Maintenance. Thomas Built Institute. Center for Education
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- Darrell Jefferson
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1 1 Maintenance Thomas Built Institute Center for Education
2 Center for Education Thomas Built Buses 2 Maintenance Schedule C2 Chassis Information
3 Center for Education Thomas Built Buses 3 Maintenance Schedule C2 Chassis Information
4 Center for Education Thomas Built Buses 4 Maintenance Schedule Schedule I < 20,000 miles/year Schedule II > 20,000 miles/year
5 Center for Education Thomas Built Buses 5 Maintenance Schedule Maintenance Manual Pages 00/5-00/6
6 Maintenance Schedule Center for Education Thomas Built Buses 6
7 Maintenance Schedule Center for Education Thomas Built Buses 7
8 Maintenance Schedule Center for Education Thomas Built Buses 8
9 Center for Education Thomas Built Buses 9 Maintenance - Initial Lubrication and Fluid Level Check Frame Fastener Torque Checking Suspension U-Bolt Torque Check Draw Key Nut Inspection Axle Breather - free and clear Air Brake System Valve Inspection Haldex & Gunite Slack Adjuster Lubrication Meritor Slack Adjuster Lubrication Power Steering Fluid Level Inspection Power Steering Gear Lubrication Drag Link Lubrication Fuel Tank Band Nut Tightening Door Seal Lubrication Air filter, check clamps and associated piping.
10 Center for Education Thomas Built Buses 10 Maintenance Hood Service Access 15 lbs of force to open hood Always use hand hold to open Removable 4 bolt grill
11 Center for Education Thomas Built Buses 11 Maintenance Hood INSPECT Integrated intake Sealing gasket to air cleaner Integrated drains
12 Center for Education Thomas Built Buses 12 Maintenance LH-side Access Power steering reservoir Steering gear linkages Fuel filters Centrifugal oil filter Fuel/water separator Oil dipsticks Windshield wiper motor and linkage
13 Center for Education Thomas Built Buses 13 Maintenance RH-side Access Radiator surge tank Air cleaner / restriction indicator Oil filter Windshield washer reservoir Heater cutoff valves Crossing control arm
14 Center for Education Thomas Built Buses 14 Maintenance Air Cleaner Replace the element at the service interval or when the restriction indicator signals red (see Section 09 in Workshop) Always place a cover over the air cleaner when the hood is open to keep from exposing the element to contamination
15 Center for Education Thomas Built Buses 15 Type D Access Filters, Air, fuel Oil Engine Belts Dip stick A/C Connections Coolant Tank Hydraulic Reservoir
16 Maintenance Engine CHECK ALL LEVELS DAILY Lube Oil & Lube, Fuel, Coolant Filters Coalescing Filter (Cummins Engine) Air Filter (Paved Roads) Coolant Test Overhead Adj. DEF & DPF Filters 15K Miles / 6 Months 60K Miles / 24 Months 12 Months 250 Hours / 3 or 4 Months 150K Miles / 48 Months 200K Miles Install Fuel Filters DRY Center for Education Thomas Built Buses 16
17 Center for Education Thomas Built Buses 17 Initial oil 6000 miles for break in period. Change oil every 24M/30K miles. Flush with nontoxic, nonflammable solvent. Lubriplate Syn Flush Lubriplate Pure Flush Whitmore s Flushing Oil Medallion Flushing Oil Kosher Maintenance Cooling Use Mobile Delvac 75W-90 synthetic lubricant. Make sure breather is clear. Do not overfill!!!! 2013 HDX Fan Drive Gearbox
18 Center for Education Thomas Built Buses 18 Maintenance Cooling 2013 HDX Fan Drive Gearbox OUTPUT SHAFT SEAL REPLACEMENT Drain unit. Use extreme care to not damage seal bore or shaft surface. Drill two holes 180 deg. apart. Install sheet metals screws leaving about 3/16 exposed. Using prybar, lift seal out.
19 Center for Education Thomas Built Buses 19 Maintenance Cooling 2013 HDX Fan Drive Gearbox SEAL INSTALLATION Inspect output shaft for grooving, scratches, score marks. Try removing imperfections with emery cloth (no.240) Cover keyway with tape to prevent cutting new seal. Use RTV sealant on O.D. of seal. Coat inner seal lip with oil or grease to facilitate installation.
20 Maintenance Engine Center for Education Thomas Built Buses 20
21 Center for Education Thomas Built Buses 21 Maintenance Engine Fuel Priming System J (J-47912QC Fitting 4 Only) (For Cust. Supplied Pumps over 30 PSI) 1 Kit
22 Center for Education Thomas Built Buses 22 Maintenance Engine Cummins ISB Fuel Filters LS RS Oil Filter LS Coalescing Filter
23 Center for Education Thomas Built Buses 23 Maintenance Engine EGR valve ISB LS RS LS Refer to Cummins cleaning Procedure Clean care kit part #
24 Center for Education Thomas Built Buses 24 Maintenance Engine Davenport Seat Access Panel LS RS LS
25 Center for Education Thomas Built Buses 25 Maintenance Engine Current configuration LS RS LS Prototype to be in production soon.
26 Maintenance Alternator Maintenance Check for corrosion and loose connections Remove buildup of dirt and grease Check airflow vents Check belt condition LS and tension. RS LS Center for Education Thomas Built Buses 26
27 Center for Education Thomas Built Buses 27 Maintenance Alternator Corrosion- LS -Excessive dirt/debris (heat) RS Oil soaked due to engine/hydraulic failure- LS
28 Center for Education Thomas Built Buses 28 Maintenance Transmissions CHECK FLUID LEVELS DAILY Oil / filter change as recommended, or as indicated by prognostic controller. w/ TES295 Fluid: 2K 60K/48M 3K 90K/48M Filters: 2K 40K/48M 3K 40K/48M Both Initial 5K w/ Dexron Fluid: 2K 50K/24M 3K 25K/12M Filters: 2K 40K/24M 3K 25K/12M Both Initial 5K Revised 10/11
29 Center for Education Thomas Built Buses 29 Maintenance Transmissions Fluid: TES-295 Filters: 2K: Spin-On Filter Magnet Deep In-Pan K: Filter Kit (2) NSBU Switches: plug plug J A Adj. Tool
30 Center for Education Thomas Built Buses 30 Maintenance Transmissions Allison 09 Prognostics Oil Life Monitor Indicator or Lamp remains illuminated for 2 minutes after Drive is selected Change transmission fluid. Filter Life Monitor Indicator or Lamp remains flashing for 2 minutes after Drive is selected. Change transmission filter(s) Transmission Health Monitor Indicator or Lamp remains illuminated at all times during vehicle operation. Clutch system may have exceeded specified limits Series Dash Lamp 3000 Series Indicator
31 Center for Education Thomas Built Buses 31 Maintenance Transmissions Allison 09 Prognostics 3000 Series New Accessing Prognostic via the 3000 Shifter Resetting procedures vary with model
32 Center for Education Thomas Built Buses 32 Maintenance Trans Linkage For earlier Allison 2000 PTS Transmission Check linkage and NSBU switch adjustment D
33 Center for Education Thomas Built Buses 33 Maintenance - Electrical Batteries Inspect cables and connections Load test Grounds Inspect, test and repair
34 Center for Education Thomas Built Buses 34 Maintenance HVAC Dash HVAC Filter Current Filter is ABP N10G
35 Center for Education Thomas Built Buses 35 Maintenance HVAC Passenger & Stepwell heaters have aluminum filters Inspect and / or clean filters every 30 days Inspect / tighten hose clamps after 30 days and routinely thereafter
36 Center for Education Thomas Built Buses 36 Maintenance Head Lights Head Light Aiming 1. Park bus 25 feet from wall to front bumper 2. Measure up to center of headlight 3. Measure up from floor and mark wall with same dimension 4. Turn on headlights and adjust to focus on line
37 Center for Education Thomas Built Buses 37 Maintenance Fasteners Check spring tension after 30 days and every 6 months thereafter Check torque after 30 days and every 6 months thereafter Check torque on body clips after 30 days and every 6 months thereafter Torque ft/lbs
38 Center for Education Thomas Built Buses 38 Maintenance Fasteners Seat Bolts Check mounting bolts after 30 days and every 90 days thereafter.
39 Center for Education Thomas Built Buses 39 Maintenance Doors & Floors Open and close all exits - confirm buzzer operation Use silicone spray on all door seals. Lube / grease door hinges. Use grease gun needle adapter. Recommend using a Dry lube on rear exit for the HDX. Keep flooring clean and free of abrasive debris During first 30 days, mop/rinse often with clean water Apply wax after 30 days, Using non-skid type floor wax.
40 Center for Education Thomas Built Buses 40 Maintenance Entrance door HDX/EFX Does the entrance door slam shut when setting release switch to normal? Adjust flow control valve for soft close. Make this adjustment first, before any other adjustments to door are made. To retrofit this valve on older Units use part# TBB
41 Center for Education Thomas Built Buses 41 Maintenance Entrance door HDX/EFX Adjust flow control s for approx. 3-5 sec OPEN 3-5 sec CLOSE Door close flow control Door open flow control
42 Center for Education Thomas Built Buses 42 Maintenance Entrance door HDX/EFX Door adjustment Open the doors fully and check the measurement across the opening. It should be 28 1/2 or 90 deg.
43 Center for Education Thomas Built Buses 43 Maintenance Entrance door HDX/EFX Door adjustment Inspect for worn/loose components Disconnect rear door leaf control rod. Adjust FWD leaf for 90 deg. opening via air ram clevis. (check for proper close position) Reconnect control rod and adjust rear leaf for proper timing. (lead/lag) Use blue loctite on jam nuts when final adjustments have been made.
44 Center for Education Thomas Built Buses 44 Maintenance Entrance door C2 Adjust flow control s for approx. 3-5 sec OPEN 3-5 sec CLOSE Door close flow control Door open flow control
45 Center for Education Thomas Built Buses 45 Maintenance Entrance door C2 Adjust door using same procedure as HDX/EFX After final adjustments, test 8-light operation. Adjust reed switch as necessary.
46 Center for Education Thomas Built Buses 46 Maintenance Axle s Synthetic axle oil Standard fill for all C and D buses Extends drain interval to 3 years from the original 1 year. Front/rear axle fluid level checks quarterly. Helps lower TCO
47 Center for Education Thomas Built Buses 47 Maintenance Suspension Maintain proper torque of front shackle bolts. Check torque every 60 days, Or at quarterly service. 320 ft/lbs Worn/Grooved shackle bolts
48 Maintenance Auto chains Center for Education Thomas Built Buses 48
49 Center for Education Thomas Built Buses 49
50 Center for Education Thomas Built Buses 50 Type D Maintenance ICON
51 Center for Education Thomas Built Buses 51 Auxiliary Screens - Maintenance SETUP MAINTENANCE DIAGNOSTICS MAINTENANCE SCREEN are next.
52 Center for Education Thomas Built Buses 52 Maintenance Screens There are a minimum of two maintenance screens. In select cases depending on the vehicles transmission type, you may see four maintenance screens. In this case the cluster S/W receives a message from the engine ECU and the transmission maintenance screen are then activated. Otherwise only the two default maintenance screens are available. MAINTENANCE MENU ENGINE OIL ENGINE AIR FILTER Right & Engine Oil Highlighted / ENGINE OIL CHANGE INTERVAL: ddddd MILES PRESS TO CHANGE Right & Engine Air Filter Highlighted / AIR FILTER CHANGE INTERVAL ddddd MILES PRESS TO CHANGE Default Right & Transmission Oil Life Highlighted Right & Transmission Oil Filter Highlighted TRANSMISSION OIL LIFE REMAINING = ppp% HOLD TO RESET TRANSMISSION OIL FILTER IS FUNCTIONAL HOLD TO RESET Optional
53 Center for Education Thomas Built Buses 53 Auxiliary Screens - Maintenance..Engine Oil MAINTENANCE MENU ENGINE OIL ENGINE AIR FILTER To set the interval for engine oil changes, use the down button to scroll to ENGINE OIL in the maintenance menu. To select ENGINE OIL, press the Right button.
54 Center for Education Thomas Built Buses 54 Auxiliary Screens - Maintenance..Engine Oil ENGINE OIL CHANGE INTERVAL: 1000 Miles PRESS TO CHANGE To change the interval to 6000 miles, continue to press the Down button until 6000 Miles is selected. Engine oil change intervals range from 1000 miles to 15,000 miles. If desired, you may choose to disable the oil change reminder by selecting the REMINDER IS DISABLED choice from the menu.
55 Center for Education Thomas Built Buses 55 Auxiliary Screens - Maintenance..Engine Oil ENGINE OIL CHANGE INTERVAL: 2000 Miles PRESS TO CHANGE To change the interval to 6000 miles, continue to press the Down button until 6000 Miles is selected.
56 Center for Education Thomas Built Buses 56 Auxiliary Screens - Maintenance..Engine Oil ENGINE OIL CHANGE INTERVAL: 3000 Miles PRESS TO CHANGE To change the interval to 6000 miles, continue to press the Down button until 6000 Miles is selected.
57 Center for Education Thomas Built Buses 57 Auxiliary Screens - Maintenance..Engine Oil ENGINE OIL CHANGE INTERVAL: 4000 Miles PRESS TO CHANGE To change the interval to 6000 miles, continue to press the Down button until 6000 Miles is selected.
58 Center for Education Thomas Built Buses 58 Auxiliary Screens - Maintenance..Engine Oil ENGINE OIL CHANGE INTERVAL: 5000 Miles PRESS TO CHANGE To change the interval to 6000 miles, continue to press the Down button until 6000 Miles is selected.
59 Center for Education Thomas Built Buses 59 Auxiliary Screens - Maintenance..Engine Oil ENGINE OIL CHANGE INTERVAL: 6000 Miles PRESS TO CHANGE To confirm and select 6000 miles, press the Right button.
60 Center for Education Thomas Built Buses 60 Auxiliary Screens - Maintenance..Engine Oil 6000 Miles TO NEXT ENGINE OIL CHANGE HOLD TO RESET To go back to the MAINTENANCE menu, press the Right button.
61 Center for Education Thomas Built Buses 61 Auxiliary Screens - Maintenance..Engine Air Filter MAINTENANCE MENU ENGINE AIR FILTER EXIT To set the interval for engine air filter, use the down button to scroll to ENGINE AIR FILTER in the maintenance menu. To select ENGINE AIR FILTER, press the Right button.
62 Center for Education Thomas Built Buses 62 Auxiliary Screens - Maintenance..Engine Air Filter AIR FILTER CHANGE INTERVAL: Miles PRESS TO CHANGE Air filter change intervals range from 16,000 miles to 30,000 miles. If desired, you may choose to disable the air filter change reminder by selecting the REMINDER IS DISABLED choice at the end of the interval choices. EXAMPLE -To change the interval to miles, continue to press the Down button until Miles is selected. Pressing the Right button will select the interval value on that screen.
63 Center for Education Thomas Built Buses 63 Auxiliary Screens - Maintenance..Engine Air Filter AIR FILTER CHANGE INTERVAL: Miles PRESS TO CHANGE Continue to press the Down button until Miles is selected.
64 Center for Education Thomas Built Buses 64 Auxiliary Screens - Maintenance..Engine Air Filter AIR FILTER CHANGE INTERVAL: Miles PRESS TO CHANGE Continue to press the Down button until Miles is selected.
65 Center for Education Thomas Built Buses 65 Auxiliary Screens - Maintenance..Engine Air Filter AIR FILTER CHANGE INTERVAL: Miles PRESS TO CHANGE Continue to press the Down button until Miles is selected. To confirm and select miles, press the Right button.
66 Center for Education Thomas Built Buses 66 Auxiliary Screens - Maintenance..Engine Air Filter Miles TO NEXT AIR FILTER CHANGE HOLD TO RESET To go back to the MAINTENANCE menu, press the Right button.
67 Center for Education Thomas Built Buses 67 Auxiliary Screens - Maintenance MAINTENANCE MENU ENGINE AIR FILTER EXIT Transmission maintenance screens work the same as the Engine maintenance screens. Using the Down button scroll to highlight Exit.
68 Center for Education Thomas Built Buses 68 Auxiliary Screens - Maintenance MAINTENANCE MENU ENGINE AIR FILTER EXIT To return to Auxiliary menu, select EXIT by pressing the Right button.
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