D3FE. VOLUME 1 Introduction Chassis Frame Front Axle & Suspension Rear Axle & Suspension Air Brakes Hydraulic Brakes SERVICE MANUAL
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2 VOUME 1 Introduction Chassis Frame Front Axle & Suspension Rear Axle & Suspension Air Brakes Hydraulic Brakes 2010 D3FE SERVICE MANUA APPIES TO THESE MODES A AMERICAN FORWARD ENGINE TX3 FORWARD ENGINE GOBA TRANSIT FORWARD ENGINE
3 D3FE
4 SERVICE MANUA 2009 Blue Bird Corporation. All rights reserved. The Blue Bird All American complies with all applicable federal and state regulations. These include, but are not limited to, Federal ADA as well as state accessibility, safety and security requirements. The Blue Bird All American meets all applicable Federal Motor Vehicle Safety Standards (FMVSS) rules and regulations. In the event of any conflict between the requirements of this publication and any applicable legal requirement, the legal requirement prevails. Technical requirements that exceed the legal requirements are not considered to conflict. Many of the components of Blue Bird buses are obtained from outside suppliers. Where maintenance and/or service information conflicts with the component manufacturers documentation, the manufactures s documentation prevails. Blue Bird Corporation continually endeavors to improve its product and reserves the right to change without notice. The material presented in this manual is accurate at the time of publication.
5 Introduction / 15 Blue Bird Strength; Blue Bird Innovation / 15 Backed By Blue Bird / 15 Reporting Safety Defects / 17 About This Manual / 18 About the TechReference CD / 20 Chassis Frame / 23 Chassis Frame Overview / 23 Frame Maintenance Overview / 23 Huck Fasteners / 24 Body Tie-down Clamps and Angles / 25 Swing-Out Radiator / 26 Rubber Mounting Pads / Front Axle & Suspension / 35 Overview / 35 Maintenance / 35 Airtek / Softek Suspension: Appendix 1 / 41 Rear Axle & Suspension / 155 Overview / 155 Maintenance / 156 Rear Spring & Axle Removal / 159 Rear Spring & Axle Installation / 161 Rear Air Suspension / 164 Comfort Air Suspension: Appendix 1 / 167
6 Air Brakes / 205 Overview / 205 Automatic Traction Control / 209 Brake Interlock / 213 Maintenance Overview / 214 Air Compressor / 215 Air Compressor Governor (D-2) / 216 Air Dryer (Optional) / 218 Air Tanks / 221 Treadle Valve (E-8P) / 223 Relay Valve (R-12) / 225 Park Brake Control Valve (PP-DC) / 227 ABS Modulator Valves (M-32QR) / 228 ABS Wheel Speed Sensors (WS-24) / 230 ABS Controller (EC-60) / 232 Brake Chambers, Front / 233 Brake Chambers, Rear / 235 Slack Adjusters / 239 Brake Shoes & Drums / 244 Front Brake Assembly / 246 Rear Brake Assembly / 248 AD-9 Air Dryer: Appendix 1 / 251 PP-DC Park Control Valve: Appendix 2 / 275 SR-7 Spring Brake Valve: Appendix 3 / 281 EC-60 ABS / ATC Controllers: Appendix 4 / 289 Cam Brakes & Automatic Slack Adjustes: Appendix 5 / Hydraulic Brakes / 389 Overview / 389 Maintenance Overview / 390 Master Cylinder / 395 Booster / 397 ABS Modulator / 400 Wheel Speed Sensors / 402 ABS Electronic Control Unit (ECU) / 404 Calipers / 407 Brake Pads / 408 Brake Rotors / 409 Brake Rotor Removal / 409 Front Brake Reassembly / 410 Rear Brake Removal, / 412 Rear Brake Rotor Reassembly / 414 Brake Interlock, Hydraulic / 420 Hydraulic Brake Booster & Master Cylinder: Appendix 1 / 427 Hydraulic Anti-ock Braking System: Appendix 2 / 455 Four-Piston Quadraulic Disc Brake Caliper: Appendix 3 / 491 Brake Interlock System: Appendix 4 / 517
7 Power Drivetrain / 539 Overview / 539 Engine Access / 540 Transmission / 542 Transmission Maintenance / 544 Shift Cable Adjustment / 546 Drive ine / 547 Transmission Service Prognostics / 550 Cooling / 553 Overview / 553 About Coolant / 560 Standard Equipment Coolant / 560 Optional Extended ife Coolant / 560 Coolant Decals / 560 Coolant Maintenance / 561 Radiator Shutters / 563 Radiator / 566 Cooling System Drain, Flush & Refill / 568 Fan Clutch / 572 Intake & Exhaust / 573 Intake Overview / 573 Intake System Maintenance / 575 Exhaust System / 578 Regeneration Process In Cummins Engines / 579 DPF Regeneration In Blue Bird Buses / 582 evels of Notification / 583 Stationary Regeneration Precautions / 586 Exhaust Piping / Fuel System / 595 Fuel System / 595 Accelerator Control, Electronic / 600 Throttle Position Sensor / 600 Auto Calibration / 601 Accelerator Testing And Troubleshooting / 602 Instrumentation / 603 Overview / 603 Instrument Cluster Removal / 605 Testing a Gauge By Substitution / 605 Instrument Cluster: Appendix 1 / 607
8 Body Electrical / 677 Overview / 677 Body Control Module (BCM) / 678 adder ogic ines / 681 Troubleshooting Body Electrical Circuits / 685 Body Wiring Schematics / 686 BCM adder ogic Diagrams / 687 Doran Warning ight Monitor / 691 Doran Troubleshooting / 691 Heat and Air Control Panels / 692 eft Switch Panel / 694 Right Switch Panel / 696 Chassis Electrical / 699 Charging System / 699 Alternator Removal / 703 Automatic Belt Tensioner / 704 Starter / 705 Starter Motor Removal / 711 J-1939 Harness Diagnostics / 712 Chassis Wiring Schematics / 713 Steering / 765 Overview / 765 Steering System Operation / 766 Steering System Maintenance / 767 Steering Column & Steering Wheel / 768 Steering Gear / 770 Steering Pump / 771 Flushing the Steering System: Appendix 1 / 775 Air Bleeding the Steering System: Appendix 2 / 777 THP / PCF Steering Gear: Appendix 3 / 779 Steering Diagnostics: Appendix 4 / 845 TAS Poppets: Appendix 5 /
9 Body Structure / 909 Overview / 909 Body Glass / 909 Windshield Glass Replacement / 909 Rear Vision Glass Replacement / 911 Split Sash Window and Glass Replacement / 912 Rear Vision Glass Replacement / 913 Transit Sliding Window Removal / 914 Transit Window Glass Replacement / 914 Outward Opening Entrance Door / 916 Manual Door Control / 918 Pneumatic Door Opener / 919 Electric Door Opener / 920 Door Panels / 921 Stop Arms / 924 Auto Glass Replacement: Appendix 1 / 925 Body Interior / 983 Overview / 983 Driver s Seat / 983 Deluxe Driver s Seat / 984 Seat Care and Cleaning Tips / 985 Passenger DOT Seats / 985 Track Mounted Passenger Seats / 987 Seat Belts & Shoulder Harnesses / 987 Body Finish / 991 Exterior Paint / 991 Interior Paint / 991 Front End / 991 Rear End / 992 Headlining / 992 Fastening / 992 Floor Covering / 992 Undercoating / 993 ettering/decals /
10 Specs & Maintenance / 995 General Specification, Chassis / 995 General Specification, Body / 1000 Dimensions / 1006 Fastener Grades / 1007 Service Precautions / 1010 Jacking and Towing / 1012 Fluids & Filters / 1015 General Maintenance Schedules / 1017 Maintenance Task Schedule / 1018 Index /
11 Volume 2 Power Drivetrain / 539 Overview / 539 Engine Access / 540 Transmission / 542 Transmission Maintenance / 544 Shift Cable Adjustment / 546 Drive ine / 547 Transmission Service Prognostics / 550 Cooling / 553 Overview / 553 About Coolant / 560 Standard Equipment Coolant / 560 Optional Extended ife Coolant / 560 Coolant Decals / 560 Coolant Maintenance / 561 Radiator Shutters / 563 Radiator / 566 Cooling System Drain, Flush & Refill / 568 Fan Clutch / Intake & Exhaust / 573 Intake Overview / 573 Intake System Maintenance / 575 Exhaust System / 578 Regeneration Process In Cummins Engines / 579 DPF Regeneration In Blue Bird Buses / 582 evels of Notification / 583 Stationary Regeneration Precautions / 586 Exhaust Piping / 588 Fuel System / 595 Fuel System / 595 Accelerator Control, Electronic / 600 Throttle Position Sensor / 600 Auto Calibration / 601 Accelerator Testing And Troubleshooting / 602 Instrumentation / 603 Overview / 603 Instrument Cluster Removal / 605 Testing a Gauge By Substitution / 605 Instrument Cluster: Appendix 1 / 607
12 Body Electrical / 677 Overview / 677 Body Control Module (BCM) / 678 adder ogic ines / 681 Troubleshooting Body Electrical Circuits / 685 Body Wiring Schematics / 686 BCM adder ogic Diagrams / 687 Doran Warning ight Monitor / 691 Doran Troubleshooting / 691 Heat and Air Control Panels / 692 eft Switch Panel / 694 Right Switch Panel / 696 Chassis Electrical / 699 Charging System / 699 Alternator Removal / 703 Automatic Belt Tensioner / 704 Starter / 705 Starter Motor Removal / 711 J-1939 Harness Diagnostics / 712 Chassis Wiring Schematics / 713 Steering / 765 Overview / 765 Steering System Operation / 766 Steering System Maintenance / 767 Steering Column & Steering Wheel / 768 Steering Gear / 770 Steering Pump / 771 Flushing the Steering System: Appendix 1 / 775 Air Bleeding the Steering System: Appendix 2 / 777 THP / PCF Steering Gear: Appendix 3 / 779 Steering Diagnostics: Appendix 4 / 845 TAS Poppets: Appendix 5 /
13 Body Structure / 909 Overview / 909 Body Glass / 909 Windshield Glass Replacement / 909 Rear Vision Glass Replacement / 911 Split Sash Window and Glass Replacement / 912 Rear Vision Glass Replacement / 913 Transit Sliding Window Removal / 914 Transit Window Glass Replacement / 914 Outward Opening Entrance Door / 916 Manual Door Control / 918 Pneumatic Door Opener / 919 Electric Door Opener / 920 Door Panels / 921 Stop Arms / 924 Auto Glass Replacement: Appendix 1 / 925 Body Interior / 983 Overview / 983 Driver s Seat / 983 Deluxe Driver s Seat / 984 Seat Care and Cleaning Tips / 985 Passenger DOT Seats / 985 Track Mounted Passenger Seats / 987 Seat Belts & Shoulder Harnesses / 987 Body Finish / 991 Exterior Paint / 991 Interior Paint / 991 Front End / 991 Rear End / 992 Headlining / 992 Fastening / 992 Floor Covering / 992 Undercoating / 993 ettering/decals /
14 Specs & Maintenance / 995 General Specification, Chassis / 995 General Specification, Body / 1000 Dimensions / 1006 Fastener Grades / 1007 Service Precautions / 1010 Jacking and Towing / 1012 Fluids & Filters / 1015 General Maintenance Schedules / 1017 Maintenance Task Schedule / 1018 Index /
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