FLUIDS AND LUBRICANTS

Transcription

1 SECTION / MR14 IMPORTANT THIS VEHICLE MUST ONLY BE FUELED WITH ULTRA LOW-SULFUR DIESEL FUEL IMPORTANT NOTICE The following information is a summary of the standards, recommendations and specifications of our suppliers and is taken from documents produced by them, with regard to the maintenance of the components that they manufacture. This information has been verified and is up-to-date as of the date of this publication. The information reproduced in this section has been prepared strictly as a quick reference. CHARACTERISTICS Recommended lubricants are indicated in the Maintenance Schedule. A description of each type of lubricant is provided in the following paragraphs. See Table 1: lubricant specifications. When choosing the appropriate lubricant, you must take into consideration the oil supplier s reputation. The supplier must be accountable for the quality of the product. Lubricant descriptions will allow the transit authority to demand the appropriate type and quality. NOTE: Please note that the standards, recommendations and specifications of our suppliers can vary at any time. Our supplier s manuals have precedence over this document, and it is the user s responsibility alone, to obtain the latest updated versions. Nova Bus assumes no responsibility for any damages or losses incurred as a result of not obtaining the most recent updates. The efficiency and life of any mechanical equipment is largely dependent upon proper lubrication and servicing. All mechanical components rely on a lubricating film between moving parts to reduce friction, prevent wear, help cool the contacting sliding parts, and keep dirt and wear particles away from mating parts. Proper lubrication depends upon using the right type of lubricant at proper intervals and filling to proper capacities. This section provides a maintenance schedule for parts requiring a periodic lubrication. The locations of those parts are shown in Figure 1 through 3, depending on the model of the vehicle. ENGINE OIL Oil companies sell various types of engine oil under certain maintenance designations and technical specification numbers. By choosing a reliable supplier and paying special attention to the recommendations regarding oil and filter changes, you will get satisfactory lubrication and a longer life span for your engine. The engine manufacturer recommends using a high-quality Low Ash SAE 15W-40 lubricating oil all year round that meets American Petroleum Institute (API) performance classification CJ-4 (PC10). CAUTION: The use of particular mixes of complementary additives or concentrates (such as anti-smoking, covering, or deodorizing agents, tuning primers, superior grade oil, breaking-in oils, graphite lubricants, and anti-friction compounds) is not recommended as greasing oil used for diesel engines. For further details concerning lubricating oils for Cummins engines, please see cummins engine oil recommendations.

2 2011MR14 2 / LUBRICANT SPECIFICATIONS ENGINE OIL TRANSMISSION ELECTRIC DRIVE DIFFERENTIAL OIL MULTIPURPOSE CHASSIS GREASE FRONT AND REAR WHEEL BEARINGS STEERING GEAR OIL HYDRAULIC OIL AC COMPRESSOR ENGINE COOLANT ARTICULATION JOINT SPECIFICATIONS low ash SAE 15W-40 (API). Replacement oil must meet Cummins CES20081 specification. Fluids can be mixed. See transmission manufacturer s documentation. Transynd is approved as a 14C fluid class. See ZF reference document TE-ML-14. Fluids can be mixed. For Ecolife transmission see ZF reference document TE-ML-20. Drive oil (TranSynd for Allison Electric Drive ONLY) Hypoid Gear oil GL-5, SAE 80W90 Meeting MIL-L-2105-D (ZF transmissions): Already filled by ZF with ZF Ecofluid X. 80W-140 oil is approved as a 12B fluid class, see ZF reference document TE-ML-12. Fluids can be mixed. Universal Joint Grease NLGI Grade 2, Lithium 12-Hydroxy Stearate with Molybdenum Disulfide Already filled by the vendor. As per ZF, must use Fuchs Renolit LXPurpose NLGl#2 grease PEP 2 or Fuchs Renolit LX-N EP 2 or Fuchs Renolit LX-NHU 2. Alternative fluids not approved. Dexron-III type Automatic Transmission Oil Dexron-III type Transynd is approved for hydraulic wheelchair ramp, power steering, etc. Fluids can be mixed. Already filled by vendor. Synthetic polyol ester ISO viscosity 68 for AC compressors with R134A refrigerant. Replacement coolant must meet ASTM D6210 and CES14603 specifications. Fluids can be mixed. Vendor filled with Shell Tellus T15 Table 1 - Lubricant Specifications POWER STEERING FLUID Dexron III or Hydrex XV should be used in the hydraulic reservoir. Refer to section 09: hydraulic system in this manual for oil filter replacement and system purge. AUTOMATIC TRANSMISSION FLUID The transmission oil supplied with the vehicle may vary, depending on the type of transmission installed. See section 10: transmission for procedures on fluid checks, filter and fluid change. See the transmission manufacturer s documentation, supplied with the vehicle, regarding the appropriate types of oil to be used, as well as recommended oil change intervals. DRIVE FLUID (HEV) The fluid used in the drive on the Nova Bus LFS-HEV is TranSynd, distributed exclusively by Allison Electric Drive (AED). Refer to the drive manufacturer s service manuals provided by Nova Bus for detailed information concerning the drive fluid. See section 10: allison electric drive e p -40, as well as Allison Electric Drive s Service manuals for procedures on fluid checks, filter and fluid change. HYPOID GEAR OIL A multigrade gear oil SAE 80W/90, API GL-5 is recommended for year-round service to lubricate the rear axle, even under maximum torque and speed conditions. This oil is also recommended for front axle bearing lubrication. See the axle manufacturer s Service Manuals, provided by Nova Bus, for detailed information on oil checks, change and filling.

3 / MR14 MULTIPURPOSE GREASE This lubricant should be a good quality grade 2 lithium soap multipurpose chassis grease. It must be designed to offer protection against water and corrosion and to withstand extreme pressure and high temperatures. It also must have a melting point of approximately 520 F (270 C). Starplex 1 or 2 is an example of this type of grease. DRIVESHAFT LUBRICATION The universal joints and the sliding joint of the driveshaft require a particular lubrication procedure. It is important to consult section : driveshaft, as well as the manufacturer s documentation, before performing driveshaft lubrication. Also see the manufacturer s documentation for approved lubricants. COOLANT AND ANTIFREEZE See section 09: engine cooling for more information on the recommended products. DIESEL EXHAUST FLUID (DEF) - ISL 2010 ENGINE DEF is the name given to the fluid when urea is mixed with water to a 32.5% solution. The composition of diesel exhaust fluid for use in the Cummins 2010 engines is defined in ISO standard ISO LUBRICATION This heading only mentions a few particular procedures and safety measures. For any other procedure linked to the lubrication of a component, such as removal, installation, disassembly, cleaning, etc., see the corresponding section of this manual or the manufacturer s maintenance manual. WARNING: Respect all security instructions and rules during any lubrication activity or maintenance inspection. CAUTION: All grease fittings must be cleaned before applying the lubricant. Also, make sure the equipment used to apply the lubricant is clean. Every precaution must be taken to avoid the penetration of dirt, abrasive dust, lint, or other foreign matter in the lubricant containers. Replace broken, damaged or defective fittings. WHEEL BEARING LUBRICATION Instructions for removing, installing and adjusting the wheel bearings can be found in the axle manufacturer s service manual. CLEANING Thoroughly clean the wheel bearings and the wheel hubs with a stiff-bristled brush and some solvent to remove all traces of old lubricant and dirt. Check that the bearings are not damaged and have them replaced, if necessary. APPLICATION CAUTION: When applying lubricant by hand, ensure that sufficient grease penetrates the spaces between the rollers and the bearing race. A mechanical greaser may also be used, but make sure the bearings are thoroughly lubricated. Clean the bearings and the hub cavity on the inside diameter of the bearing holders. Also, clean the filling cavity at the hub extremities of the driving axles, between the outside bearing and the joint seal. The amount of lubricant inside the hubs must not exceed the capacity of the bearing holders. The amount of bearing lubricant is sufficient to provide adequate lubrication until the next scheduled maintenance.

4 2011MR14 4 / MAINTENANCE SCHEDULE For item numbers, see Figures 1, 2 or 3, according to vehicle type. The maintenance schedule is intended to serve as a ready reference for systems and components that require periodic lubrication. The maintenance schedule consists of general recommendations based on the manufacturer s specifications for the type of fluid supplied at time of delivery of the vehicle. Consult the annexes at the end of this document to obtain the maintenance schedule applicable to your vehicle: module A: Bus with ZF transmission module B: Bus with Voith transmission module C: Bus with Allison transmission module D: Bus with Allison E p -40 drive The ONLY suitable way to establish intervals of adequate oil draining is to proceed by analysis. Analysis of the engine oil, the power steering fluid, the automatic transmission fluid (or drive fluid) and hypoid oil ensures that the viscosity of oil is within the range allowed by the manufacturer. The lubrication of some items listed below may be part of an optional manual greasing system. See section 08: manual greasing system to obtain more details on the system and the greasing points. In this case, disregard the corresponding lubricant specification and use Multipurpose Chassis Grease EP1/EP2. An automatic greasing system can also manage the lubrication of certain components. See section 08: automatic greasing system for more details.

5 / MR WIPER POST 2. MITER BOX 3. BRAKE PEDAL 4. ACCELERATOR PEDAL 5. WINDSHIELD WASHER RESERVOIR 6. INTERMEDIATE STEERING SHAFT 7. STEERING SHAFT 8. BATTERY TERMINALS 9. BATTERY TRAY GUIDE RAIL 10. DOOR RODS AND LEVER 11. FRONT ACCESS RAMP (OPTIONAL) 12. STEERING GEARBOX 13. AUTOMATIC GREASING RESERVOIR 14. DRAG LINK END 15. STEERING KNUCKLES 16. WHEEL BEARING 17. TIE ROD END 18. REAR ACCESS RAMP (OPTIONAL) 19. DIFFERENTIAL 20. DRIVESHAFT UNIVERSAL JOINT 21. DRIVESHAFT SLIDING JOINT 22. TRANSMISSION/DRIVE DIPSTICK 23. TRANSMISSION/DRIVE OIL FILTER 24. FUEL FILTER 25. TRANSMISSION/DRIVE OIL PAN 26. RADIATOR 27. ENGINE OIL FILTER FILTER 28. ENGINE COOLANT FILTER 29. ENGINE DIPSTICK 30. COOLANT SURGE TANK 31. HYDRAULIC RESERVOIR 32. A/C COMPRESSOR (OPTIONAL) 33. COOLANT FILLING CONTROL BOX Figure 1 - Lubrication and Servicing Components (Nova LFS and Nova HEV - 40 ft standard)

6 2011MR14 6 / WIPER POST 2. MITER BOX 3. BRAKE PEDAL 4. ACCELERATOR PEDAL 5. WINDSHIELD WASHER RESERVOIR 6. INTERMEDIATE STEERING SHAFT 7. STEERING SHAFT 8. BATTERY TERMINALS 9. BATTERY TRAY GUIDE RAIL 10. DOOR RODS AND LEVER 11. FRONT ACCESS RAMP (OPTIONAL) 12. STEERING GEARBOX 13. AUTOMATIC GREASING RESERVOIR 14. DRAG LINK END 15. STEERING KNUCKLES 16. WHEEL BEARING 17. TIE ROD END 18. REAR ACCESS RAMP (OPTIONAL) 19. DIFFERENTIAL 20. DRIVESHAFT UNIVERSAL JOINT 21. DRIVESHAFT SLIDING JOINT 22. TRANSMISSION/DRIVE DIPSTICK 23. TRANSMISSION/DRIVE OIL FILTER 24. FUEL FILTER 25. TRANSMISSION/DRIVE OIL PAN 26. RADIATOR 27. ENGINE OIL FILTER FILTER 28. ENGINE COOLANT FILTER 29. ENGINE DIPSTICK 30. COOLANT SURGE TANK 31. HYDRAULIC RESERVOIR 32. A/C COMPRESSOR (OPTIONAL) 33. COOLANT FILLING CONTROL BOX 34. DIESEL EXHAUST FLUID RESERVOIR (W/2010 ENGINE ONLY) Figure 2 - Lubrication and Servicing Components (Nova LFS and Nova HEV - 40 ft T-Drive)

7 / MR WIPER POST 2. MITER BOX 3. BRAKE PEDAL 4. ACCELERATOR PEDAL 5. WINDSHIELD WASHER RESERVOIR 6. INTERMEDIATE STEERING SHAFT 7. STEERING SHAFT 8. BATTERY TERMINALS 9. BATTERY TRAY GUIDE RAIL 10. DOOR RODS AND LEVER 11. FRONT ACCESS RAMP (OPTIONAL) 12. STEERING GEARBOX 13. AUTOMATIC GREASING RESERVOIR 14. DRAG LINK END 15. STEERING KNUCKLES 16. WHEEL BEARING 17. TIE ROD END 18. REAR ACCESS RAMP (OPTIONAL) 19. DIFFERENTIAL 20. DRIVESHAFT UNIVERSAL JOINT 21. DRIVESHAFT SLIDING JOINT 22. TRANSMISSION/DRIVE DIPSTICK 23. TRANSMISSION/DRIVE OIL FILTER 24. FUEL FILTER 25. TRANSMISSION/DRIVE OIL PAN 26. RADIATOR 27. ENGINE OIL FILTER FILTER 28. ENGINE COOLANT FILTER 29. ENGINE DIPSTICK 30. COOLANT SURGE TANK 31. HYDRAULIC RESERVOIR 32. A/C COMPRESSOR (OPTIONAL) 33. COOLANT FILLING CONTROL BOX 34. DIESEL EXHAUST FLUID RESERVOIR (W/2010 ENGINE ONLY) 35. ARTICULATION PIVOT Figure 3 - Lubrication and Servicing Components (Nova LFS Artic)

8 2011MR14 8 / BLANK PAGE

9 SECTION A MAINTENANCE SCHEDULE (ZF) / MR14 MAINTENANCE SCHEDULE This schedule applies to all vehicles equipped with a Cummins ISL 07 or ISL 2010 engine and a ZF transmission. According to the model of your vehicle, see Figures 1, 2 or 3 in the general section, for the item numbers indicated in the chart. + NOTE: If the vehicle is equipped with an automatic greasing system, lubrication of the items marked with an asterisk (*) in the maintenance schedule is managed by this system. See section : central lubrication for more details. ON RECEIPT OF VEHICLE ITEM Change the oil and filter in all systems. DAILY INSPECTION OR AS REQUIRED OUTSIDE THE VEHICLE ITEM Check for leaks under vehicle and in engine compartment. Check that all doors close properly, lubricate as required. Drain accumulated water in air tanks. 5 Check windshield washer fluid level and add if necessary. ENGINE COMPARTMENT ITEM 22 Check transmission fluid level, adjust if necessary. 24 Drain accumulated water in fuel filter/water separator. 29 Check engine oil level, adjust if necessary. Check coolant fluid level and adjust if necessary. 31 Check hydraulic reservoir fluid level at sight glass. 34 Check DEF level, adjust if necessary (Cummins 2010 engines only) INSIDE THE VEHICLE ITEM 1 Verify proper operation of windshield wiper/washer. 11, 18 Deploy the ramp and check for proper operation.

10 2011MR14 10 / EVERY 1,500 MI (2,400 KM) HOURS OR 6 MONTHS - FOR VEHICLES AVERAGING 2-4 MPH (3-6 KM/HR) 24 Replace the primary (suction side) fuel filter at every EVERY 3,000 MI (5,000 KM) HOURS OR 6 MONTHS - FOR VEHICLES AVERAGING 4-6 MPH (6-10 KM/HR) 24 Replace the primary (suction side) fuel filter at every EVERY 4,000 MI (6,500 KM) HOURS OR 6 MONTHS - FOR VEHICLES AVERAGING 6-8 MPH (10-13 KM/HR) 24 Replace the primary (suction side) fuel filter at every EVERY 5,000 MI (8,000 KM) HOURS OR 6 MONTHS - FOR VEHICLES AVERAGING 8-10 MPH (13-16 KM/HR) 24 Replace the primary (suction side) fuel filter at every

11 EVERY 6,000 MI (10,000 KM) HOURS OR 6 MONTHS / 11 REAR AXLE - SECTION Check the differential oil level. Correct if necessary. See manufacturer s documentation STEERING MECHANISM - SECTION 07 Inspect all fluid lines and connections for leaks. * 2 Lubricate the miter box upper bearing. Mobil Mobilith SHC PM * 14 Lubricate the drag link ends. Lithium-based grease * 15 Lubricate the steering knuckles. Saponified lithium mineral oil-based multigrade grease of the NLGI class 2 Check for oil leaks at air compressor oil lines. Inspect all fluid lines and connections for leaks. 26 Inspect the radiator for leaks - FOR VEHICLES AVERAGING MPH (16-24 KM/HR) DRIVESHAFT - SECTION MR14 20, 21 Lubricate universal joints, slip yoke and splines according to the manufacturer s procedure. NLGI grade 2, lithium 12-hydroxy stereate with molybdenum disulfide grease for universal joints (Meritor specification O-634-B). See the manufacturer s documentation for approved lubricants. 24 Replace the primary (suction side) fuel filter at every BATTERIES - SECTION 16 8 Clean with sodium bicarbonate and inspect.

12 2011MR14 12 / EVERY 10,000 MI (20,000 KM) PNEUMATIC SYSTEM - SECTION 08 Lubricate the kneeling system linkage. Lubriplate 3 Lubricate the brake pedal pivots. Lubriplate 4 Lubricate the accelerator pedal pivots. Lubriplate 28, 30 Test coolant solution and replace filter. TRANSMISSION (EXCEPT ECOLIFE) - SECTION Change Dexron-III oil and filter FOR ECOLIFE TRANSMISSIONS USING ECOFLUID A PLUS, SEE 150,000 MI (240,000 KM) REAR ACCESS RAMP (opt.) - SECTION 12 Transynd: see 25,000 mi (40,000 km). Other type: see manufacturer s documentation. For Ecolife, use Ecofluid A Plus: see 150,000 mi (240,000 km). 18 Lubricate all the bearings. Low Temperature Grease HEATING AND VENTILATION - SECTION 14 Check refrigerant level.

13 EVERY 25,000 MI (40,000 KM) EVERY 50,000 MI (80,000 KM) / 13 DOORS - SECTION Lubricate door rod bearings. Lithium-based grease STEERING MECHANISM - SECTION 07 2 Refill the miter box housing with fresh oil. EP150 gear oil 31 Replace the filter in the hydraulic reservoir. Clean the outside of the reservoir before opening. TRANSMISSION (EXCEPT ECOLIFE) - SECTION Change Transynd oil, the main filter and the lubrication filter. FOR ECOLIFE TRANSMISSIONS USING ECOFLUID A PLUS, SEE 150,000 MI (240,000 KM) Check the external oil hoses. Replace them if they are perforated, worn, degraded, stiff or tight. FRONT ACCESS RAMP (opt.) - SECTION Check the hydraulic oil level in the reservoir and fill if necessary. BATTERIES - SECTION 16 9 If equipped with a pivoting battery tray, lubricate the pivot using the grease fitting. Dexron-III: see 10,000 mi (20,000 km). Other type :see manufacturer s documentation. Ecofluid A Plus : see 150,000 mi (240,000 km). Mobil Aero hydraulic oil that meets the military specification MIL-H Change the hydraulic oil. Type Dexron-III or Hydrex XV 2011MR14 EVERY 150,000 MI (240,000 KM) BUT AT LEAST ONCE EVERY 3 YEARS TRANSMISSION (ECOLIFE) - SECTION Change Ecofluid A Plus oil and filter. Use ZF approved transmission fluid.

14 2011MR14 14 / EVERY 310,000 MI (500,000 KM) FRONT AND REAR AXLES - SECTIONS 04 AND Lubricate the bearings on each axle. Saponified lithium mineral oil-based multigrade grease of the NLGI class 2 EVERY 620,000 MI (1,000,000 KM) ARTICULATION SYSTEM - SECTION Lubricate the articulation pivot using the five grease fittings. (Artic only). See the manufacturer s documentation

15 / 15 SECTION B MAINTENANCE SCHEDULE (VOITH) 2011MR14 MAINTENANCE SCHEDULE This schedule applies to all vehicles equipped with a Cummins ISL 07 or ISL 2010 engine and a Voith transmission. According to the model of your vehicle, see Figures 1, 2 or 3 in the general section, for the item numbers indicated in the chart. To extend the life of the Voith transmission and to maximize its performance, it is important to respect the two phases of breaking-in the transmission described below. Recommended periodic maintenance of the transmission in the maintenance schedule must be performed following the break-in period recommended by the manufacturer. + NOTE: If the vehicle is equipped with an automatic greasing system, lubrication of the items marked with an asterisk (*) in the maintenance schedule is managed by this system. See section : central lubrication for more details. ON RECEIPT OF VEHICLE ITEM REMARKS LUBRICANT Change the oil and filter in all systems. Calibrate the oil level gauge. Compare the oil level in the Voith transmission gauge with the gauge installed by Nova Bus. ONCE AFTER 2,500 MI (4,000 KM) ITEM REMARKS LUBRICANT 23 Change transmission oil and filter. Phase I of breaking-in transmission. (DIWA 3 transmission only) See the manufacturer s documentation ONCE AFTER 10,000 MI (16,000 KM) ITEM REMARKS LUBRICANT 23 Change transmission filter only DIWA 5 transmission only See the manufacturer s documentation ONCE AFTER 11,500 MI (18,500 KM) ITEM REMARKS LUBRICANT 23 Change transmission oil and filter. Phase II of breaking-in transmission. (DIWA 3 transmission only) See the manufacturer s documentation

16 2011MR14 16 / DAILY INSPECTION OR AS REQUIRED OUTSIDE THE VEHICLE ITEM Check for leaks under vehicle and in engine compartment. Check that all doors close properly, lubricate as required. Drain accumulated water in air tanks. 5 Check windshield washer fluid level and add if necessary. ENGINE COMPARTMENT ITEM 22 Check transmission fluid level, adjust if necessary. 24 Drain accumulated water in fuel filter/water separator. 29 Check engine oil level, adjust if necessary. Check coolant fluid level and adjust if necessary. 31 Check hydraulic reservoir fluid level at sight glass. 34 Check DEF level, adjust if necessary (ISL 2010 engine only) INSIDE THE VEHICLE ITEM 1 Verify proper operation of windshield wiper/washer. 11, 18 Deploy the ramp and check for proper operation.

17 EVERY 1,500 MI (2,400 KM) HOURS OR 6 MONTHS / 17 - FOR VEHICLES AVERAGING 2-4 MPH (3-6 KM/HR) 24 Replace the primary (suction side) fuel filter at every 2011MR14 EVERY 3,000 MI (5,000 KM) HOURS OR 6 MONTHS - FOR VEHICLES AVERAGING 4-6 MPH (6-10 KM/HR) 24 Replace the primary (suction side) fuel filter at every EVERY 4,000 MI (6,500 KM) HOURS OR 6 MONTHS - FOR VEHICLES AVERAGING 6-8 MPH (10-13 KM/HR) 24 Replace the primary (suction side) fuel filter at every EVERY 5,000 MI (8,000 KM) HOURS OR 6 MONTHS - FOR VEHICLES AVERAGING 8-10 MPH (13-16 KM/HR) 24 Replace the primary (suction side) fuel filter at every

18 2011MR14 18 / EVERY 6,000 MI (10,000 KM) REAR AXLE - SECTION Check the differential oil level. Correct if necessary. See manufacturer s documentation STEERING MECHANISM - SECTION 07 Inspect all fluid lines and connections for leaks. * 2 Lubricate the miter box upper bearing. Mobil Mobilith SHC PM * 14 Lubricate the drag link ends. Lithium-based grease * 15 Lubricate the steering knuckles. Saponified lithium mineral oil-based multigrade grease of the NLGI class 2 Check for oil leaks at air compressor oil lines. Inspect all fluid lines and connections for leaks. 26 Inspect the radiator for leaks. - FOR VEHICLES AVERAGING MPH (16-24 KM/HR) DRIVESHAFT - SECTION 10 20, 21 Lubricate universal joints, slip yoke and splines according to the manufacturer s procedure. NLGI grade 2, lithium 12-hydroxy stereate with molybdenum disulfide grease for universal joints (Meritor specification O-634-B). See the manufacturer s documentation for approved lubricants. 24 Replace the primary (suction side) fuel filter at every BATTERIES - SECTION 16 8 Clean with sodium bicarbonate and inspect. EVERY 10,000 MI (20,000 KM) PNEUMATIC SYSTEM - SECTION 08 Lubricate the kneeling system linkage. Lubriplate 3 Lubricate the brake pedal pivots. Lubriplate 4 Lubricate the accelerator pedal pivots. Lubriplate 28, 30 Test coolant solution and replace filter. REAR ACCESS RAMP (opt.) - SECTION Lubricate all the bearings. Low Temperature Grease HEATING AND VENTILATION - SECTION 14 Check refrigerant level.

19 EVERY 25,000 MI (40,000 KM) EVERY 50,000 MI (80,000 KM) / 19 DOORS - SECTION Lubricate door rod bearings. Lithium-based grease STEERING MECHANISM - SECTION 07 2 Refill the miter box housing with fresh oil. EP150 gear oil 31 Replace the filter in the hydraulic reservoir. Clean the outside of the reservoir before opening. FRONT ACCESS RAMP (opt.) - SECTION Check the hydraulic oil level in the reservoir and fill if necessary. BATTERIES - SECTION 16 9 If equipped with a pivoting battery tray, lubricate the pivot using the grease fitting. EVERY 36,000 MI (58,000 KM) OR ONE YEAR Mobil Aero hydraulic oil that meets the military specification MIL-H-5606 TRANSMISSION - SECTION Change the transmission oil and filter. See the manufacturer s documentation (DIWA 5 transmission only - if mineral oil used) EVERY 40,000 MI (60,000 KM) TRANSMISSION - SECTION Inspect the inside of the transmission oil pan. Check the external oil hoses. Replace them if they are perforated, worn, degraded, stiff or tight. 31 Change the hydraulic oil. Type Dexron-III or Hydrex XV 2011MR14

20 2011MR14 20 / EVERY 72,000 MI (115,000 KM) TRANSMISSION - SECTION Change the transmission oil and filter. See the manufacturer s documentation (DIWA5 transmission - if synthetic oil used) EVERY 310,000 MI (500,000 KM) FRONT AND REAR AXLES - SECTIONS 04 AND Lubricate the bearings on each axle. Saponified lithium mineral oil-based multigrade grease of the NLGI class 2 EVERY 620,000 MI (1,000,000 KM) ARTICULATION SYSTEM - SECTION Lubricate the articulation pivot using the five grease fittings. (Artic only). See the manufacturer s documentation

21 / 21 SECTION C MAINTENANCE SCHEDULE (ALLISON) 2011MR14 MAINTENANCE SCHEDULE This schedule applies to all vehicles equipped with a Cummins ISL 07 or ISL 2010 engine and an Allison transmission. According to the model of your vehicle, see Figures 1, 2 or 3 in the general section, for the item numbers indicated in the chart. + NOTE: If the vehicle is equipped with an automatic greasing system, lubrication of the items marked with an asterisk (*) in the maintenance schedule is managed by this system. See section : central lubrication for more details. ON RECEIPT OF VEHICLE ITEM Change the oil and filter in all systems. DAILY INSPECTION OR AS REQUIRED OUTSIDE THE VEHICLE ITEM Check for leaks under vehicle and in engine compartment. Check that all doors close properly, lubricate as required. Drain accumulated water in air tanks. 5 Check windshield washer fluid level and add if necessary. ENGINE COMPARTMENT ITEM 22 Check transmission fluid level, adjust if necessary. 24 Drain accumulated water in fuel filter/water separator. 29 Check engine oil level, adjust if necessary. Check coolant fluid level and adjust if necessary. 31 Check hydraulic reservoir fluid level at sight glass. 34 Check DEF level, adjust if necessary (ISL 2010 engine only) INSIDE THE VEHICLE ITEM 1 Verify proper operation of windshield wiper/washer. 11, 18 Deploy the ramp and check for proper operation.

22 2011MR14 22 / EVERY 1,500 MI (2,400 KM) HOURS OR 6 MONTHS - FOR VEHICLES AVERAGING 2-4 MPH (3-6 KM/HR) 24 Replace the primary (suction side) fuel filter at every EVERY 3,000 MI (5,000 KM) HOURS OR 6 MONTHS - FOR VEHICLES AVERAGING 4-6 MPH (6-10 KM/HR) 24 Replace the primary (suction side) fuel filter at every EVERY 4,000 MI (6,500 KM) HOURS OR 6 MONTHS - FOR VEHICLES AVERAGING 6-8 MPH (10-13 KM/HR) 24 Replace the primary (suction side) fuel filter at every EVERY 5,000 MI (8,000 KM) HOURS OR 6 MONTHS - FOR VEHICLES AVERAGING 8-10 MPH (13-16 KM/HR) 24 Replace the primary (suction side) fuel filter at every

23 EVERY 6,000 MI (10,000 KM) / 23 REAR AXLE - SECTION Check the differential oil level. Correct if necessary. See manufacturer s documentation STEERING MECHANISM - SECTION 07 Inspect all fluid lines and connections for leaks. * 2 Lubricate the miter box upper bearing. Mobil Mobilith SHC PM * 14 Lubricate the drag link ends. Lithium-based grease * 15 Lubricate the steering knuckles. Saponified lithium mineral oil-based multigrade grease of the NLGI class 2 Check for oil leaks at air compressor oil lines. Inspect all fluid lines and connections for leaks. 26 Inspect the radiator for leaks. - FOR VEHICLES AVERAGING MPH (16-24 KM/HR) DRIVESHAFT - SECTION MR14 20, 21 Lubricate universal joints, slip yoke and splines according to the manufacturer s procedure. NLGI grade 2, lithium 12-hydroxy stereate with molybdenum disulfide grease for universal joints (Meritor specification O-634-B). See the manufacturer s documentation for approved lubricants. 24 Replace the primary (suction side) fuel filter at every BATTERIES - SECTION 16 8 Clean with sodium bicarbonate and inspect. EVERY 10,000 MI (20,000 KM) PNEUMATIC SYSTEM - SECTION 08 Lubricate the kneeling system linkage. Lubriplate 3 Lubricate the brake pedal pivots. Lubriplate 4 Lubricate the accelerator pedal pivots. Lubriplate 28, 30 Test coolant solution and replace filter. REAR ACCESS RAMP (opt.) - SECTION Lubricate all the bearings. Low Temperature Grease HEATING AND VENTILATION - SECTION 14 Check refrigerant level.

24 2011MR14 24 / EVERY 25,000 MI (40,000 KM) DOORS - SECTION Lubricate door rod bearings. Lithium-based grease STEERING MECHANISM - SECTION 07 2 Refill the miter box housing with fresh oil. EP150 gear oil 31 Replace the filter in the hydraulic reservoir. Clean the outside of the reservoir before opening. TRANSMISSION - SECTION Change the transmission oil and filter. Transynd Check the external oil hoses. Replace them if they are perforated, worn, degraded, stiff or tight. FRONT ACCESS RAMP (opt.) - SECTION Check the hydraulic oil level in the reservoir and fill if necessary. BATTERIES - SECTION 16 9 If equipped with a pivoting battery tray, lubricate the pivot using the grease fitting. Mobil Aero hydraulic oil that meets the military specification MIL-H-5606 EVERY 50,000 MI (80,000 KM) 31 Change the hydraulic oil. Type Dexron-III or Hydrex XV EVERY 310,000 MI (500,000 KM) FRONT AND REAR AXLES - SECTIONS 04 AND Lubricate the bearings on each axle. Saponified lithium mineral oil-based multigrade grease of the NLGI class 2 EVERY 620,000 MI (1,000,000 KM) ARTICULATION SYSTEM - SECTION Lubricate the articulation pivot using the five grease fittings. (Artic only). See the manufacturer s documentation

25 / 25 SECTION D MAINTENANCE SCHEDULE (ALLISON EP-40) 2011MR14 MAINTENANCE SCHEDULE This schedule applies to all vehicles equipped with a Cummins ISB/ISL 07 or ISB/ISL 2010 engine and an Allison electric drive. According to the model of your vehicle, see Figures 1, 2 or 3 in the general section, for the item numbers indicated in the chart. To extend the life of the Allison E p -40 electric drive and to maximize its performance, it is important to respect the breaking-in instructions described in the following table. Recommended maintenance of the electric drive in the maintenance schedule, further in this section, must be performed following the break-in period recommended by the manufacturer. + NOTE: If the vehicle is equipped with an automatic greasing system, lubrication of the items marked with an asterisk (*) in the maintenance schedule is managed by this system. See section : central lubrication for more details. ON RECEIPT OF VEHICLE Change the oil and filter in all systems. ONCE AFTER 5,000 MI (8,000 KM) 23 Change the control main filter, according to Allison s recommendations.

26 2011MR14 26 / DAILY INSPECTION OR AS REQUIRED OUTSIDE THE VEHICLE ITEM Check for leaks under vehicle and in engine compartment. Check that all doors close properly, lubricate as required. Drain accumulated water in air tanks. 5 Check windshield washer fluid level and add if necessary. ENGINE COMPARTMENT ITEM 22 Check drive oil level, adjust if necessary. 24 Drain accumulated water in fuel filter/water separator. 29 Check engine oil level, adjust if necessary. Check coolant fluid level and adjust if necessary. 31 Check hydraulic reservoir fluid level at sight glass. 34 Check DEF level, adjust if necessary (Cummins 2010 engines only) INSIDE THE VEHICLE ITEM 1 Verify proper operation of windshield wiper/washer. 11, 18 Deploy the ramp and check for proper operation.

27 EVERY 1,500 MI (2,400 KM) HOURS OR 6 MONTHS / 27 - FOR VEHICLES AVERAGING 2-4 MPH (3-6 KM/HR) 24 Replace the primary (suction side) fuel filter at every 2011MR14 EVERY 3,000 MI (5,000 KM) HOURS OR 6 MONTHS - FOR VEHICLES AVERAGING 4-6 MPH (6-10 KM/HR) 24 Replace the primary (suction side) fuel filter at every EVERY 4,000 MI (6,500 KM) HOURS OR 6 MONTHS - FOR VEHICLES AVERAGING 6-8 MPH (10-13 KM/HR) 24 Replace the primary (suction side) fuel filter at every EVERY 5,000 MI (8,000 KM) HOURS OR 6 MONTHS - FOR VEHICLES AVERAGING 8-10 MPH (13-16 KM/HR) 24 Replace the primary (suction side) fuel filter at every

28 2011MR14 28 / EVERY 6,000 MI (10,000 KM) REAR AXLE - SECTION Check the differential oil level. Correct if necessary. See manufacturer s documentation STEERING MECHANISM - SECTION 07 Inspect all fluid lines and connections for leaks. * 2 Lubricate the miter box upper bearing. Mobil Mobilith SHC PM * 14 Lubricate the drag link ends. Lithium-based grease * 15 Lubricate the steering knuckles. Saponified lithium mineral oil-based multigrade grease of the NLGI class 2 Check for oil leaks at air compressor oil lines. Inspect all fluid lines and connections for leaks. 26 Inspect the radiator for leaks. - FOR VEHICLES AVERAGING MPH (16-24 KM/HR) ELECTRIC DRIVE - SECTION 10 Check drive for leaks. Inspect the oil cooler and lines. DRIVESHAFT - SECTION 10 20, 21 Lubricate universal joints, slip yoke and splines according to the manufacturer s procedure. NLGI grade 2, lithium 12-hydroxy stereate with molybdenum disulfide grease for universal joints (Meritor specification O-634-B). See the manufacturer s documentation for approved lubricants. 24 Replace the primary (suction side) fuel filter at every BATTERIES - SECTION 16 8 Clean with sodium bicarbonate and inspect.

29 / MR14 EVERY 10,000 MI (20,000 KM) PNEUMATIC SYSTEM - SECTION 08 Lubricate the kneeling system linkage. Lubriplate 3 Lubricate the brake pedal pivots. Lubriplate 4 Lubricate the accelerator pedal pivots. Lubriplate 28, 30 Test coolant solution and replace filter. REAR ACCESS RAMP (opt.) - SECTION Lubricate all the bearings. Low Temperature Grease HEATING AND VENTILATION - SECTION 14 Check refrigerant level. EVERY 25,000 MI (40,000 KM) DOORS - SECTION Lubricate door rod bearings. Lithium-based grease STEERING MECHANISM - SECTION 07 2 Refill the miter box housing with fresh oil. EP150 gear oil 31 Replace the filter in the hydraulic reservoir. Clean the outside of the reservoir before opening. FRONT ACCESS RAMP (opt.) - SECTION Check the hydraulic oil level in the reservoir and fill if necessary. BATTERIES - SECTION 16 9 If equipped with a pivoting battery tray, lubricate the pivot using the grease fitting. Mobil Aero hydraulic oil that meets the military specification MIL-H-5606

30 2011MR14 30 / EVERY 50,000 MI (80,000 KM) 31 Change the hydraulic oil. Type Dexron-III or Hydrex XV ELECTRIC DRIVE - SECTION Change the control main filter. EVERY 100,000 MI (160,000 KM) ELECTRIC DRIVE - SECTION Change the drive oil and the lube filter. Transynd for Allison Electric Drive ONLY EVERY 310,000 MI (500,000 KM) FRONT AND REAR AXLES - SECTIONS 04 AND Lubricate the bearings on each axle. Saponified lithium mineral oil-based multigrade grease of the NLGI class 2 EVERY 620,000 MI (1,000,000 KM) ARTICULATION SYSTEM - SECTION Lubricate the articulation pivot using the five grease fittings. (Artic only). See the manufacturer s documentation