Thomas SAF-T-LINER C2 School Bus Operation & Maintenance Manual

STI-466-6 TBB Part # 85410323 SAF-T-LINER C2 SCHOOL BUS Driver’s Manual

Introduction This manual provides information needed to operate and understand the vehicle and its components. More detailed information is contained in the Owner’s Warranty Information Manual, the vehicle’s workshop manual, and the vehicle’s maintenance manual. Custom-built Thomas Built Buses are equipped with various chassis and body components. Not all of the information contained in this manual applies to every vehicle. For details about components in your vehicle, refer to the chassis specification pages included in all new vehicles and to the vehicle specification decal, located inside the vehicle. For your reference, keep this manual in the vehicle at all times. IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing. Thomas Built Buses reserves the right to dis- continue models and to change specifications or design at any time without notice and without incurring obligation. Descriptions and specifications contained in this publication provide no warranty, expressed or implied, and are subject to revisions and editions without notice. Environmental Concerns and Recommendations Whenever you see instructions in this manual to dis- card materials, you should first attempt to reclaim and recycle them. To preserve our environment, fol- low appropriate environmental rules and regulations when disposing of materials. Event Data Recorder This vehicle is equipped with one or more devices that record specific vehicle data. The type and amount of data recorded varies depending on how the vehicle is equipped (such as the brand of engine, if an air bag is installed, or if the vehicle features a collision avoidance system, etc.). Emissions and Fuel Efficiency Compliance This vehicle must be regularly inspected and main- tained as indicated in the Saf-T-Liner C2 Mainte- nance Manual, and in the Pre- and Post-Trip Inspec- tions and Maintenance chapter in this manual, in order to continue satisfactory performance and ensure coverage of the vehicle under the manufacturer’s warranty. Many maintenance procedures ensure that the vehicle and engine continue to comply with applicable emissions standards. Maintenance procedures, using components engineered to comply with greenhouse gas emissions and fuel efficiency regulations, may be performed by an authorized Daimler Trucks North America dealer, an independent outlet, or the vehicle owner or operator. The vehicle owner is responsible for determining the suitability of replacement components to maintain compliance with federal and local jurisdictional regulations. Components including, but not limited to, low- rolling resistance tires are specifically designed and manufactured to exacting standards for regulatory fuel efficiency and greenhouse gas emissions compliance. It is important that these components are al- ways replaced with components that meet or exceed the performance of the originally installed components. Customer Assistance Center Having trouble finding service? Call the Customer Assistance Center at 1-800-385-4357 or 1-800-FTL- HELP. Call night or day, weekdays or weekends, for dealer referral, vehicle information, breakdown coor- dination, or Fleetpack assistance. Our people are knowledgeable, professional, and committed to following through to help you keep your vehicle moving. Reporting Safety Defects 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 Daimler Trucks North America LLC. 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 Foreword STI-466-6 (3/14) TBB85410323 Printed in U.S.A.

and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Daimler Trucks North America LLC. To contact NHTSA, you may call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424-9153); go to www.safercar.gov; or write to: Administrator, NHTSA, 1200 New Jersey Avenue, SE, Washington, DC 20590. You can also obtain other information about motor vehicle safety from www.safercar.gov. Canadian customers who wish to report a safety- related defect to Transport Canada, Defect Investi- gations and Recalls, may telephone the toll-free hotline 1-800-333-0510, or contact Transport Canada by mail at: Transport Canada, ASFAD, Place de Ville Tower C, 330 Sparks Street, Ottawa, Ontario, Canada K1A 0N5. For additional road safety information, please visit the Road Safety website at: www.tc.gc.ca/ roadsafety. © 2004–2014 Daimler Trucks North America LLC. All rights reserved. Daimler Trucks North America is a Daimler com- pany. No part of this publication, in whole or part, may be translated, reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written per- mission of Daimler Trucks North America LLC. For additional information, please contact Daimler Trucks North America LLC, Service Systems and Documentation, P.O. Box 3849, Portland OR 97208–3849 U.S.A. or refer to www.Daimler-TrucksNorthAmerica.comand www.ThomasBus.com. Foreword

Contents Chapter Page Introduction, Environmental Concerns and Recommendations, Event Data Recorder, Emissions and Fuel Efficiency Compliance, Customer Assistance Center, Reporting Safety Defects .................... Foreword 1 Vehicle Identiﬁcation ...................................................... 1.1 2 Vehicle Access .......................................................... 2.1 3 Bus Features ........................................................... 3.1 4 Instruments ............................................................. 4.1 5 Controls ................................................................ 5.1 6 Electrical Systems ....................................................... 6.1 7 Engines ................................................................ 7.1 8 Exhaust Aftertreatment Systems ............................................ 8.1 9 Drivetrain ............................................................... 9.1 10 Hydraulic and Air Brake Systems .......................................... 10.1 11 Pre- and Post-Trip Checklists ............................................. 11.1 12 Pre- and Post-Trip Inspections and Maintenance .............................. 12.1 13 Cleaning and Care ...................................................... 13.1 14 In an Emergency ....................................................... 14.1 15 Headlight Aiming ........................................................ 15.1 16 Hybrid Electric Vehicle ................................................... 16.1 17 Propane Fuel System .................................................... 17.1 18 Speciﬁcations .......................................................... 18.1 Index .................................................................. I.1

1 Vehicle Identiﬁcation Vehicle Certiﬁcation Plate and Data Plate ............................................. 1.1 Federal Motor Vehicle Safety Standard Labels .......................................... 1.1 Canadian Motor Vehicle Safety Standard Labels ........................................ 1.2 Tire and Rim Information ........................................................... 1.2 Vehicle Loading .................................................................. 1.2 Emissions Labels ................................................................. 1.2

Vehicle Certification Plate and Data Plate NOTE: Labels shown in this chapter are ex- amples only. Actual label locations and specifications may vary from vehicle to vehicle. The certification plate is installed on the inside roof liner above the driver’s window, or on the front bulkhead. The certification plate indicates compliance with all Federal Motor Vehicle Safety Standards (FMVSS) at the time of manufacture, gross axle weight rating (GAWR) front and rear, gross vehicle weight rating (GVWR), vehicle identification number (VIN), vehicle type, body identification, and build date. See Fig. 1.1. The data plate is installed on the inside roof liner above the driver’s window, or on the front bulkhead, and lists manufacturing information. See Fig. 1.2. Whenever contacting parts, service, or warranty per- sonnel regarding the vehicle, the following three numbers will be requested: • chassis identification number • body identification number • VIN Federal Motor Vehicle Safety Standard Labels NOTE: Due to the variety of Federal Motor Ve- hicle Safety Standard (FMVSS) certification requirements, not all of the labels shown will apply to your vehicle. Buses purchased in the U.S. are marked as certified by means of an FMVSS certification label. See Fig. 1.3. The tire and rim information are combined into one label. This label is located in the driver area. Chassis built without a cargo body that are intended for service in the U.S. have an incomplete vehicle certification label attached by the final-stage manufacturer. See Fig. 1.4. This label will be attached to the incomplete vehicle document included with the vehicle, and certifies that the vehicle conforms to all applicable FMVSS regulations in effect on the date of completion. The tire and rim portion of the FMVSS certification label certifies suitable tire and rim combinations that can be installed on the vehicle, for the given gross axle weight rating. Tires and rims installed on the vehicle at the time of manufacture may have a higher f080137 HIGH POINT NORTH CAROLINA MFD BY THOMAS BUILT BUSES INC. INC VEH MFD BY: GVWR: GAWR FRONT: GAWR REAR: THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT IN: V.I.N.: BODY ID: CHASSIS ID NO: VEH. TYPE: 01/16/2009 Fig. 1.1, Certification Plate f080136 HIGH POINT NORTH CAROLINA MFD BY THOMAS BUILT BUSES INC. DATE: CHASSIS YARD NO.: ENGINE: TRANS: FRONT AXLE: INT AXLE: REAR AXLE: MODEL YEAR: SER NO: SER NO: MOD NO: MOD NO: MOD NO: 02/17/2004 Fig. 1.2, Vehicle Data Plate 11/14/2001 f080118 1 2 3 1. Date of Manufacture 2. Gross Vehicle Weight Rating 3. Gross Axle Weight Rating Fig. 1.3, Vehicle Certification Label 11/14/2001 f080120 Fig. 1.4, Incomplete Vehicle Certification Label Vehicle Identification 1.1

load capacity than that certified by the tire and rim label. If the tires and rims currently on the vehicle have a lower load capacity than that shown on the tire and rim label, then the tires and rims determine the load limitations on each of the axles. Canadian Motor Vehicle Safety Standard Labels In Canada, buses are marked as certified by means of a statement of compliance label with the Canadian National Safety Mark, which is located in the driver area. See Fig. 1.5. If purchased for service in Canada, chassis built without a body are marked as certified by a "State- ment of Compliance" label. See Fig. 1.3. This label must be attached by the final-stage manufacturer to certify that the vehicle conforms to all applicable Canada Motor Vehicle Safety Standard (CMVSS) regulations in effect on the date of completion.. Tire and Rim Information The tire and rim label certifies suitable tire and rim combinations that can be installed on the vehicle for the given gross axle weight rating. Tires and rims installed on the vehicle at the time of manufacture may have a higher load capacity than that certified by the tire and rim label. If the tires and rims currently on the vehicle have a lower load capacity than that shown on the tire and rim label, then the tires and rims determine the load limitations on each of the axles. See Fig. 1.6 for U.S. and Canadian tire and rim labels. Vehicle Loading The gross axle weight rating (GAWR) is the maxi- mum weight the axle can carry. GAWR is the combined capacity of the axle, brakes, tires, wheel equipment, and suspension. The gross vehicle weight rating (GVWR) is the maxi- mum loaded weight of the vehicle. See Fig. 1.3. NOTICE Never load the vehicle over the GVWR. Consider- able damage to the drivetrain may result if the vehicle is over the GVWR. IMPORTANT: Passenger and cargo loads should be distributed proportionately over both the front and rear axles, and sides of the bus. NOTE: Actual loads on the front and rear axles can only be determined by weighing the vehicle at highway weigh stations or similar facilities. Overloading the vehicle is considered misuse and will void the vehicle warranty. Emissions Labels EPA Noise Emission Control Label A vehicle noise emission control label is attached either to the left side of the dashboard or in the driver’s area. See Fig. 1.7. It is the owner’s responsibility to maintain the vehicle so that it conforms to EPA regulations. IMPORTANT: Certain incomplete vehicles may be produced with incomplete noise control hard- ware. Such vehicles will not have a vehicle noise emission control information label. For f080024 10/10/2006 Fig. 1.5, Canadian National Safety Mark 11/14/2001 f080119 1 2 1. Gross Weight Rating By Component in Axle System 2. Gross Vehicle Weight Rating By Component in Vehicle as a Whole Fig. 1.6, Tire and Rim Information Vehicle Identification 1.2

such vehicles, it is the final-stage manufacturer’s responsibility to complete the vehicle in conformity to U.S. EPA regulations (40 CFR Part 205) and label it for compliance. Aftertreatment System Indicators Label Engines and vehicles manufactured after December 31, 2006 and domiciled in the U.S. or Canada are required to meet all EPA regulations effective as of the vehicle build date, and are equipped with an emission aftertreatment system (ATS). Vehicles domiciled outside of the U.S. and Canada may not have aftertreatment equipment, depending upon local statutory emissions guidelines. See Table 1.1. There is a warning label (placement will vary by bodybuilder) for important warning indicators in the instrument cluster that pertain to the ATS. It is a violation of U.S. federal law to alter exhaust plumbing, ATS, or other components in any way that would bring the engine/vehicle out of compliance with certification requirements [Ref: 42 U.S.C. S7522(a) (3)]. It is the owner’s responsibility to maintain the vehicle so that it conforms to EPA regulations. Vehicle Emission Control Information Label Model year 2013 and later vehicles meet additional requirements as specified by federal greenhouse gas and fuel efficiency regulations (GHG14). These vehicles may be equipped with components, such as low-rolling resistance tires, that increase fuel efficiency and reduce GHG emissions. A Vehicle Emission Control Information label is located on the fan shroud. See Fig. 1.8. It is the owner’s responsibility to maintain the vehicle so that it conforms to EPA and NHTSA regulations. 10/06/98 f080026 24-00273-020 VEHICLE NOISE EMISSION CONTROL INFORMATION FREIGHTLINER CORPORATION THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS FOR NOISE EMISSION APPLICABLE TO MEDIUM AND HEAVY TRUCKS. THE FOLLOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE PROHIBITED BY THE NOISE CONTROL ACT OF 1972: A. THE REMOVAL OR RENDERING INOPERATIVE, OTHER THAN FOR PURPOSES OF MAINTENANCE, REPAIR, OR REPLACEMENT, OF ANY NOISE CONTROL DEVICE OR ELEMENT OF DESIGN (LISTED IN THE OWNER’S MANUAL) INCORPORATED INTO THIS VEHICLE IN COMPLIANCE WITH THE NOISE CONTROL ACT. B. THE USE THIS VEHICLE AFTER SUCH DEVICE OR ELEMENT OF DESIGN HAS BEEN REMOVED OR RENDERED INOPERATIVE. DATE OF MANUFACTURE 01/96 Fig. 1.7, Vehicle Noise Emission Control Label 03/02/2012 f080183 Fig. 1.8, Vehicle Emission Control Information Label Vehicle Identification 1.3

Applicable Emissions System Based on Build Date and EPA Regulations Build Date Regulation: Emissions Components January 1, 2007–December 31, 2009 EPA07 (reduce nitrogen oxides (NOx) emissions to 1.1 g/bhp-hr, and reduce particulate matter emissions to 0.01 g/bhp-hr): Aftertreatment device (ATD) containing a diesel particulate filter that traps soot and ash. * January 1, 2010–December 31, 2012 EPA10 (reduce NOx emissions to 0.2 g/bhp-hr): EPA07-type ATD, with additional selective catalyst reduction (SCR) technology that utilizes diesel exhaust fluid (DEF) to convert NOx to nitrogen and water vapor. From March 5, 2012 GHG14: Aerodynamic and fuel efficiency components including low-rolling resistance tires specifically designed to meet regulatory fuel efficiency and greenhouse gas emissions standards. * Cummins, Detroit, and Mercedes-Benz ATD’s are also equipped with a diesel oxidation catalyst to break down pollutants. Table 1.1, Applicable Emissions System Based on Build Date and EPA Regulations Vehicle Identification 1.4

2 Vehicle Access Assist Rails and Access Steps ...................................................... 2.1 Entering and Exiting the Bus ........................................................ 2.1 Front Door Opening and Closing ..................................................... 2.2 Battery Access ................................................................... 2.2 Hood Opening and Closing ......................................................... 2.3 Emergency Roof Escape Hatch ...................................................... 2.4 Emergency Door .................................................................. 2.4 Emergency Window Exits .......................................................... 2.5

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Thomas SAF-T-LINER C2 School Bus Operation & Maintenance Manual

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