRUISE ENABLED telltale on the RH cluster stays on until the cruise control is turned off. Note: Cruise control will not operate under 20 mph (32 km/h). Increasing Set Speed 1. Press and hold the RES switch until the desired speed is reached, OR 2. Press the accelerator pedal until the desired speed is reached, then press and release the SET switch. NOTE: When driving with cruise control, speed may be increased (for passing, etc.) by pressing the accelerator in the usual way. Releasing the accelerator returns the coach to the set speed. Figure 25. JACOBS (JAKE) ENGINE BRAKE The Jake brake controls are mounted on the RH side of the steering wheel. The four controls are: OFF, LOW, MEDIUM and HIGH. Decreasing Set Speed 1. Press and hold the Set switch until the desired speed is reached, OR 2. Lightly press the brake to disengage the system. Allow the vehicle to coast to the desired speed, then press and release the Set switch. NOTE: The transmission may be shifted in the normal way without disengaging the cruise control. Canceling the Set Speed 1. Press the OFF switch or the CANCEL button, OR 2. Make a slight brake application. NOTE: When automatic operation is canceled, Res may be used to return to cruise control. Figure 26. The button located at the top of the RH control features a "courtesy light" that momentary flashes the coach marker lights to acknowledge passing vehicles. July 2015 27 ELECTRIC HORN Press the horn bar on the steering wheel center hub to activate the electric horn. ANTI-LOCK BRAKES (ABS) The anti-lock brake system (ABS) minimizes brake lock-up at each wheel. ACCELERATOR PEDAL The accelerator pedal is to the right of the service brake pedal. SERVICE BRAKES DO NOT pump the brake pedal.This defeats the purpose of the ABS. Do not apply the parking brakes until the coach has come to a complete stop. The coach has air-operated service brakes that are applied with the foot pedal to the left of the accelerator pedal. Stop lamps on the rear of the coach light when the brake pedal is pressed. The STOP LAMPS telltale on the RH telltale cluster lights. The ABS telltale on the LH telltale cluster is used for blink code diagnostics and lets the driver know the status of the system. The telltale lights briefly at ignition. If it lights at any other time, the system requires service. Full regular braking remains, and partial ABS may be present (refer to Figure 27.). If an ABS malfunction is indicated by the ABS telltale lamp, the driver must safely stop the coach and safely check all six (6) wheel ends for an overheat condition. If an overheat condition exists, the coach must NOT be driven until inspected by a qualified technician. ABS Telltale In the event of an ABS malfunction, the braking system will default to a normal braking system. Exercise caution to avoid potential wheel-lock conditions. Figure 27. 28 July 2015 OPERATING FEATURES ENTRANCE DOOR The entrance door is controlled by a switch on the RH switch panel on the instrument panel, or by an exterior switch located rearward of the door (Figure 28.). sound. When the coach reaches kneel height, the telltale remains lit, but the exterior lamp and buzzer(s) go off (Figure 28.). To return to normal ride height, press and release the RECOVER half of the switch. If the KNEEL switch is released before the coach is fully knelled, the coach stops lowering. To resume kneeling, press and hold RECOVER to return to normal ride height, then press and hold KNEEL to reactivate kneeling. Figure 28. Exterior Entrance Door Switch The DOOR OPEN telltale turns ON when the door is open. To operate, hold the switch until the door is fully opened or closed. The door may be stopped anywhere in its travel by releasing the switch. The door catch will engage when the door is in the fully closed position only, with the ignition ON. KNEELING The coach has a kneeling feature that allows the operator to lower the front of the coach five (5) inches (127 mm) for ease of boarding. To activate the kneeling feature, the park brake must be set, the transmission must be in Neutral and the entrance door must be closed. The coach automatically returns to normal height if the park brake is released or the transmission is shifted out of Neutral. REAR RISE The coach may be equipped with the rear rise option, which prevents rear bumper scuffing in offhighway situations by raising the rear bumper approximately three (3) inches (76 mm) above normal ride height. The Rear Rise switch is located on the RH switch panel. When the coach is traveling under 20 mph (30 kph) and the RAISE half of the switch is pressed, the rear of the coach rises, the HIGH RIDE telltale lights and a buzzer sounds. Pressing LOWER or traveling above 20 mph (30 kph) returns the coach to normal ride height. To avoid personal injury and property damage, ensure that nothing is under the coach when kneeling. To lower the coach, press and hold the KNEEL half of the switch in the RH switch panel. While the coach is lowering, the KNEEL telltale and exterior kneel lamps flash, and interior and exterior (optional) buzzers Do not operate the coach in the high position for extended periods. Lower the rear rise system before any suspension maintenance or inspection. July 2015 29 TAG AXLE UNLOAD, ELECTRICAL (OPTIONAL) The electrical tag axle unloading feature allows the operator to partially unload the tag axle using a dashmounted switch. When the coach cannot get traction, this transfers weight to the drive axle. The operator should refill the tag as soon as the coach has regained traction. It is unsafe to drive the coach with the tag axle air springs unloaded. Only the tag axle unloading feature in low traction situations. Do not use it for normal driving. Reduce coach speed when the tag axle air springs are unloaded. To unload, press the TAG AXLE switch located on the LH switch panel. The TAG UNLOAD telltale will light and a buzzer will sound. To re-load, press the TAG AXLE switch again or drive above 17 mph. Applying the service brake prevents MDSS from self-leveling the coach when the tag axle is unloaded. IN-STATION LIGHTING/BATTERY CHARGER (J4500) (OPTIONAL) An optional 110V AC receptacle in the battery compartment provides for in-station lighting and battery charging. AUTOMATIC TRACTION CONTROL (ATC) This system improves traction when the coach is on slippery surfaces by reducing drive wheel spin. If one drive wheel starts to spin, ATC applies the brake to transfer engine torque to the wheel with better traction. If all drive wheels spin, ATC reduces engine torque to improve traction. The telltale comes on when the drive wheels spin during acceleration. It goes out when the drive wheels stop spinning. ATC is always active; the operator does not have to select it. The MUD/SNOW switch is included with ATC. On extra soft surfaces, such as mud, deep snow or gravel, this feature increases traction by slightly increasing wheel spin. When MUD/SNOW is active, the LOW TRACTION telltale blinks continuously. ELECTRONIC STABILITY CONTROL Coaches are equipped with a stability control system that features Electronic Stability Control (ESC) combined with Roll Stability Control (RSC). ESC is a computerized technology that improves the safety of a vehicle's handling by detecting and potentially preventing skids by automatically applying brakes to help steer the vehicle where the driver wants to go. ESC is automatic in that these systems become active when the system Electronic Control Unit (ECU) senses conditions that could produce imminent roll or directional instabilities. Rapid lane changes or cornering at excessive speed on dry or slippery surfaces can create the potential for spin-out or drift out, often before the operator is aware. The ESC system uses a lateral accelerometer, a steer angle sensor in the steering column and a yaw rate sensor to enhance the operator's control in these conditions. The stability control system is designed to assist the operator, not to replace the operator. The operator will notice a difference in the coach when the ESC system becomes active, but should continue to drive as normal and provide any additional needed corrections. In an ESC event, the operator may first sense a decrease in engine power as the system ECU overrides the accelerator pedal, and may then sense additional deceleration from an engine brake application and service brake applications on the steer axle brakes or all axle brakes, depending on whether the conditions suggest the possibility of a directional control or a rollover event. 30 July 2015 WHEELCHAIR LIFT (OPTIONAL) GENERAL DESCRIPTION A wheelchair lift is installed in the storage compartment on the curbside rear of the coach, between the wheel housing and the rear service door. The lift provides safe on-loading and off-loading of wheelchair passengers with easy ground level access. The platform raises to coach floor level where the passenger enters the coach through the cabin access door. The lift is powered by an electrically operated hydraulic pump, with emergency manual back-up, and operated with a hand held WCL controller. Keyed operation and a safety interlock prevents unsafe deployment. The wheelchair lift platform features: · folding handrails, · a manually operated front barrier, · a powered rear barrier that acts as a bridge between the platform and the coach floor. A cabin access door is located directly above the wheelchair lift storage compartment. The door has a forward hinge and a positive lock mechanism to prevent accidental closing. The cabin access door is operated manually. Two wheelchair parking spaces are available next to and across from the lift platform. Special sliding and folding seats can be repositioned to provide wheelchair parking area. A seven point wheelchair and passenger restraint system is included at both wheelchair locations. The electric pump, emergency hand pump (Figure 29.) and reservoir assembly are located in the rear service compartment. WHEELCHAIR INTERLOCK SYSTEM This system prevents the WCL controller to be enabled until the following functions occur: · the main battery disconnect switch is in the ON position, · the engine is running, · Neutral is selected on the transmission shift pad, · the Park Brake is set, · the master wheelchair lift key switch (located on the lower, LH switch panel) is turned to the ON position. Only after these conditions are met, the following functions occur: · the vehicle assumes normal ride height, · the throttle is disabled, · the WCL INTRLK dash telltale illuminates, · the engine is running at fast idle, · theHazard/Warninglightsautomatically activate, · theaudible backupalarmautomatically activates, · the transmission shift inhibit and MDSS inhibit are energized, · the park brake lock valve is energized, · the wcl interior light illuminates, · the wcl controller is enabled, · the key will release from the master wheelchair lift key switch, eliminating the possibility of theft or engaging the coach during wheelchair operation. Figure 29. July 2015 31 THRESHOLD WARNING SYSTEM The threshold warning system is located above the wheelchair parking (threshold) area (Figure 30.). The module status indicator light illuminates when the wheelchair lift is powered, indicating that the module is activated. Two acoustic sensors monitor the doorway threshold area. If the acoustic sensors detect a passenger in the threshold area; when the lift is below coach floor height and the cabin access door is open, an audible buzzer and flashing light are actuated. Figure 30. 32 July 2015 BRAUN WHEELCHAIR LIFT OPERATION 1. Stop the coach, ensuring that there is adequate clearance to deploy the lift and to allow the passenger to maneuver onto the platform. 2. Place the transmission in Neutral and set the Park Brake. 3. Turn ON the wheelchair lift master switch key on the lower, LH switch panel (Figure 31.). The alarm will sound and the WCL INTRLK dash telltale in the RH telltale cluster will illuminate. Deploying The Lift From Compartment 7. Lift to remove control pendant from lift storage clip. 8. Press POWER switch on the pendant to ON (POWER button illuminates only when the lift is operating and receiving power). Figure 31. WCL Master Switch 4. Fold and position passenger sliding seats to provide wheelchair parking area. 5. Remove the key and exit the coach. 6. Open the wheelchair lift compartment door. Place the steel pin through the two holes, securing the door in the open position Figure 33. Braun WCL Pendant 1. Up Button 2. Down Button 3. Stow Button 4. Power Enable Switch4 9. Stand clear. Press and hold the UP switch until lift stops (extends fully). 10. Lift the RH handrail and swing out. Lower the handrail to the locked position. 11. Lift the LH handrail and swing out. Lower the handrail to the locked position 12. Securely support platform with right hand and rotate yellow platform latch (Figure 34.) up to Unlock platform. Figure 32. 1. WCL control pendant 2. Pin location July 2015 Figure 34. 33 13. Grab the top of the platform and apply enough force to pull down platform to horizontal position, ensuring that it engages on the pin of the handrail assembly. (Figure 35. and Figure 36.) Figure 35. Figure 38. 15. Exhaust the door locks and actuating cylinder on the cabin door by placing the air dump valve to the release position (Figure 39.). 16. Reach into the compartment and push the manual latch handle upwards to release the cabin door (Figure 39.). Figure 36. 14. Grip outer barrier and pull outer platform out fully, ensuring the center transition plate engages (locks) outer platform. Figure 39. 1. Latch handle location 2. Air dump valve 17. When the passenger is ready to board, grasp the edge of the cabin door to open it fully, and secure in full open position. using rocker switch on door (Figure 40.). Figure 37. The platform will not raise or lower unless the outer barrier is in the vertical and locked position. 34 Figure 40. July 2015 TO LOAD PASSENGER: 1. Load passenger onto platform, lock wheelchair brakes. 2. Latch handrail belt. 3. Press UP switch on the pendant to fold outer barrier up. Raise platform to floor level. At coach floor level, the inner roll stop will automatically unfold as a ramp. 4. Carefully unlock wheelchair brakes and unload passenger from platform. 5. Position and securely restrain wheelchair in the wheelchair parking area using the proper restraints. TO UNLOAD PASSENGER: 1. Latch handrail belt. 2. Press UP button on the pendant until lift stops (raises to floor level), and inner roll stop unfolds to floor level. 3. Carefully load passenger onto platform and lock wheelchair brakes. 4. Latch handrail belt. 5. Press DOWN button on the pendant until entire platform reaches ground level and outer barrier unfolds fully. 6. Unlatch handrail belt, unlock wheelchair brakes and unload passenger from platform. TO STOW PLATFORM: 1. Press STOW button on the pendant until platform reaches stow level (stops). 2. Using strap, lift center transition plate and push outer barrier in fully. 3. Manually stow (fold) platform to vertical position. 4. Support platform with right hand and rotate yellow platform latch to Unlock position (up). 5. Push platform in and rotate yellow platform latch to Lock position. TO STOW HANDRAILS: 1. Lift the LH handrail and swing in. 2. Lower handrail to locked position. 3. Lift the RH handrail and swing in. 4. Lower handrail to locked position. Ensure handrails are locked together (Figure 41.). Figure 41. TO STOW LIFT (IN): 1. Press STOW button until lift stops (retracts fully). 2. Release the cabin door by placing the LOCK/ UNLOCK switch at the end of the heat duct to UNLOCK. The cabin door must be closed before the lift key is switched OFF. This action controls both the pneumatic door locks as well as providing power to the lift. 3. Press POWER switch to OFF. 4. Store hand-held pendant in lift storage clip. 5. Remove pin from lower door hinge. Insert pin in storage clip. 6. Close door. 7. Turn wheelchair lift key switch on the lower, LH switch pane to OFF. July 2015 35 MANUAL WHEELCHAIR LIFT OPERATION In case of an electrical or other malfunction, passengers may be unloaded by manually operating the lift. The manual bypass valves and hand pump are located in the side service compartment directly to the rear of the w/c compartment. Manual operation should only be used for unloading passengers during a malfunction. DO NOT use the manual operation feature to load passengers. Refer to the BRAUN manual provided with your coach and the decal on wheelchair lift door (Figure 42.) for information on manual wheelchair lift operation. Figure 42. 36 July 2015 WHEELCHAIR PASSENGER SEATING Securing The Passenger The self-locking and self-tensioning features of the QRT enables the driver to secure the wheelchair beginning with either the front or rear retractors or if standing on the lift with the wall side front and rear retractors if this is more convenient. Figure 43. Positioning The Wheelchair Since the QRT Retractable System consists of self-locking and self-tensioning retractors which retract and lock automatically, the driver can position the wheelchair anywhere within the clear floor space which will allow for convenient access to securement points on the wheelchair. Explain to the passenger what you are doing to make them feel comfortable with the process. Figure 44. QRT Instruction placard mounted on cabin access door July 2015 37 Securing The Passenger (cont'd) 1. Ensure a straight line from anchorage to wheelchair attachment. 2. Select the appropriate attachment points on the wheelchair. Look for frame members that are welded or securely bolted to each other. NOTE: DO NOT use removable armrests, footrests, wheels of the crisscross supports on folding wheelchairs. 3. The rear attachment points should be a solid frame member as near as possible to where the seat and the back meet. The front attachment points should be a solid frame member, which will create an angle between 30 and 45 degrees to the retractor. 4. Attach the "J" hooks on all four retractor belts to solid frame members. 5. Ensure that the belts are properly tensioned. NOTE: DO NOT allow the webbing to be twisted inside the retractor. 6. Extend the shoulder belt from the retractor and attach the female pin connector end to the male pin connector on the lap belt. The belt will remain comfortable on the passenger and lock only in an emergency when an inertial force is applied. NOTE: When positioned properly, the shoulder belt should lay across the torso and angle up from the mid-point of the shoulder to the wall. NOTE: Adjust the belt as firmly as possible consistent with user comfort. DO NOT twist the belt. 7. Engage the wheel locks on the wheelchair. Care and Maintenance 1. Clean the webbing periodically with mild soap and water. After cleaning, fully extend the belts and position them to prevent water from entering the retractor until completely dry. Take care to prevent contamination of the webbing with polishes, oils and chemicals, particularly battery acid. 2. Webbing and components should be inspected, cleaned and maintained regularly. 3. Frayed, contaminated and damaged webbing should be replaced. 4. Broken and worn parts should be replaced. 5. Components, including anchorages, that are suspected to have been in use during an impact from which the vehicle must be towed, should be replaced. 6. Clean bolt threads and re-apply permanent thread locker if bolts are adjusted. Do not use the wheelchair life for lifting freight. The warranty will be void. Do not use the wheelchair life for lifting Ensure all passengers and wheelchair equipment is secured correctly. Failure to do so can result in property damage, personal injury or death. 38 July 2015 ENGINE OPERATION, FUEL AND EXHAUST Starting the Engine The controls necessary to starting and stopping the engine from the driver's area or engine compartment are mounted on the instrument panel in front of the driver and on the remote box in the engine compartment. These controls and a description of their operation and function follow: Do not engage the started for longer than 15 seconds at a time. Wait 30 seconds before cranking again. Continuous use can damage the starter motor. Front Start Procedure Rear Start/Remote Engine Operation This feature is primarily for maintenance purposes. Before attempting to start engine from rear of coach, make sure transmission is in Neutral and parking brake is applied. The remote electrical control panel is located at the LH side in the engine compartment. To gain access to the panel, open rear engine compartment doors. 1. Ensure the ENGINE ENABLE switch on the remote engine control box (located in the engine compartment) is set to ON. Figure 45. 1. Master Power / Ignition Switch - Pressing this switch to the ON (upper) position will enable all of the multiplex modules and turn on the coach's electrical system (Figure 45.). 2. Engine Start Switch - Used to start the coach using the rocker switch ignition (Figure 45.).To START the coach, place the master power / ignition switch in the ON (upper) position. Press the upper portion of the engine start momentary-on spring return switch to engage the starter. Release the switch once the coach has started. Allow the coach to idle for 30 seconds. To STOP the engine, place the master power switch / ignition in the OFF (lower) position. Be very careful when the engine is running and the engine door is open. If it is necessary to have the engine running for certain inspections or checks, keep a safe distance from moving belts, pulleys, shafts or fans. Keep hands and limbs away from moving belts and pulleys and also hot areas such as exhaust and turbocharger components and coolant lines. DO NOT wear loose, baggy or frayed clothing when working near any moving parts such as pulleys, belts, shafts or fans. 2. Actuate the "REAR START" switch to start engine. The start switch is a momentary-on spring return type and must be held in the depressed position to engage the starter. Do Not engage the starter for longer than 15 seconds at a time.Wait 30 seconds before cranking again. Continuous use can damage the starter motor. Engine Warm-Up Activate the FAST IDLE switch to warm up the engine, fill the air system quickly, and to increase electrical and HVAC output. Parking brake must be applied. Watch gauges and telltales. If abnormalities arise, stop engine and find cause. July 2015 39 Stopping the Engine 1. Bring coach to a complete stop. 2. Place the transmission in Neutral. 3. Apply the parking brake. 4. Idle the engine at low rpm for 30 seconds, then turn the ignition OFF. Regeneration Switch The regeneration toggle switch is located in the rear, side service compartment (Figure 14.). To avoid serious personal injury or property damage, ensure that no persons or objects are at or within two feet of the exhaust outlet at any time during a regeneration. Ensure that exhaust and outlet are clear of any trash, grasses, or other vegetation or Use extreme caution during a stationary regeneration, as exhaust gas tail pipe outlet temperatures can exceed 900 degrees F (482 degrees C). Stationary regenerations are to be performed outdoors only. DO NOT perform inside a garage or maintenance facility. DO NOT attach an exhaust extraction hose to the exhaust outlet. Shutting down the engine from high idle can damage the turbine bearings. Multiplex Bypass Circuit If the engine cranks but does not start because the ignition module fails, the engine ignition bypass switch, located in the rear junction box, provides emergency power to start the engine. NOTE: In this mode, the coach should be driven straight to a service facility. 1. Open the rear junction box compartment door (baggage bay compartment #3) (Figure 47.). Locate the emergency engine switch on the upper section of the junction box (Figure 48.). Figure 47. Figure 46. 40 Figure 48. 2. Lift the red self-canceling cover and position the toggle switch ON. 3. Get service assistance as soon as possible. July 2015 ENGINE CODE RETRIEVAL Using the touch screen diagnostic interface (Optional), the operator can retrieve coach electrical or drive train diagnostics to notify the garage. (Figure 49.). There are three (3) interface port connections on the coach: 1. underneath the instrument panel, 2. in the rear junction box located in baggage bay compartment #3, and, 3. the bottom face of the engine compartment remote control box. Figure 49. LCD diagnostic interface connected underneath the instrument panel. July 2015 41 IMMERSION HEATER - Engine Block (Optional) Use the engine block heater when the coach is parked for an extended period in cold weather. The plug is in the curb-side rear service door (Figure 50.) DO NOT put anything but DEF in the DEF tank ( blue cap ). One (1) diesel exhaust fuel (DEF) filler door is provided next to the curbside diesel (ULSD) filler door (Figure 52.). Figure 50. FUELING Two (2) diesel (ULSD) fuel fillers are installed on the coach. One is located behind a filler door in the fuel tank compartment door on the curbside (Figure 51.). The second location is on the roadside behind a filler door in the A/C condenser door. Figure 52. DEF Tank Door Diesel Fuel Specification Engines must comply with EPA mandated low emission guidelines by using ULSD (ultra low sulfur diesel) fuel. Failure to use ULSD fuel in 2015 EPA engines will result in component damage. Figure 51. Diesel (ULSD) Fuel Door The fuel tank is equipped with a whistle that stops when the tank is full. Close filler and latch it securely after filling. Do not fill the tank from both necks at once or have both fill caps open; the tank will over-fill and overflow. Diesel Exhaust Fuel (DEF) Specification DEF must meet ISO standard 22241-1. Diesel Fuel System Maintenance The fuel filter(s) require(s) periodic maintenance, and fuel lines and connections must be inspected regularly for evidence of leaks. When filling the tank, take care to prevent the entry of dirt and water. See the MCI Maintenance Manual and the Service and Maintenance section of this operator's manual for further information. Do not smoke while handling fuel. 42 July 2015 Diesel Fuel Contamination Water is the most common contaminant. It can be introduced through poor maintenance (loose or open fuel tank cap), a contaminated fuel supply or condensation. A fuel filter with water separator is located on the curb side of the engine. Inspect the bowl for water accumulation and drain as required. The auxiliary heater also has a fuel filter. Inspect and drain regularly. Lubricant Additives Do not use any lubricant additives. Failure to use CJ-4 engine oil in 2015 EPA engines will reduce component life. FUEL PRO FUEL FILTER The Fuel Pro extends filter change intervals and features a clear cover that provides visual identification of the fuel level (Figure 53.). When the fuel level reaches the change filter line on the filter cartridge, the element should be replaced at the next scheduled maintenance interval. Fuel filters should be replaced as a set. EXHAUST Exhaust gases contain carbon monoxide, which can cause unconsciousness and death. Strictly follow safety guidelines: 1. Do not inhale exhaust fumes. 2. If you suspect that exhaust fumes are entering the coach, discharge passengers and do not drive the coach. Have the cause determined and corrected immediately. 3. The exhaust system, body and ventilation system must be inspected and maintained regularly. 4. Keep the tailpipe area clear of snow and other material. 5. The exhaust system and coach body must be inspected any time the exhaust system or coach are damaged, or when the exhaust system sounds different. 6. Keep the engine air inlet grille clear of snow, dirt and other obstructions. 7. Do not run the engine inside confined areas without using an exhaust removal system. 8. Do not run the engine while parked in narrow alleys. 9. If the coach must be parked with the engine running for an extended period and is in an unconfined area, turn the HVAC system on. Figure 53. July 2015 43 THIS PAGE INTENTIONALLY LEFT BLANK 44 July 2015 TRANSMISSION OPERATION GEN V AUTOMATIC TRANSMISSION The B500 series GEN V is an electronicallycontrolled hydraulic auto-shifting six-speed transmission. This transmission controls all aspects of the shift function once placed into the desired drive range. Shift range selections are made with the touchpad module located on the side console. A two-character digital display is located at the top of automatic transmission shift selector. The left character of the display, SELECT, designates N, R, or the highest gear available of the selected forward range. The right character of the display, MONITOR, designates the actual gear which is being commanded by the transmission control module (TCM). Two-character diagnostic codes can be accessed using the touch-pad on the pushbutton shift selector. The MODE button, can be utilized to invoke a special function that has been programmed into the TCM. A small red light is illuminated on the MODE button when the function is activated. 1. Two Character Digital Display 2. Mode ID 3. Mode ON Indicator 4. Mode Button 5. Manual Shift Up / Down Shift Selection Controls D - DRIVE is used for normal driving. All shifting is automatic. N - NEUTRAL R - REVERSE - Used to select gear ranges manually. The display will show the highest gear in the selected range. Lower gears can be selected to provide engine braking on steep grades. NOTE: The gear selector should always be in the NEUTRAL position when the coach is parked. The transmission may select a gear range higher than the selected range if damage due to engine over-speed is possible. There is no PARK position on the transmission touch-pad. Select N (Neutral) and apply the parking brake. When shifting from Drive to Reverse or Reverse to Drive, select Neutral first. The engine must be at normal idle before shifting. If the coach is at fast idle, turn fast idle off and wait for the idle speed to slow before shifting. Figure 54. GEN V pushbutton shift selector July 2015 45 GEN V Diagnostic Code Retrieval Diagnostic codes, displayed as two digit numbers, indicate a transmission malfunction. Diagnostic codes can be accessed through the pushbutton shift selector. These codes are logged in the TCM / ECU with the most severe or recent code listed first. A maximum of five codes, identified as d1 to d5, can be listed at one time. As codes are added, the oldest non-active codes are dropped from the list. If all codes are active, the code with the lowest priority not included on the severity list is dropped. If the displayed code is active, the red light is illuminated on the MODE button. If the displayed code is non-active, the red light will not illuminate on the MODE button. The display will show two dashes (--) if diagnostic cycle was performed and no problems were found. Pressing the N key on the touch-pad, with the ignition turned ON (engine can be running), will allow the user to retrieve the transmission codes. Observe the two digit display for codes. Press the MODE button to view the next code. Record all codes. Diagnostic Code Example Code - P0722. Displayed as: d1, P, 07, 22. d1 is the diagnostic code list position. P is the main diagnostic code. 07, 22 are the sub codes. Each item is displayed for about one second. Clearing a Fault Code Record all codes prior to clearing. LED flashes when the code clears. 46 July 2015 ALLISON GEN V TRANSMISSION FLUID LEVEL CHECKS Automatic Transmission Fluid Access the transmission dipstick and fill tube from the rear engine door. Electronic Fluid Check 1. After reaching normal operating temperature [140F - 220F (60C - 104C)], park the vehicle on a level surface, select Neutral and allow the engine to idle (500-800 rpm). NOTE: Coach should be stationary for approx. two minutes to allow the fluid to settle. NO fast idle during electronic fluid check. 2. Simultaneously press the buttons once. There may be a short delay while the fluid and temperature stabilizes. 3. The fluid level will display: If correct, OL-OK. If low, OL-LO-# (number of quarts of transmission fluid required). If high, OL-HI-# (number of quarts overfilled). 4. Confirm with a manual fluid level check. Manual Cold Fluid Level Check Do a cold check to ensure that the transmission has enough fluid for safe operation until a hot check can be done. Check the reading at least twice. 1. Park the coach on a level surface and apply the parking brake. 2. Run the engine for at least 1 minute. 3. Apply the service brakes, shift the transmission to drive (D) and operate the engine at 1000 to 1500 rpm for 30 seconds. Shift to reverse (R) to clear air from the hydraulic system. Shift to neutral (N) and idle the engine at 500-800 rpm. 4. With the engine running, remove the dipstick from the tube and wipe it clean. 5. Insert the dipstick into the tube and remove it. Check the level reading. 6. Repeat to verify the reading. 7. If the fluid level is within the COLD RUN band, the transmission may be operated until the fluid is hot enough to perform a hot check. As required, add fluid to bring the level to the middle of the band. 8. Perform a hot check as soon as the coach reaches normal operating temperature [140F 220F (60C - 104C)]. Low and High fluid levels cause overheating and irregular shift patterns. If not corrected, transmission damage can occur. Dipstick checks may not agree exactly with sensor checks, because the oil level sensor compensates for fluid temperatures. July 2015 47 THIS PAGE INTENTIONALLY LEFT BLANK 48 July 2015 EMERGENCY CONDITIONS Check gauges and telltales at start-up and regularly during operation. If abnormalities arise, take action at once. If the following telltales light, action is required Regeneration (DPF) High Exhaust Temperature (HET) Malfunction Indicator (MIL) Not Generating Tag Unloaded (Optional) ABS Check Transmission Telltale Telltale Telltale Telltale Telltale Telltale Telltale Regeneration required for 2015 engines Exhaust outlet temp exceeds predetermined level Failure of an emission component on DD13 engine Alternator(s) not functioning, Alternator belt broken Tag axle is unloaded Anti-lock braking system malfunction Transmission problem, Do not change gear. Check Engine Stop Engine Low Coolant Supply Air Low Fire Alarm Lavatory Emergency Digital Wheel End Sensor Voltmeter Gauge LED Oil Pressure Gauge LED Temperature Gauge LED Tachometer Gauge LED Air Pressure Gauge LED Fuel Gauge LED Telltale Engine fault Telltale Engine is powering down or stopped Telltale Add coolant. Check for leaks in the engine compartment Telltale System air pressure is low Telltale Fire in the engine compartment Telltale Passenger has pressed buzzer in lavatory Speedometer High temperature warning in rear wheel Instrument Voltage too low Instrument Oil pressure is too low Instrument Engine coolant temperature too high Instrument Engine RPM too high Instrument Front or rear brake pressure too low Instrument Low Fuel July 2015 49 EMERGENCY ESCAPE Roof Hatch Two escape hatches are located in the roof for emergency exiting (Figure 55.). To open in case of an emergency, follow the instructions on the applicable roof hatch. Side Windows Select side passenger windows can be opened from inside for emergency escape purposes. These non-bonded side windows are top hinged, and open from the inside. To open, lift the release bar at the lower edge, disengaging the safety latches. Push the window out. Emergency instructions decals are attached to the release bars (Figure 58.). Inspect regularly to assure the decals are legible. Figure 55. A prop rod is located in the hatch opening. Figure 57. Figure 56. The roof hatch may be partially propped open by the operator for ventilation purposes when it is safe to do so. Before doing so, the operator should ensure that the coach will have adequate roof clearance with the partially opened hatch throughout the operator's intended route of travel. The partial opening should not be performed while the coach is in motion. In no event should the roof hatch be fully opened for ventilation or any other purpose while the coach is being operated. Figure 58. Do not open the side windows while the coach is moving. Windows close with enough force to cause injury. Ensure that hands are clear. 50 July 2015 EMERGENCY STARTING If the coach has dead batteries, it can be jump started. Negative and positive boosting posts are in the curb-side rear service compartment. 5. Attach the other end of the same cable to the positive booster post on the upper frame rail below the lavatory tank. Follow procedures exactly or personal injury or property damage may result, and the starting or charging system of the booster or immobilized vehicle may be damaged. Do not jump start a vehicle with a frozen battery. Frozen batteries can rupture or explode. Examine the fill vents for ice. If ice is visible, do not jump start. Connect and disconnect jumper cables as described. Connecting Booster Cables (Figure 59.) 1. Set the parking brake, turn off lights, heater and all electrical accessories. Figure 59. 6. Attach one end of the remaining negative cable to the negative terminal of the booster battery. 7. Attach the other end to the negative booster post on the lower coach frame rail. 1. Positive Boost Post 2. Negative Boost Post Disconnecting Booster Cables (Figure 59.) To reduce the chance of an explosion, take steps to prevent hydrogen buildup. Remove the vent caps from the booster and the dead batteries. Ensure the battery compartment is well ventilated. Do not permit vehicles to touch each other. Take care that clamps from one cable do not touch clamps on the other cable. 2. Remove the vent caps from the booster and the discharged batteries. 3. Remove the rubber boot that covers the positive booster post located on the upper frame rail below the lavatory tank. 4. Attach one end of one jumper cable to the positive terminal of the booster battery. Do not lean over the booster battery when disconnecting the ground lead. Take care that clamps from one cable do not touch clamps on the other cable. 1. Disconnect the jumper cable from the ground stud. 2. Remove the remaining end of the negative jumper cable from the booster battery. 3. Remove one end of the remaining jumper cable from the positive booster post on the upper frame rail. 4. Remove the other end of the same cable from the positive terminal of the booster battery. 5. Install the rubber boot over the positive booster post. 6. Install the vent caps on the batteries. POWER STEERING SYSTEM If the power steering system fails, the coach can be steered, but much greater effort is required. July 2015 51 BRAKES (EMERGENCY OPERATION) Parking Brake (Emergency Operation) If the front and rear brake system air pressure falls below approximately 50 5 psi (345 35 kPa), the parking brake will automatically apply. An isolated emergency release reservoir has enough air to release the parking brake three times. Press and hold the emergency parking brake release button (lower LH console switch panel). The parking brake springs will reapply as soon as the knob is released. Brake System Emergency Fill Emergency fill provisions allow the primary or secondary service reservoirs to be filled independently. The fill provisions are in the front roadside service compartment (Figure 60.). The parking brake emergency release button allows the coach to be moved to safety when both brake reservoirs are depleted and the parking brake has applied automatically.Do not use this feature other than to move the coach to a safe parking location. Do not drive the coach until the air loss problem is fixed and the brake reservoirs are fully charged. Service Brakes (Emergency Operation) This coach has a dual-circuit service brake system with separate reservoirs for rear and front brakes to ensure that brakes are available if one circuit fails. If low air pressure occurs in both brake circuits at the same time, an alarm sounds. The brakes will remain operable until air pressure falls to 50 5 psi (345 35 kPa) and the parking brakes apply automatically to stop the coach. Figure 60. Coach Air Service Fill A service fill provision is located behind the curbside rear service door (Figure 61.) allows filling the coach air system from an external source, provided the air system is intact. Figure 61. 52 July 2015 TOWING Only operators authorized to and experienced in towing intercity coaches may tow coaches. Towing Airline Connections The towing air connections are in the roadside front service compartment, along the rear wall (Figure 62.). Route the hoses away from the steering gear and linkage. Ensure that the tow hoses will not be pinched or damaged during towing. 3. Use the TOW SUPPLY connection for the supply line from the tow vehicle. 4. Use the TOW BRAKE connection for the line from the tow vehicle that operates the service brakes. If this line accidentally detaches or is severed while towing, the parking brake will activate. 5. Connect the coach to the tow vehicle. Figure 62. Towing Procedures Disconnect the drive shaft or remove the axle shafts, before towing the coach. See Section 3F Towing, in the Maintenance manual for axle shaft removal procedure. Highway towing must be from the front. Only tow from the rear to extract the coach from ditches or snowbanks. Only operators authorized to and experienced in towing intercity coaches may tow coaches. DO NOT INSTALL SOLID PLUGS. 1. Remove the 1/4 NPT threaded mufflers to install the fitting style required by the tow truck. 2. Route the tow vehicle hoses to the coach connection points. Reinstall the muffler when towing is completed. The connections must vent to atmosphere for the parking brakes to release properly. If it is necessary to cage the spring brakes, see Section 4 of the Maintenance Manual. Always use extreme caution around spring brakes. July 2015 53 EMERGENCY STOPS If you must stop the coach because of a breakdown or unsafe condition, ensure that it is safely parked. 1. Pull the coach as far out of traffic as possible. 2. Turn on the hazard lights. 3. Place reflector triangles in front of and behind the coach (refer to Figure 63. for storage location). Figure 65. Pull the entrance door knob to dump the air, allowing the entrance door to be manually pushed opened (Figure 66.). Figure 63. ENTRANCE DOOR OVERRIDE VALVE The entrance door override valve (Figure 64.) allows air to be dumped from the entrance door actuating air cylinder, door claw and header locking devices. After dumping air, the entrance door can be manually pushed open. Figure 66. TOOLS AND SAFETY EQUIPMENT · A fire extinguisher is installed under the #2 curbside passenger seat. · Three reflector triangles are provided in a container mounted in the upper corner of the #1 curbside baggage bay compartment. A container of fusees are mounted in the battery compartment. · A lug wrench, hydraulic jack with handle and wooden run-up block (used for raising the axle when changing tires) are located in the front side service compartment (Figure 67.). Figure 64. In addition to the valve, there is a provision for release of the front service compartment door, beside the windshield washer reservoir. This allows the compartment door release to be operated from outside the coach. Push upwards on mechanism, threw hole opening, to release compartment door latch (Figure 56.) 54 Figure 67. July 2015 ENGINE DOOR RELEASE LEVER The engine compartment door release lever is in the rear curbside service door (Figure 68.). Figure 68. MAIN BATTERY DISCONNECT SWITCH Activate the disconnect feature of the main battery disconnect (MDS) system by turning the rotary switch 45 degrees counter-clockwise to OFF (located in the battery compartment) (Figure 69.). To turn ON (wake up) power from the exterior of the coach, press the exterior entrance door open switch. To turn ON (wake up) coach power from the interior of the coach when the coach is in sleep mode, press the entrance door open rocker switch or position the ignition rocker switch to the RUN position. CIRCUIT BREAKERS AND FUSES Self-resetting circuit breakers, located in the battery compartment on the curb side of the coach, provide overload and short circuit protection for the main HVAC blowers, condenser fans, driver's evaporator blowers and 12 and 24 volt relay modules. Three self-resetting circuit breakers for the driver's blowers are in the control box for the driver's evaporator, and two self-resetting circuit breakers for the parcel rack blowers are located in the fuse box. Fuses, provided for the auxiliary heater, engine ECM, transmission ECU, interlock modules, door sensors and HVAC controllers, are located in the battery compartment fuse box. LAVATORY EMERGENCY A momentary ON lavatory emergency button is located in the lavatory compartment (Figure 70.). Pressing this button will illuminate the LAV EMERG tell-tale and activate a buzzer. Releasing the button cancels the tell-tale and buzzer. Figure 69. The multiplex modules installed on MCI coaches have been programmed with a system sleep mode. After thirty (30) minutes of no coach system activity, the power management supply module will remove electrical power from all the components connected to the main disconnect switch (now a rotary switch, located in the battery compartment). When the coach goes into sleep mode after thirty (30) minutes, coach power is turned OFF which allows the coach systems to conserve coach power, (providing that the hazard lights and master power switch are in the OFF position). July 2015 Figure 70. 55 AMEREX FIRE SUPPRESSION SYSTEM The AMEREX fire suppression system is an automatic system that continuously monitors the engine compartment for fires. The system uses thermo-sensors connected to an electronic circuit monitor/control panel to electrically trigger the release of the dry chemical (ABC) extinguisher. In the event of a fire, the engine will shutdown 15 seconds after the fire system is activated. If more than 15 seconds are required to move the coach to a safe parking area, the operator can push the ENGINE OVERRULE switch, located on the second row of the LH Switch Panel. Push the button at approximately 1012 second intervals to delay shutdown for another 15 seconds. An audible buzzer will sound continuously during fires. This alarm will operate until the Alarm Silence button is pushed. When the Alarm Silence button has been pushed, the LED will be illuminated. Figure 71. Control Panel The control panel is responsible for driver alerts and for the automatic activation of the system during fire hazards. The control panel has both audible and visual alarms. Normal Operation During normal operation, a green System OK LED is illuminated on the front of the control panel. This indicates that all circuits are intact and functioning. Fire Hazard Conditions In the event of fire, the green System OK LED will go out and the red FIRE LED will come on. The system will force chemical fire suppressant through four spray nozzles located in the engine compartment. As a safety provision, the silence feature cannot be operated in advance of a fire or fault condition. When the fire is extinguished and the thermosensor cools, the red FIRE LED will remain illuminated until the system is serviced and the monitor is reset. Fault Condition If a fault occurs in the actuator circuit, the Service System LED will be illuminated and will remain so until the condition is repaired. Manual Operation The manual function is used when a fault exists that could inhibit auto/electrical actuation via the control panel. During a fire emergency, the driver must manually pull the disarming pin that retains the actuator switch and push the button (Figure 72.). The manual fire button is located behind the drivers seat, on the LH side. The Relay Reset button on the Amerex control panel is disabled (Figure 71.). 56 Figure 72. July 2015 HEATING AND AIR CONDITIONING MICROMAX HVAC DISPLAY 5. Micromate Control Panel - The Micromate Control Panel displays the set point temperature, interior (return air) temperature and exterior temperature. To read interior or exterior temperature, press the TEMPERATURE display button to illuminate the indicator light. After a short delay, the display will return to the default set point temperature. Set point temperature may be changed by pressing the UP or DOWN arrow button. The UP button will increase the set point temperature and the DOWN button will decrease the set point temperature. The set point temperature can be adjusted from 60F to 80F (15C to 27C). KEY FUNCTIONS Figure 73. MICROMAX HVAC SWITCHES 1. Driver's Fan (Defrost) Control - Controls driver's defroster fan speed from OFF, LO, MED, HIGH. 2. Driver's Heat Control - Controls driver's heat and cooling. 3. Parcel Rack Ventilation Switch - The PARCEL RACK switch turns the parcel rack blowers ON and OFF. 4. Auxiliary Heater Switch - When the engine is OFF, the engine can be preheated by pushing the AUXILIARY HEATER switch forward, which activates a 90 minute timer in the Proheat unit. When the Proheat burner is ON, the HEATER ON telltale lights. To turn the Proheat OFF, push the switch back. It will purge for 2 to 3 minutes. If the coach is started during preheating, the temperaturedependent control overrides the timer. July 2015 57 START-UP AND SETTINGS The HVAC system self tests and starts automatically after the engine speed reaches idle. If the coach ignition key is ON, but the engine does not start by the end of the self test, the display will indicate "No Data" and the system will wait for the engine to start. The main HVAC system will start at the same setting as when it was turned OFF. When heating, the main fans will not start until the engine coolant temperature exceeds 120F (49C). The fans start immediately when cooling. The fans operate automatically at high, medium or low, depending on the heating or cooling requirements. NOTE: Turn fast idle ON if running the air conditioning while stopped. PARAMETERS and ALARM CODE RETRIEVAL Pressing the UP and DOWN arrow buttons for 3 - 5 seconds will allow the user to scroll up or down through the parameters and alarms. When scrolling through the parameters, the current parameter will be displayed for 2 seconds. When the last parameter is reached, the list will wrap back. Pressing the ON/OFF key at any time, or if no key is pressed for 30 seconds the mode will exit and will revert back to the default display. Lights indicate alarm codes. Each alarm code is a 2 digit number. The first display is the first digit, and after a slight pause the second display is the second digit. When the end of the alarm is reached the display will show "---". If the AUTO key is held down for 5 seconds while"---" is displayed, all inactive codes are cleared. Record all codes prior to clearing. PASSENGER ZONE Default Settings The default setting for the passenger zone is 70F (21C). The fans operate at high until the interior temperature reaches the set point. Manual Settings Alarms The display will toggle between an alarm and the temperature setting when there is a system malfunction. The system may shut down if the malfunction is serious. NOTE: To turn the heat OFF in an emergency, use the valves located in the engine compartment or the valve located under the driver's area. Refer to Section 6 of the Maintenance Manual. HVAC PRE-TRIP INSPECTION After starting system operation, allow the system to stabilize for ten to fifteen minutes, then check the following: 1. Listen for abnormal noises in the compressor or fan motors. 2. Check compressor oil level. 3. Check refrigerant level. 4. Ensure that the self-test has been performed successfully and that there are no errors or alarms indicated. 5. View compressor drive belt for excessive belt flap. (Refer to Section 16 of the Maintenance Manual.) Back-lit Function The back-lit function of the Micromate control panel is actuated when the headlight or clearance lights are turned ON (Figure 74.). Temperature Settings The temperature setting will be visible on the display. Pressing the AUTO key returns settings to auto control. Fan Settings The fans can be set at LOW or HIGH. Figure 74. 58 July 2015 AUDIO AND VIDEO SYSTEMS The REI Dual Zone system has the following features: · DVD/CD/MP3/MP4/Radio/MIC Player with USB Input, · Aux / IPod/ USB Playback · Bluetooth Hands Free Calling and Wireless Audio Streaming · The CD/AM/FM radio has built-in amplifier for powering driver's speakers · Six station pre-sets. · Separate tone control (Dual Zone) for driver and passengers, Figure 76. Figure 77. Figure 75. 1. REI EC-750 Dual Zone Player 2. REI ECD-5500 Dual Zone Player 3. REI DVD Player 4. Wireless Microphone (Optional) 5. Media Hub (Optional) July 2015 Figure 78. MP-1000 Media Player (Optional) · Passenger Safety Announcements · Custom Video Playback · Rolling Text 59 Figure 79. REI EC-750 Dual Zone controls. 60 July 2015 Figure 80. REI DVD Player Dual Zone controls. July 2015 61 Figure 81. REI ECD-5500 Dual Zone controls. 62 July 2015 REI Video Monitors Six (6) 15.4 inch LCD monitors are installed throughout the coach cabin. The LCD monitors have a self protection feature against extreme climate temperatures. Figure 82. Figure 83. July 2015 63 THIS PAGE INTENTIONALLY LEFT BLANK 64 July 2015 SERVICE AND MAINTENANCE Take care when inspecting or servicing the coach to avoid being injured. Some components may be hazardous if handled improperly. Poor maintenance could also lead to malfunctions, which could cause personal injury or damage to the coach. Figure 84. J4500 Exterior Components EXTERIOR COMPONENTS (Figure 84.) 1. Entrance Door 8. Rear Engine Service Compartment 2. Entrance Door Exterior Switch 9. Front Junction Box 3. Baggage Compartment 10. Front Service Compartment 4. Battery Compartment 11. A/C Condenser Compartment 5. A. Diesel Exhaust Fuel (DEF) Tank Filler Door B. Diesel (ULSD) Fuel Tank Filler Door 6. Wheelchair Lift Compartment 7. Rear Side Service Compartment 12. Radiator Compartment 13. Spare Tire Compartment 14. Roof Hatch July 2015 65 EXTERIOR LIGHTING (Figure 84.) a. Headlights b. Multi-function LED (sweep style), Directional Light / Hazard Light / Daytime Running Light c. Reflectors d. Identification Light e. Marker Light f. Supplemental Stop Light g. LED Directional Light h. LED Backup Light i. LED Stop Light j. License Plate Light k. LED Cornering Light l. l. Directional Light COMPARTMENT ACCESS (Figure 84.) Engine Compartment The engine service compartment door release is in the rear, curbside, side service compartment. Front Service Compartment The T-handle, located at the rear of the drivers lower, LH console, is utilized to release the front service compartment door. In addition to the T handle, there is a provision for release of the front service compartment door, beside the windshield washer reservoir. This allows the compartment door release to be operated from outside the coach. Push upwards on mechanism, thru hole opening, to release compartment door latch (Figure 86. and Figure 87.). Stand clear when opening the rear engine door. It swings up. Turn OFF the engine enable switch any time the engine compartment is opened. Condenser Compartment The latch is located in the roadside fuel fill door.Radiator Compartment Open with a handle located on the road side of the rear engine compartment. Spare Tire Compartment The bumper release handle is in the roadside front service compartment. Ensure sufficient clearance prior to releasing the compartment door (Figure 85.). Figure 86. Figure 87. Figure 85. 66 July 2015 Fuel Tank Access the fuel tank assembly through the fuel tank door on the curb side. Fuel Tank Filler Doors Two diesel (ULSD) filler doors are provided: one through the condenser door on the roadside and one through the fuel tank door on the curbside. One diesel exhaust fuel (DEF) filler door is provided next to the curbside diesel (ULSD) filler door (Figure 88.). COOLING SYSTEM The engine cooling system controls the engine temperature and supplies water for the heating system. The cooling system is filled through the surge tank filler neck. Coolant Surge Tank There is no coolant recovery system. Check the coolant level through the sight glass. TIRE CHANGE Figure 88. 1. Diesel (ULSD) Fuel Tank Filler Door 2. Diesel Exhaust Fuel (DEF) Tank Filler Door Auxiliary Storage / Wheelchair Lift Located at the rear curb-side of the coach, immediately behind the trailing axle. Baggage Compartments Baggage compartments are located between the front and rear axle. Do not access suspension components from the wheel wells. Unintentional actuation could cause serious injury or death. NEVER go under the coach while it is raised and supported on a jack only (Figure 87.). Wheel and tire assemblies weight more than 200 lbs. (90 kg). Use caution when loosening the wheel nuts, and when lifting the wheel off the hub. DO NOT attempt to fit stud mount rims. DO NOT attempt to fit 8.25" rims. Only use tires that are sufficiently rated. Fit similar tires in similar condition on both sides of the axle. Only use correctly-profiled valve stems in hub-mounted 9" x 22.5" rims. Front or Trailing Axle To avoid pinching fingers, do not hold the edge of the door when closing it. Baggage doors are locked by driver-controlled switches on the switch panel. 1. Turn the front wheels straight ahead. 2. Run the flat tire up on the run-up block. Stop the coach and apply the parking brake. 3. Place the bottle jack under the axle beam so that the jack ram pad fits into the round recess at the bottom of the axle beam. Partially raise the wheel (Figure 89.). July 2015 67 2. Place the bottle jack under the drive axle (Figure 91.) so that the jack ram pad fits the recess at the bottom of the jacking pad. The jack pad is on the rear face of the drive axle beam below the suspension support structure attachment. Partially raise the wheel. Figure 89. 4. Before the tire is completely off the ground, loosen the wheel nuts. 5. Raise the wheel completely, remove the run-up block, and remove the wheel nuts and the wheel and tire assembly. 6. Mount the wheel on the hub pilot. 7. Torque the wheel nuts to 450-500 ft.-lbs using the criss-cross sequence shown (Figure 90.). Re-torque wheel nuts after 100 miles. Figure 91. 3. Before the tire is completely off the ground, loosen the wheel nuts. The wheel and tire assemblies weigh more than 200 lbs. (90 Kg). Use caution when loosening the wheel nuts, and when lifting the wheel off the hub. 4. Raise the wheel completely, remove the run-up block, and remove the wheel nuts and the wheel and tire assemblies as required. Figure 90. Drive Axle 1. Run the inflated tire up onto the run-up block. Stop the coach and apply the parking brake. The drive axle wheel nuts are hub mounted: the wheel nuts hold both the outer and inner wheels. Take care when removing the nuts and tire assemblies. 5. Ensure that both wheels are properly seated on the hub pilot before tightening the nuts fully. Torque wheel nuts to 450-500 ft.-lbs using the criss-cross sequence shown in Figure 90. Re-torque wheel nuts after 100 miles. 68 July 2015 FUELING Two diesel (ULSD) fuel fillers are installed on the coach. One is located behind a filler door in the fuel tank compartment door on the curbside and the second location is on the roadside behind a filler door in the A/C condenser door (Figures 92 and 93). Diesel Fuel Specification Engines must comply with EPA mandated low emission guidelines by using ULSD (ultra low sulfur diesel) fuel. Failure to use ULSD fuel in 2015 EPA engines will result in component damage. Figure 92. Diesel (ULSD) Fuel Door Figure 93. A/C Condenser Door The fuel tank is equipped with a whistle that stops when the tank is full. Close filler and latch it securely. Do not fill the tank from both necks at once or have both fill caps open; the tank will over-fill and overflow. DO NOT put anything but DEF in the DEF tank ( blue cap ). One diesel exhaust fuel (DEF) filler door is next to the curbside diesel (ULSD) filler door (). Biodiesel not to exceed B20. Diesel Exhaust Fuel (DEF) Specification DEF must meet ISO standard 22241-1. AUXILIARY HEATER The auxiliary heater is located in the left rear of the engine compartment. The auxiliary heater turns on automatically to augment the temperature of engine coolant for coach heating. To preheat the coolant or test the heater, turn the auxiliary heater ON with the AUX HEAT switch. Auxiliary Heater Diagnostics The operator can identify function and component diagnostics by checking the light bars or number display located on the front of the control module. Figure 94. DEF Tank Door July 2015 Figure 95. 69 FLUID REPLACEMENT Engine Lubricating Oil The engine oil dipstick is accessible through the rear engine access door (Figure 100.). Always check the engine oil level with: · the engine at normal operating temperature · the coach on level ground · the engine OFF. NOTE: Leave the engine stopped for at least 5 minutes. Do not overfill. Withdraw the dipstick and wipe it clean. Insert the dipstick fully, then withdraw it and read the oil level. If it is down to LOW mark, add sufficient oil to bring the level up to FULL mark. Power Steering Fluid The coach has a power steering fluid reservoir in the engine compartment (Figure 100.). The reservoir has a filler nozzle, sight glass and vent tube. The correct cold level is at the center of the sight glass. (Use the dipstick in the fill cap for hot level checks.) Check levels periodically and add if necessary. Figure 96. All fluids must be handled, stored and maintained according to the instructions on the "Waste Fluid Removal" decal. The decal is located in the rear engine compartment (Figure 97.). Do not spill oil on the fan belts. The oil will cause the belt material to degrade rapidly and break. Automatic Transmission Fluid - Allison Refer to the heading "Transmission Operation" Allison Automatic Transmission - Transmission Fluid Level Checks, for the dipstick location and transmission fluid specifications. Windshield Washer Reservoir The windshield washer reservoir is in the front service compartment (Figure 96.). Figure 97. 70 July 2015 LAVATORY TANK SERVICE PROCEDURES Refer to local health regulations for proper disposal procedures and equipment. Lavatory waste must be disposed of according to the instructions on the "Lavatory Waste" decal. The decal is located on the inside of the curbside rear service door (Figure 98.). Figure 99. Figure 98. Draining the Lavatory Tank 1. Position the coach over a suitable sanitary sewage drain. 2. Open the dump valves (2.) and drain the tanks completely. 3. Connect a water hose to the rinse connection. 4. Close the upper dump valve and fill the upper tank. 5. Press the flush button for 30 seconds (if the coach has a flush toilet). 6. Open the dump valve and drain the tank. 7. Repeat Steps 1 to 5 until the discharged water appears clean. Charging the Lavatory Tank 1. Close both dump valves and fill the primary tank with water to one-third sight glass level. Do not allow the lavatory chemicals to contact your skin. 2. Add approved chemical charge to the tank. 3. If the coach has a flush toilet, test. July 2015 71 1. Coolant Fill, 15 psi Rad Cap 2. Remote Electrical Control Box 3. Back-up Alarm 4. Air Filter 5. Power Steering Reservoir 6. Lavatory Service Valves 7. Dual Denso Alternator, Top 8. Dual Denso Alternator, Bottom 9. A/C Belt 72 Figure 100. 10. Alternator Belt 11. Fan Belt 12. Aux Heater 13. Engine Oil Fill Tube / Dipstick 14. Filter Minder 15. Gear Box Filler Tube 16. Radiator Door Handle location 17. Fuel Pro Fuel Filter 18. Transmission Oil Tube July 2015 1. Coolant Fill, 15 psi Rad Cap 2. Remote Electrical Control Box 3. Back-up Alarm 4. Air Filter 5. Power Steering Reservoir 6. Lavatory Service Valves 7. Dual Denso Alternator, Top 8. Dual Denso Alternator, Bottom July 2015 Figure 101. 9. A/C Belt 10. Alternator Belt 11. Fan Belt 12. Aux Heater 13. Engine Oil Fill Tube (2 locations) 14. Filter Minder 15. Gear Box Filler Tube 16. Radiator Door Handle location 73 THIS PAGE INTENTIONALLY LEFT BLANK 74 July 2015 SPECIFICATIONS VEHICLE HEIGHT (MAXIMUM NORMAL RIDE HEIGHT).................................................141.25 Inches (3587 mm) (From Top Of Roof Hatches) VEHICLE WIDTH (MAXIMUM) .............................................................................................102 Inches (2590 mm) (Excludes Mirrors And Side Turn Lights) GROSS VEHICLE WEIGHT RATING...................................................................................54,000 Lbs. (24,500 Kg) CAPACITIES CAPACITIES DIESEL FUEL TYPE......................................................................................................ULSD (ultra low sulfur diesel) DEF (DIESEL EXHAUST FUEL) TYPE....................................................................................ISO Standard 22241-1 ENGINE CRANKCASE.................................................................................. (SAE 15W-40) API Classification CJ-4 POWER STEERING SYSTEM.............................................................................................................7.5 Qts.(7.1 L) (TES-389) AUTOMATIC TRANSMISSION...............................................................................................................25 Qts.(23 L) (TES-389) COOLING SYSTEM............................................................................................................................25 Gals.(100 L) (Glycol-based coolant) AIR CONDITIONING.........................................................................................................................23 Lbs.(10.4 Kg) (R134 Refrigerant) LAVATORY FRESH WATER TANK..................................................................................................10 Gals.(37.8 L) LAVATORY WASTE RETENTION TANK: PRIMARY.......................................................................................................................................................16 Gals. SECONDARY.................................................................................................................................................24 Gals. PARCEL RACK (Right Side)...........................................................................................................1184 Lbs (537 kg) PARCEL RACK (Left Side).............................................................................................................1332 Lbs (604 kg) BATTERIES..........................................................................................................................8D, 1350 CCA Post type TIRE SIZE (Basic)....................................................................................................315/80R22.5 on a 9.00 inch rim TIRE SIZE (Minimum)................................................................................................................................."J" Rated July 2015 75 Figure 102. J4500 MODEL BODY AND DOOR CLEARANCE DIAGRAM 76 July 2015 502.00 41'-10" 278.62 23'-2 5/8" 53 78.25 45 449.01 37'-5" 223.38 18'-7 3/8" 314.96 27.86 102.00 49.02 105.16 Figure 103. J4500 TURNING RADIUS July 2015 77 TIRE SPECIFICATIONS The tires listed below meet GHG regulations as LRR tires. It is the owner's responsibility for tire maintenance. Replacement Tires Always replace the tires with the same rating, size and the same or better rolling resistance coefficient (CRR). Contact the tire manufacturer for tires' CRR rating. TIRE CHART Make and Type Goodyear G409 MBA Michelin XZY-2 Michelin XZA2 Michelin XDN2 Firestone FS400 Bridgestone R249 Firestone HP 3000 Goodyear G124 (Grip Style) BF Goodrich 2T234 Matador DH1 Matador FH1 Continental HSL ECO plus Size B315/80R22.5 315/80R22.5 315/80R22.5 315/80R22.5 315/80R22.5 315/80R22.5 315/80R22.5 12R22.5 315/80R22.5 315/80R22.5 315/80R22.5 315/80R22.5 Load Range J L L L L J J H L J J J Axle All Axles All Axles All Axles Drive Axle All Axles All Axles All Axles Drive Axle All Axles Drive Axle Front/Tag Axle All Axles Front Pressure 120 psi (827 kPa) 120 psi (827 kPa) 120 psi (827 kPa) Not approved 120 psi (827 kPa) 120 psi (827 kPa) 120 psi (827 kPa) Not approved 120 psi (827 kPa) Not approved 120 psi (827 kPa) 120 psi (827 kPa) Drive Pressure 100 psi (690 kPa) 100 psi (690 kPa) 100 psi (690 kPa) 100 psi (690 kPa) 100 psi (690 kPa) 100 psi (690 kPa) 100 psi (690 kPa) 100 psi (690 kPa) 100 psi (690 kPa) 100 psi (690 kPa) Not approved 100 psi (690 kPa) Tag Pressure 120 psi (827 kPa) 120 psi (827 kPa) 120 psi (827 kPa) Not approved 120 psi (827 kPa) 120 psi (827 kPa) 120 psi (827 kPa) Not approved 120 psi (827 kPa) Not approved 120 psi (827 kPa) 120 psi (827 kPa) TIRE SIZE (Basic)....................................................................................................315/80R22.5 on a 9.00 inch rim TIRE SIZE (Minimum)................................................................................................................................."J" Rated 78 July 2015 SPN 51 51 51 70 70 84 84 84 84 84 84 84 84 84 84 84 84 84 84 84 84 84 84 84 84 91 91 91 91 97 98 98 98 100 100 100 100 100 100 107 108 108 108 110 110 110 110 DIAGNOSTIC CODES / ENGINE DD13 DIAGNOSTIC CODES FMI CODE DESCRIPTION 2 Intake Throttle Position Deviation Error 3 Intake Air Throttle Circuit Failed High 4 Intake Air Throttle Circuit Failed Low 13 J1939 Park Brake Switch Signal from Source #1 is missing 19 J1939 Park Brake Switch Signal from Source #1 is erratic 0 Vehicle Speed Above Programmable Threshold1 While Driving 2 J1939 Wheel-Based Vehicle Speed Signal from Source#1 is erratic 2 VSS Anti Tamper Detection via Virtual Gear Ratio 3 Vehicle Speed Sensor Circuit Failed High 3 Vehicle Speed Sensor Circuit Failed High 4 Vehicle Speed Sensor Circuit Failed Low 4 Vehicle Speed Sensor Circuit Failed Low 6 VSS Anti-Tamper Detection via ABS Vehicle Speed Comparison 8 VSS Anti Tamper Detection via Fixed Frequency Device 9 J1939 Wheel-Based Vehicle Speed Signal from Source#2 is missing 10 J1939 Wheel-Based Vehicle Speed Signal from Source#3 is erratic 11 Vehicle Speed Above Programmable Threshold2 While Driving 13 J1939 Wheel-Based Vehicle Speed Signal from Source#1 is missing 13 J1939 Wheel-Based Vehicle Speed Signal from Source#1 is missing 14 J1939 Wheel-Based Vehicle Speed Signal from Source#3 is missing 19 J1939 Wheel-Based Vehicle Speed Signal from Source#1 is erratic 19 J1939 Wheel-Based Vehicle Speed Signal from Source#2 is erratic 20 Vehicle Speed Sensor Drifted High Error (VSS signal not plausible) 21 Vehicle Speed Sensor Erratic 21 Vehicle Speed Failure 0 Accelerator Pedal Circuit Failed High 3 Accelerator Pedal Signal Circuit Failed High 4 Accelerator Pedal Circuit Failed Low 13 J1939 EEC2 Message is missing 15 Water in Fuel 0 Oil Level High 1 Oil Level Very Low 18 Oil Level Low 1 Engine Oil Pressure Low 1 Oil Pressure Very Low 3 Engine Oil Pressure Circuit Failed High 4 Engine Oil Pressure Circuit Failed Low 17 Oil Pressure Plausibility 18 Oil Pressure Low 0 Air Filter Restriction High 3 Barometric Pressure Circuit Failed High 4 Barometric Pressure Circuit Failed Low 13 Ambient Air Pressure Signal Not Available via CAN 0 Coolant Temperature Very High 0 Coolant Temperature High 2 Coolant Outlet Temperature Not Plausible 3 Engine Coolant Outlet Temperature Circuit Failed High July 2015 79 SPN FMI 110 4 110 9 110 14 110 16 111 1 111 3 111 4 111 18 111 19 120 13 157 7 157 16 157 18 158 2 158 2 158 7 164 0 164 1 164 3 164 4 164 5 164 20 164 21 168 0 168 0 168 0 168 1 168 1 168 1 168 7 168 14 168 18 171 2 171 9 171 13 171 14 174 0 174 2 174 3 174 4 175 0 175 3 175 4 175 14 175 15 188 31 190 0 190 9 191 9 191 13 80 DD13 DIAGNOSTIC CODES CODE DESCRIPTION Engine Coolant Outlet Temperature Circuit Failed Low Coolant Temperature Signal Not Available via CAN Coolant Temperature / Engine Oil Temperature Plausibility Fault Coolant Temperature High Coolant Level Very Low Coolant Level Circuit Failed High Coolant Level Circuit Failed Low Coolant Level Low Coolant Level Low (CAN) J1939 Retarder Fluid Message is missing No Description Fuel Rail Pressure Low Fuel Rail Pressure High Ignition Switch Not Plausible Kl15 ignition switch status of CPC2 and MCM do not match Keys witch battery potential SA61 Quantity Control Valve (Low Side) Error Quantity Control Valve (High Side) Error Rail Pressure Sensor Circuit Failed High Rail Pressure Sensor Circuit Failed Low Rail Pressure Sensor Circuit Failed Open Rail Pressure Sensor - Drift High Rail Pressure Sensor - Drift Low Battery Voltage High Battery Voltage High Battery Voltage High Battery Voltage Low Battery Voltage Very Low Battery Voltage Low Opt Idle Detected Charging System or Battery Failure ECU power-down not completed (Main Battery Terminal Possibly Floating) Battery Voltage Low Ambient Temperature Sensor Data Erratic J1587 Ambient Air Temp Sensor Data Message Stopped Arriving Ambient Air Temperature Signal Not Available via CAN J1587 Ambient Air Temp Sensor Data Not Received This Ignition Cycle Fuel Temperature Too High Fuel Temperature Sensor, General Temp. Plausibility Fuel Temperature Circuit Failed High Fuel Temperature Circuit Failed Low Oil Temperature High Warning Engine Oil Temperature Circuit Failed High Engine Oil Temperature Circuit Failed Low Engine Oil Temperature Sensor Plausibility Fault Oil Temperature High Pre-Warning Idle Speed Out of range Engine Speed High Engine Speed Signal Not Available via CAN J1939 ETC1 Message is missing J1939 Transmission Output Shaft Speed Signal is missing July 2015 SPN FMI 191 13 191 19 191 19 247 0 247 1 247 9 247 10 247 14 411 0 411 1 411 2 411 3 411 4 411 13 513 9 523 13 523 19 523 19 524 9 527 9 558 2 558 3 558 4 558 558 6 596 13 596 19 597 2 597 13 597 19 599 4 600 13 600 19 602 13 602 19 608 14 609 12 625 2 625 2 625 4 625 8 625 8 625 9 625 9 625 14 625 14 625 17 625 18 628 2 628 12 July 2015 DD13 DIAGNOSTIC CODES CODE DESCRIPTION J1939 Transmission Output Shaft Speed Signal is missing J1939 Transmission Output Shaft Speed Signal is erratic J1939 Transmission Output Shaft Speed Signal is erratic MCM Engine Hours Data higher than expected MCM Engine Hours Data lower than expected MCM Engine Hours Data not received or stopped arriving MCM Engine Hours Data increasing at an implausible rate MCM Reported Ash Mileage is Lower then the CPC Stored Value EGR Differential Pressure Too High (Low Box) EGR Differential Pressure Too Low (High Box) EGR Delta Pressure Sensor Out Of Calibration EGR Delta Pressure Sensor Circuit High EGR Delta Pressure Sensor Circuit Low EGR Delta Pressure Sensor Out Of Calibration Actual Torque Signal Not Available via CAN J1939 Transmission Current Gear Signal is missing J1939 Transmission Current Gear Signal is erratic J1939 Transmission Current Gear Signal is erratic J1939 ETC2 Message is missing J1939 CCVS Message is missing Idle Validation Switch Inputs Reversed Idle Validation Switch 1 Circuit Failed High Idle Validation Switch 1 Circuit Failed Low Idle Validation Switch 2 Circuit Failed Low Idle Validation Switch 2 Circuit Failed High J1939 Cruise Control Enable Switch Signal from Source #1 is missing J1939 Cruise Control Enable Switch Signal from Source #1 is erratic Service Brake Status Not Plausible J1939 Service Brake Switch Signal from Source #1 is missing J1939 Service Brake Switch Signal from Source #1 is erratic Cruise Control SET and RESUME Circuits Failed Low J1939 Cruise Control Coast Switch Signal from Source #1 is missing J1939 Cruise Control Coast Switch Signal from Source #1 is erratic J1939 Cruise Control Accelerate Switch Signal from Source #1 is missing J1939 Cruise Control Accelerate Switch Signal from Source #1 is erratic J1708 Data Link Failure CPC2 Hardware Failure Invalid Data on Engine CAN Link Incorrect MCM System ID Received ECAN Link Circuit Failure MCM PT-CAN DM1 Message Not Received or has Stopped Arriving MCM UDS DM1 Message Not Received or has Stopped Arriving ACM PT-CAN DM1 Message Not Received or has Stopped Arriving No Data Received from Engine CAN Link ACM UDS DM1 Message Not Received or has Stopped Arriving MCM System ID Not Received or Stopped Arriving No ACM Communication - Pre Warning No ACM Communication - Warning EEPROM Checksum Failure EEPROM Checksum Failure for the SCR Block 81 SPN FMI 628 14 628 17 629 2 629 12 630 13 636 1 636 2 636 3 636 8 636 10 636 11 639 9 639 13 639 14 639 14 647 3 647 4 647 5 651 3 651 4 651 6 652 3 652 4 652 6 653 3 653 4 653 6 654 3 654 4 654 6 655 3 655 4 655 6 656 3 656 4 656 6 677 2 677 3 677 4 677 5 677 7 679 7 701 3 701 4 702 3 702 4 703 3 703 4 704 3 704 4 82 DD13 DIAGNOSTIC CODES CODE DESCRIPTION XFLASH Static Fault Code Memory Page Read Write Failure 1000ms ECU OS Task Timed out Prior to Completion CPC Hardware/Software Mismatch DDEC Data X flash Write Error. Replace CPC2. SCR Number Out of Range Crankshaft Position Sensor Signal Voltage Too Low No Match of Camshaft and Crankshaft Signals Crankshaft Position Sensor Open Circuit Crankshaft Position Sensor Time Out Crankshaft Position Sensor Signal Erratic Crankshaft Position Sensor Failure J1939 PROP11 message is missing HDMS Fan is configured and the J1939 message was not received. J1939 Data Link Failure J1939 Data Link Failure Fan Stage 1 Circuit Failed High Fan Stage 1 Circuit Failed Low Fan Stage 1 Circuit Failed Open Injector Cylinder #1 Needle Control Valve Abnormal Operation (MAX) Injector Cylinder #1 Needle Control Valve Abnormal Operation (MIN) Injector Cylinder #1 Needle Control Valve, Valve Shorted Circuit Injector Cylinder #2 Needle Control Valve Abnormal Operation (MAX) Injector Cylinder #2 Needle Control Valve Abnormal Operation (MIN) Injector Cylinder #2 Needle Control Valve, Valve Shorted Circuit Injector Cylinder #3 Needle Control Valve Abnormal Operation (MAX) Injector Cylinder #3 Needle Control Valve Abnormal Operation (MIN) Injector Cylinder #3 Needle Control Valve, Valve Shorted Circuit Injector Cylinder #4 Needle Control Valve Abnormal Operation (MAX) Injector Cylinder #4 Needle Control Valve Abnormal Operation (MIN) Injector Cylinder #4 Needle Control Valve, Valve Shorted Circuit Injector Cylinder #5 Needle Control Valve Abnormal Operation (MAX) Injector Cylinder #5 Needle Control Valve Abnormal Operation (MIN) Injector Cylinder #5 Needle Control Valve, Valve Shorted Circuit Injector Cylinder #6 Needle Control Valve Abnormal Operation (MAX) Injector Cylinder #6 Needle Control Valve Abnormal Operation (MIN) Injector Cylinder #6 Needle Control Valve, Valve Shorted Circuit Starter Switch Inconsistent Engine Starter Relay Shorted to High Source Engine Starter Relay Circuit Failed Low Engine Starter Relay Open Circuit Engine Starter Relay - Starter Does Not Engage Pressure Limiting Valve, Failed to Close Digital Output 4 09 Circuit Failed High Digital Output 4 09 Circuit Failed Low Digital Output 3 17 Circuit Failed High Digital Output 3 17 Circuit Failed Low Digital Output 3 09 Circuit Failed High Digital Output 3 09 Circuit Failed Low Digital Output 4 07 Circuit Failed High Digital Output 4 07 Circuit Failed Low July 2015 SPN FMI 705 3 705 3 705 4 705 4 706 3 706 4 707 3 707 4 708 3 708 4 709 3 709 4 710 3 710 3 710 4 710 4 711 3 711 4 712 3 712 4 713 3 713 4 713 5 713 7 714 3 714 4 714 5 715 3 723 8 723 10 723 11 904 9 904 13 904 19 972 2 973 2 973 9 973 13 973 13 973 19 974 2 974 3 974 4 979 9 986 9 1037 0 1037 15 1037 16 1071 3 1071 4 July 2015 DD13 DIAGNOSTIC CODES CODE DESCRIPTION Digital Output 1 13 Circuit Failed High Digital Output 1 13 Circuit Failed High Digital Output 1 13 Circuit Failed Low Digital Output 1 13 Circuit Failed Low Digital Output 3 10 Circuit Failed High Digital Output 3 10 Circuit Failed Low Digital Output 2 10 Circuit Failed High (CEL / AWL Lamp) Digital Output 2 10 Circuit Failed Low (CEL / AWL Lamp) Digital Output 3 12 Circuit Failed High Digital Output 3 12 Circuit Failed Low Digital Output 3 16 Circuit Failed High Digital Output 3 16 Circuit Failed Low Digital Output 4 06 Circuit Failed High Digital Output 4 06 Circuit Failed High Digital Output 4 06 Circuit Failed Low Digital Output 4 06 Circuit Failed Low Digital Output 1 05 Circuit Failed High Digital Output 1 05 Circuit Failed Low Digital Output 1 04 Circuit Failed High Digital Output 1 04 Circuit Failed Low Digital Output 3 07 Circuit Failed High Digital Output 3 07 Circuit Failed Low Digital Output 3 07 Open Circuit TOP2 Shift Failure Digital Output 3 08 Circuit Failed High Digital Output 3 08 Circuit Failed Low Digital Output 3 08 Open Circuit Digital Output 4 10 Circuit Failed High Camshaft Position Sensor Time Out Camshaft Position Sensor Signal Erratic Camshaft Position Sensor Failure J1939 EBC2 Message from ABS is missing J1939 Front Axle Speed Signal is missing J1939 Front Axle Speed Signal is erratic Throttle inhibit switch signal not plausible due to excess vehicle speed Evo bus 5stage retarder level position not plausible J1939 EBC1 Message is missing Evobus 5stage retarder level calibration not plausible J1939 Engine Retarder Selection Signal Missing J1939 Engine Retarder Selection Signal Erratic Remote Accelerator Pedal Supply Voltage Out of Range Remote Accelerator Pedal Circuit Failed High Remote Accelerator Pedal Circuit Failed Low J1939 PTO Message Not Received This Ignition Cycle J1939 CM1 Message is missing DPF HC Absorption Very High DPF HC Absorption Warning DPF HC Absorption High Fan Stage 2 Circuit Failed High Fan Stage 2 Circuit Failed Low 83 SPN FMI 1071 5 1072 3 1072 4 1072 5 1073 3 1073 4 1073 5 1077 5 1077 6 1077 14 1077 31 1231 9 1267 3 1267 4 1590 9 1590 19 1624 9 1624 13 1624 19 1636 0 1636 2 1636 3 1636 4 1639 2 1659 18 1663 7 1716 9 1761 1 1761 3 1761 4 1761 17 1761 18 1761 31 1814 9 1845 9 2630 2 2630 3 2630 4 2630 16 2631 1 2659 0 2659 18 2791 7 2791 9 2791 10 2791 14 2791 16 2797 3 2797 4 2798 3 84 DD13 DIAGNOSTIC CODES CODE DESCRIPTION Fan Stage 2 Circuit Failed Open Jake Brake Stage 1 Circuit Failed High Jake Brake Stage 1 Circuit Failed Low Jake Brake Stage 1 Circuit Failed Open Jake Brake Stage 2 Circuit Failed High Jake Brake Stage 2 Circuit Failed Low Jake Brake Stage 2 Circuit Failed Open Quantity Control Valve Error, Current Too Low Quantity Control Valve, Current Too High Leakage in High Pressure Fuel System Too High (Leak Down Test) Rail Pressure Governor Error, Open Loop Error ACM Message Not Received or has Stopped Arriving Digital Output 4 10 Circuit Failed Open Digital Output 4 10 Circuit Failed Low Adaptive Cruise Control Device Reporting Error Adaptive Cruise Control Message Not Received J1939 TCO1 Message is missing J1939 Tachograph Vehicle Speed Signal is missing J1939 Tachograph Vehicle Speed Signal is erratic Charge Air Cooler Low Efficiency Engine Air Temperature - Plausibility Fault Out of Range (Low Box) Intake Manifold Temperature Circuit Failed High Intake Manifold Temperature Circuit Failed Low Fan Speed Fault Thermostat Error Detected Optimized Idle Safety Loop Faulted J1939 ERC1 Message is missing DEF Tank Level 0 - Empty (Speed Limited) DEF Tank Level Sensor Circuit Failed High DEF Tank Level Sensor Circuit Failed Low DEF Tank Level 2 - Very Low DEF Tank Level 1 - Empty DEF Tank Level 3 - Low VDC1 Message was not received or has stopped arriving. J1939 TCFG2 Message is missing Engine Air Temperature - Plausibility Fault Out of Range (High Box) Charge Air Cooler Outlet Temperature Circuit Failed High Charge Air Cooler Outlet Temperature Circuit Failed Low Charge Air Cooler Performance Monitor Low Air Flow EGR Flow Target Error Diagnostic - High Flow EGR Flow Target Error Diagnostic - Low Flow EGR Valve Actuator, Failsafe Mode, Motor On EGR Valve Actuator, Failsafe Mode, Motor Off EGR Actuator Slow Response EGR Valve Actuator, No Failsafe Mode, Motor Off EGR Valve Actuator, Temperature Fault Injector Needle Control Valve Cylinder 1,2,3 Shorted to Battery Injector Needle Control Valve Cylinder 1, 2, 3 Shorted to Ground Injector Needle Control Valve Cylinder 4,5,6, Shorted to Battery July 2015 SPN FMI 2798 4 2900 9 3031 2 3031 3 3031 4 3056 2 3057 2 3216 2 3216 3 3216 4 3216 13 3216 21 3226 2 3226 3 3226 4 3226 13 3226 21 3236 9 3242 3 3242 4 3242 8 3242 20 3246 0 3246 3 3246 4 3246 8 3246 15 3246 20 3246 21 3250 0 3250 3 3250 4 3250 8 3250 14 3250 15 3250 20 3250 31 3251 0 3251 2 3251 16 3361 0 3361 1 3361 3 3361 4 3361 5 3361 7 3363 0 3363 1 3363 3 3363 4 July 2015 DD13 DIAGNOSTIC CODES CODE DESCRIPTION Injector Needle Control Valve Cylinder 4, 5, 6 Shorted to Ground J1939 ETC7 Message is missing DEF Tank Temperature - Drift DEF Tank Temperature Sensor Circuit Failed High DEF Tank Temperature Sensor Circuit Failed Low SCR Inlet Nox Sensor - Error SCR Outlet Nox Sensor - Error SCR Inlet Nox Sensor - Drift SCR Inlet Nox Sensor Circuit Failed High SCR Inlet Nox Sensor Circuit Failed Low SCR Inlet Nox Sensor Signal Not Available SCR Inlet Nox Sensor - Drift (Low Box) SCR Outlet Nox Sensor - Drift SCR Outlet Nox Sensor Circuit Failed High SCR Outlet Nox Sensor Circuit Failed Low SCR Outlet Nox Sensor Signal Not Available Nox Outlet Sensor Drift High Exhaust Mass Signal Not Available via CAN DOC Inlet Temperature Circuit Failed High DOC Inlet Temperature Circuit Failed Low DOC Inlet Temperature - Signal Spike DOC Temperature Drift - Inlet High or Outlet Low DPF Outlet Temperature - Very High DPF Oulet Temperature Circuit Failed High DPF Oulet Temperature Circuit Failed Low DPF Outlet Temperature - Signal Spike DPF Outlet Temperature - High DPF Outlet/SCR Inlet Temperature - Abnormal DPF Outlet Temperature Sensor - Not Plausible DOC Outlet Temperature - Very High DOC Outlet Temperature Circuit Failed High DOC Outlet Temperature Circuit Failed Low DOC Outlet Temperature - Signal Spike Abnormal DOC Temperature Rise 2 DOC Outlet Temperature - High DOC Temperature Drift - Inlet Low or Outlet High Abnormal DOC Temperature Rise DPF Pressure - Out of Range Very High DOC Inlet Pressure Sensor - Not Plausible DPF Pressure - Out of Range High DEF Pressure Duty Cycle High DEF Pressure Duty Cycle Low DEF Dosing Valve Circuit Failed High DEF Dosing Valve Circuit Failed Low DEF Dosing Valve Circuit Failed Open DEF Unit - Unable to clear Restriction DEF Tank Temperature - High DEF Tank Temperature - Low DEF Coolant Valve Circuit Failed High DEF Coolant Valve Circuit Failed Low 85 SPN FMI 3363 5 3364 1 3364 2 3364 17 3464 3 3464 4 3464 5 3464 31 3471 3 3471 4 3471 5 3480 0 3480 1 3480 2 3480 3 3480 4 3480 14 3480 31 3482 3 3482 4 3482 5 3509 3 3509 3 3509 4 3509 4 3510 3 3510 3 3510 3 3510 4 3510 4 3510 4 3510 7 3512 3 3512 4 3556 0 3556 1 3556 18 3563 3 3511 3 3511 4 3563 4 3563 18 3563 20 3597 3 3597 3 3597 4 3597 4 3598 3 3598 4 3599 3 86 DD13 DIAGNOSTIC CODES CODE DESCRIPTION DEF Coolant Valve Circuit Failed Open Improper DEF Quality Final Warning Improper DEF Quality Improper DEF Quality Warning H Bridge 1 Circuit Shorted to Battery H Bridge 1 Circuit Shorted to Ground H Bridge 1 Circuit Open Load Intake Air Throttle Control Electrical Fault HC Doser Circuit Failed High HC Doser Circuit Failed Low HC Doser Circuit Failed Open Fuel Compensation Pressure High Doser Fuel Supply Pressure Abnormal Doser Fuel Line Pressure Low Fuel Compensation Pressure Sensor Circuit Failed High Fuel Compensation Pressure Sensor Circuit Failed Low Doser FLP Sensors Failed Self Test Fuel Cut Off Valve Pressure Not Plausible Fuel Cut Off Valve Circuit Failed High Fuel Cut Off Valve Circuit Failed Low Cut Off Valve Circuit Failed Open ACM Sensor Supply 1 Short to Battery 5V Sensor Supply Bank 1 Circuit Failed High ACM Sensor Supply 1 Short to Ground 5V Sensor Supply Bank 1 Circuit Failed Low 5V Sensor Supply Bank 2 Circuit Failed High ACM Sensor Supply 2 Short to Battery Accelerator Pedal Supply Voltage Circuit Failed High Accelerator Pedal Supply Voltage Circuit Failed Low ACM Sensor Supply 2 Short to Ground 5V Sensor Supply Bank 2 Circuit Failed Low Accelerator Pedal Supply Voltage Circuit Failed High 3V Sensor Supply Bank 2 Circuit Failed High 3V Sensor Supply Bank 2 Circuit Failed Low Regen Temperature - Out of Range High Regen Temperature - Out of Range Low DOC Outlet Temp Low, (Low Temp Regen) Intake Manifold Pressure Circuit Failed High 3V Sensor Supply Bank 1 Circuit Failed High 3V Sensor Supply Bank 1 Circuit Failed Low Intake Manifold Pressure Circuit Failed Low Inlet Manifold Pressure Failed Low Ambient and Inlet Manifold Pressure Difference (Low Box) High Side Digital Output 1 Circuit Failed High Proportional Valve Bank 1 Circuit Failed High Proportional Valve Bank 1 Circuit Failed Low High Side Digital Output 1 Circuit Failed Low Proportional Valve Bank 2 Circuit Failed High Proportional Valve Bank 2 Circuit Failed Low High Side Digital Output 3 Circuit Failed High July 2015 SPN FMI 3599 3 3599 4 3599 4 3606 9 3609 3 3609 4 3610 2 3610 3 3610 4 3659 3 3659 4 3659 6 3660 3 3660 4 3660 6 3661 3 3661 4 3661 6 3662 3 3662 4 3662 6 3663 3 3663 4 3663 6 3664 3 3664 4 3664 6 3695 9 3695 13 3695 14 3695 19 3696 9 3696 13 3696 14 3696 19 3711 31 3713 31 3716 31 3719 0 3719 15 3719 16 3719 31 3720 15 3936 18 4041 0 4041 9 4041 16 4077 0 4077 3 4077 4 July 2015 DD13 DIAGNOSTIC CODES CODE DESCRIPTION MCM Internal Injector Power Supply Failed High High Side Digital Output 3 Circuit Failed Low MCM Internal Injector Power Supply Failed Low J1939 ESS Message is missing DOC Inlet Pressure Circuit Failed High DOC Inlet Pressure Circuit Failed Low DPF Outlet Pressure Sensor - Not Plausible DPF Outlet Pressure Circuit Failed High DPF Outlet Pressure Circuit Failed Low Injector Cylinder #1 Amplifier Control Valve Abnormal Operation (MAX) Injector Cylinder #1 Amplifier Control Valve Abnormal Operation (MIN) Injector Cylinder #1 Amplifier Control Valve, Valve Shorted Circuit Injector Cylinder #2 Amplifier Control Valve Abnormal Operation (MAX) Injector Cylinder #2 Amplifier Control Valve Abnormal Operation (MIN) Injector Cylinder #2 Amplifier Control Valve, Valve Shorted Circuit Injector Cylinder #3 Amplifier Control Valve Abnormal Operation (MAX) Injector Cylinder #3 Amplifier Control Valve Abnormal Operation (MIN) Injector Cylinder #3 Amplifier Control Valve, Valve Shorted Circuit Injector Cylinder #4 Amplifier Control Valve Abnormal Operation (MAX) Injector Cylinder #4 Amplifier Control Valve Abnormal Operation (MIN) Injector Cylinder #4 Amplifier Control Valve, Valve Shorted Circuit Injector Cylinder #5 Amplifier Control Valve Abnormal Operation (MAX) Injector Cylinder #5 Amplifier Control Valve Abnormal Operation (MIN) Injector Cylinder #5 Amplifier Control Valve, Valve Shorted Circuit Injector Cylinder #6 Amplifier Control Valve Abnormal Operation (MAX) Injector Cylinder #6 Amplifier Control Valve Abnormal Operation (MIN) Injector Cylinder #6 Amplifier Control Valve, Valve Shorted Circuit DPF Regen Inhibit MUX Switch Message Stopped Arriving DPF Regen Inhibit MUX Switch Message Contains SNV Indicator DPF Regen Inhibit MUX Switch Message Not Received this Ignition Cycle DPF Regen Inhibit MUX Switch Message Contains Data Error Indicator DPF Regen Force MUX Switch Message Stopped Arriving DPF Regen Force MUX Switch Message Contains SNV Indicator DPF Regen Force MUX Switch Message Not Received this ignition Cycle DPF Regen Force MUX Switch Message Contains Data Error Indicator Parked Regen Failed - DOC Temp In Low Preventing Dosing Parked Regen Failed - DOC Temp Out, Not Reaching Target Temp High Idle Regen - Low Temperature Soot Level Very High DPF Zone 3 Condition Soot Level High DPF Zone 2 Condition DPF Ash Clean Request DPF Pressure - Out of Range Low 20ms ECU OS Task Locked in an Endless Loop 20ms ECU OS Task Timed out Prior to Completion 1000ms ECU OS Task Locked in an Endless Loop Doser Fuel Line Pressure High Doser Fuel Line Pressure Sensor Circuit Failed High Doser Fuel Line Pressure Sensor Circuit Failed Low 87 SPN FMI 4077 14 4193 2 4193 3 4193 4 4193 10 4257 3 4257 4 4258 3 4258 4 4334 2 4334 3 4334 4 4334 7 4334 17 4335 1 4335 2 4335 3 4335 4 4335 7 4335 14 4335 31 4336 3 4336 4 4336 5 4337 2 4337 3 4337 4 4353 3 4353 4 4353 5 4354 3 4354 4 4354 5 4355 3 4355 4 4355 5 4356 3 4356 4 4356 5 4357 3 4357 4 4357 5 4358 3 4358 4 4358 5 4360 3 4360 4 4360 8 4360 20 4363 0 88 DD13 DIAGNOSTIC CODES CODE DESCRIPTION Doser Fuel Line Pressure Failed Self Test Coolant Inlet Temperature Not Plausible Engine Coolant Inlet Temperature Circuit Failed High Engine Coolant Inlet Temperature Circuit Failed Low Coolant Temperature Sensors not Plausible Injector Amplifier Control Valve Cylinder 1, 2, 3 Shorted to Battery Injector Amplifier Control Valve Cylinder 1, 2, 3 Shorted to Ground Injector Amplifier Control Valve Cylinder 4, 5, 6 Shorted to Battery Injector Amplifier Control Valve Cylinder 4, 5, 6 Shorted to Ground DEF Pressure Sensor - Drift DEF Pressure Sensor Circuit Failed High DEF Pressure Sensor Circuit Failed Low DEF Pressure Low DEF Purge Pressure High DEF Air Pressure Not Detected (from vehicle supply) DEF Air Pressure Sensor - Drift DEF Air Pressure Sensor Circuit Failed High DEF Air Pressure Sensor Circuit Failed Low DEF Air Pressure Low DEF - Information Only DEF - Information Only DEF Air Valve Circuit Failed High DEF Air Valve Circuit Failed Low DEF Air Valve Circuit Failed Open DEF Dosing Unit Temperature - Drift DEF Temperature Sensor Circuit Failed High DEF Temperature Sensor Circuit Failed Low Diffuser Heater Circuit Failed High Diffuser Heater Circuit Failed Low Diffuser Heater Open Circuit SCR Line Heater #1 Circuit Failed High SCR Line Heater #1 Circuit Failed Low SCR Line Heater #1 Open Circuit SCR Line Heater #2 Circuit Failed High SCR Line Heater #2 Circuit Failed Low SCR Line Heater #2 Circuit Failed Open SCR Line Heater #3 Circuit Failed High SCR Line Heater #3 Circuit Failed Low SCR Line Heater #3 Circuit Failed Open SCR Line Heater #4 Circuit Failed High SCR Line Heater #4 Circuit Failed Low SCR Line Heater #4 Circuit Failed Open DEF General Heater Circuit Failed High DEF General Heater Circuit Failed Low DEF General Heater Circuit Failed Open SCR Inlet Temperature Sensor Circuit Failed High SCR Inlet Temperature Sensor Circuit Failed Low SCR Inlet Temperature - Signal Spike SCR Inlet Temperature Sensor Drift High in Range SCR Outlet Temperature High July 2015 SPN FMI 4363 3 4363 4 4363 8 4363 20 4364 1 4364 18 4375 3 4375 4 4375 5 4375 6 4752 0 4752 31 5016 3 5016 4 5017 3 5017 4 5246 0 5246 15 5246 16 5298 14 5357 16 5357 18 5397 31 520231 13 520232 9 520249 4 DD13 DIAGNOSTIC CODES CODE DESCRIPTION SCR Outlet Temperature Sensor Circuit Failed High SCR Outlet Temperature Sensor Circuit Failed Low SCR Outlet Temperature - Signal Spike SCR Outlet Temperature Sensor Drift High in Range SCR NOX Conversion Efficiency Very Low SCR NOX Conversion Efficiency Low DEF Pump Circuit Failed High DEF Pump Circuit Failed Low DEF Pump Circuit Failed Open DEF Pump Supply Current High EGR Cooler Low Efficiency EGR Cooler Performance Monitor Coolant Valve Supply Voltage Failed High Coolant Valve Supply Voltage Failed Low High Side Digital Output 5 Circuit Failed High High Side Digital Output 5 Circuit Failed Low Regulatory Fault Ignored - Final Action (Speed Limit) Regulatory Fault Ignored - De-rate On Regulatory Fault Ignored - Final Action Pending SCR Abnormal Temperature Rise Fuel Quantity High Detected Fuel Quantity Low Detected DPF Regen Too Often Fuel Mass Signal Not Available via CAN NOx Mass Signal Not Available via CAN SCR Inlet Temperature High July 2015 89 CUMMINS DIAGNOSTIC CODES 90 July 2015 CUMMINS Diagnostic Codes - Continued July 2015 91 CUMMINS Diagnostic Codes - Continued 92 July 2015 CUMMINS Diagnostic Codes - Continued July 2015 93 CUMMINS Diagnostic Codes - Continued 94 July 2015 CUMMINS Diagnostic Codes - Continued July 2015 95 CUMMINS Diagnostic Codes - Continued 96 July 2015 CUMMINS Diagnostic Codes - Continued July 2015 97 CUMMINS Diagnostic Codes - Continued 98 July 2015 CUMMINS Diagnostic Codes - Continued July 2015 99 CUMMINS Diagnostic Codes - Continued 100 July 2015 CUMMINS Diagnostic Codes - Continued July 2015 101 CUMMINS Diagnostic Codes - Continued 102 July 2015 CUMMINS Diagnostic Codes - Continued July 2015 103 CUMMINS Diagnostic Codes - Continued 104 July 2015 DIAGNOSTIC CODES/TRANSMISSION ALLISON GEN V B500 DIAGNOSTIC CODES July 2015 105 106 July 2015 July 2015 107 108 July 2015 DIAGNOSTIC CODES/HVAC HVAC PARAMETERS CODES July 2015 109 110 July 2015 DIAGNOSTIC CODES/HVAC HVAC ALARM CODES July 2015 111 112 July 2015 DIAGNOSTIC CODES/AMEREX AMEREX FIRE SUPPRESSION SYSTEM DIAGNOSTIC CODES AMEREX Code - Blinking LED's on the Amerex control panel indicates diagnostic codes. Record all codes. 1. The blinking Service System LED indicates Service System Blink Codes. 2. The blinking FIRE LED indicates Alarm Blink Codes. July 2015 113 THIS PAGE INTENTIONALLY LEFT BLANK 114 July 2015 Numerics 4 IN 1 Gauge 14 A A/C Default Settings 58 Fan Settings 58 KH\ FXQFWLRQV 57 Manual Settings 58 Micromax HVAC Switches 57 Parcel Rack Ventilation Switch 57 Pre-Trip Inspection 58 Air Emergency Fill 52 Low Telltale 49 Pressure Gauge, Front 20 Pressure Gauge, Rear 20 Service Fill 52 Towing Connections 53 Anti-Lock Brakes (ABS) Telltale 11, 28, 49 Audio/Video System 59 DVD Player 61 REI EC-750 60 REI ECD-5500 62 Automatic Traction Control (ATC) Mud/Snow Switch 17 Operation 30 Automatic Transmission Fluid - Allison 70 Auxiliary Heater 69 Diagnostics 69 Switch 15 Auxiliary Storage / Wheelchair Lift 67 INDEX B Baggage Compartment Access 67 Lock Switch 16 Battery Boost 51 Charger 30 Main Disconnect Switch 55 Block Heater, Engine 42 Brakes Anti-Lock Brakes 28 Parking Brake Release 18, 19 Parking Brakes 19, 52 Service Brakes 28, 52 Telltale 11 C Certification Plate 1 Check Engine Telltale 10, 49 Check Transmission Telltale 11, 49 Circuit Breakers 55 Coach Clearance, Body, Door 75 Code Retrieval ABS 113 AMEREX 114 Engine 90 HVAC Parameters and Alarm 111 Transmission 105 Column, Steering 25 Condenser Compartment 66 Cooling System 67 Surge Tank 67 Telltale 49 Temperature Gauge 21 Cruise Control 27 Active Cruise with Braking (ACB) 22 D Daily Inspection 5 Date, Publication 1 DEF Gauge 21 Diagnostic Codes ABS 113 AMEREX 114 Engine 90 HVAC Alarm Codes 109 Transmission 105 Diesel Fuel Specification 69 Dimmer Switch, Headlights 26 Door (See Entrance Door, Baggage Doors, Service Compartment Doors) Baggage 16, 65 Entrance 16, 54 Service 65 Driver's Compartment, Light Switch 16 Driver's Seat, Seat Belt 7 E Electric Horn 28 Electronic Control System, Transmission 45 Electronic Stability Control 30 Emergency Conditions 49 Amerex Fire Suppression 56 Boosting 51 Brake Service Fill 52 Circuit Breakers and Fuses 55 Emergency Stops 54 Entrance Door Override 54 Escape (Windows, Roof Hatch) 50 Parking Brake Operation 52 Safety Equipment and Tools 54 Service Brakes Operation 52 Towing 53 Emergency Park Brake Release 18, 19 Emission Control Decal 1 Engine 39 Auxiliary Heater 69 Block Heater 42 Compartment 66 Compartment Door Release Lever 55 Oil 70 Rear Start Procedure 39 Shutdown Override 15 Starting 39 Stopping 40 Tachometer 21, 49 Telltale 10, 49 Warm-Up 39 Engine Brake, Telltale 11 Engine Code Retrieval 41 Engine Lubricating Oil 70 Entrance Door Exterior Switch 29 Interior Switch 16 Operation 29 Override Valve 54 ESC/ATC Telltale 11 Exhaust 43 Exterior Inspection 5 Exterior Lighting 66 F Fast Idle 39 Switch 17 Fire Alarm Telltale 13, 49 Fire Extinguisher 54 Flashers, (see Hazard/Warning Lights) 16 Fluid 70 Capacities 75 Engine Oil 70 Power Steering 70 Front Service Compartment 66 Fuel Contamination 43 Filler Doors 67 Fueling the coach 42 Gauge 21, 49 System Maintenance 42 Tank Access 67 Fuel Pro, Fuel Filter 43 Fuel Tank Filler Doors 67 Fuel, DEF, Specifications 42, 69 Fuel, ULSD, Specifications 42, 69 Fuses 55 G Gauge Temperature 49 Gauges 9 Air Pressure, Front 20, 49 Air Pressure, Rear 20 Coolant Temperature 21 Engine Tachometer 21, 49 Fuel 49 Oil Pressure 14, 49 Temperature 14 Voltmeter 21, 49 H Hazard Light, Switch 16 Hazard/Warning Lights, Switch 16 Headlights High Beam Control 26 High Beam Telltale 12 Heating and Air Conditioning (See HVAC) 57 Horn Air 26 Electric 28 HVAC 57 Default Settings 58 Fan Settings 58 Key Functions 57 Manual Settings 58 Pre-Trip Inspection 58 Start-Up and Settings 58 I Immersion Heater (Engine Block) 42 In Station Lighting 30 Inspections Anti Theft Precautions 8 Exterior Inspection 5 HVAC Pre Trip Inspection 58 Interior Components 5 Operational Checklist 6 Pre-Trip Inspection 8 Seat Belt 7 Instrument Panels 20 Interior Components Checklist 5 Interlocks, Parking Brake 19 International Symbols 3 J Jack (Hydraulic) 54 Jacob Brake Controls 27 Telltale 11 K Kneel Operation 29 Switch 16 Telltale 12 L Lavatory Emergency Telltale 13, 49 Tank Service Procedures 71 Lights Hazard/Warning 16 Interior 16 Reading 16 Step-well 16 M Main Battery Disconnect Switch 55 Maintenance 65 Compartment Access 66 Cooling System 67 Fluid Replacement 70 Fueling 42, 69 Lavatory 71 Tire Change 67 Mirrors 7 Controls 17 Exterior Rear-view 7 Heat Switch 15 Inside Rear-view 7 Mud/Snow Operation 30 Switch 17 Multiplex Bypass Circuit 40 N Nameplate 1 Not Generating, Telltale 10, 49 O Oil, Engine 70 Pressure Gauge 14, 49 Operational Checklist 6 Override Engine Switch 15 Entrance Door 54 P Parcel Rack Ventilation, Switch 15, 57 Parking Brake 19 Emergency Operation 52 Interlocks 19 Normal Operation 19 Telltale 11 Phone Number, MCI Service 1 Power Source, 12-Volt 18 Power Steering Fluid 70 Power Steering System 51 Emergency Operation 51 Fluid Maintenance 70 Proheat (See Auxiliary Heater) 15, 57, 72 Publication Date 1 R Radiator Compartment 65, 66 Reading Light, Switch 16 Rear Rise Operation 29 Switch 18 Telltale 12 Rear-View Mirrors Exterior 7 Interior 7 Rocker Switch Ignition 39 Roof Hatch 50 S Safety Equipment 54 Seat Belt 7 Inspection 7 Service Brakes Emergency Operation 52 Normal Operation 28 Service Fill 52 Service Compartment Door Auxiliary Storage 67 Condenser Compartment 66 Engine Compartment 66 Engine Door, Release Lever 55 Fuel Tank 67 Radiator Compartment 65 Release Switch, Front 66 Spare Tire Compartment 66 Wheelchair Lift 67 Smart Stick Controls 26 Spare Tire 66 Specifications 75 Body and Door Clearance 76 Capacities 75 Tire Inflation Chart 78 Turning Radius and Door Clearance 77 Vehicle Height 75 Vehicle Weight 75 Vehicle Width 75 Speedometer 20 Starting the Engine 39 Steering Column 25 Step-well Lights, Switch 16 Stop Engine, Telltale 10, 49 Stop Request, Telltale 13 Stop Transmission, Telltale 11 Stopping the Coach, In an Emergency 54 Stopping the Engine 40 Supply Air Low, Telltale 49 Surge Take, Coolant 67 Switch Panels Left hand 15 Right hand 16 Switch, Regeneration Toggle Switch 19, 40 Switches 16 Auxiliary Heater 15 Baggage Lock 16 Engine Shutdown Override 15 Entrance Door Open/Close 16 Fast Idle 17 Hazard/Warning Lights 16 Ignition 15 Kneeling 16 Mirror Controls 17 Mirror Heat Switch 15 Mud/Snow 17 Parcel Rack Blower 15 Reading Lights 16 Step-well Lights 16 Tag Axle Unload 17 Symbols, International 3 T Tachometer 21, 49 Tag Axle Unload Operation 30 Switch 17 Telltale 11, 12, 49 Telltales 10, 12 ABS 11, 49 Check Engine 10, 49 Check Info 12, 13 Check Transmission 11, 49 Cruise Enabled 12 Engine Brake 11 ESC/ATC 11 Fire Alarm 13, 49 High Beams 12 Kneeling 12 Lavatory Emergency 13, 49 Low Coolant 10, 49 Low Ride 12 MIL 11 Not Generating 10, 49 Parking Brake 11 Service Light 13 Stop Engine 10 Stop Request 13 Stop Transmission 11 Supply Air Low 49 Tag Unloaded 49 Turn Indicator, Left 10 Turn Indicator, Right 12 Wait to Start 10 Temperature Gauge 49 Temperature Setting 57 Threshold Warning System 32 Tire Change 67 Inflation Chart 78 Spare 65, 66 Tools and Safety Equipment 54 Towing 53 Triangles (Emergency) 54 Turn Signals 26 Turning Radius 77 U Unload, Tag Axle Operation 30 Switch 17 Telltale 12, 49 V Vehicle Identification Number (VIN) 2 VIN Plate 1 Voltmeter 21 Telltale 49 W Wheelchair Interlock System 31 Wheelchair Lift 31 Access Door 65 Manual Operation 36 Wheelchair Seating 37 Windows, Side 50 Windshield Washer 26 Reservoir 70 Wipers 26 Wrench (Lug) 54 United States Operators please notice: The National Highway Traffic Safety Administration has requested that the following statement be provided for your information. If you believe that your vehicle has a 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 Motor Coach Industries, Inc. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Motor Coach Industries, Inc. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, DC, area) or write to: NHTSA, U.S. Department of Transportation, Washington, DC, 20590. You may also obtain other information about motor vehicle safety from the Hotline. Canadian Operators please notice: To report or obtain information on motor vehicle safety-related defects, or manufacturers' recalls, call Transport Canada's Information Centre at 1-800-333-0371, or call (613) 998---8616 if you are in the Ottawa area. You can email comments or questions to roadsafetywebmail@tc.gc.ca or write to: Road Safety and Motor Vehicle Regulation Directorate, Transport Canada, Tower C, Place de Ville, 330 Sparks Street, Ottawa, Ontario, K1A 0N5Corel PHOTO-PAINT X6 ilovepdf.com