If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immedi- ately inform the National Traffic Safety Association in addition to notifying THOMAS BUILT BUSES, 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 THOMAS BUILT BUSES, 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 can also obtain other information about motor vehicle safety from the Hotline. Page i Table of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Operator's Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Operating the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Emergency Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 Page 1 Introduction This manual has been prepared to acquaint you with the necessary information for the the proper operation of your Thomas Bus body and chassis. A thorough knowledge of the operating controls is essential to the proper transit and comfort of passen- gers. The information and illustrations contained in this manual are based on the latest product information available at the time of publication. Some procedures and illustrations will pertain to optional equipment. Thomas Built Buses, Inc. reserves the right to make changes at any time without notice. We would like to say "Thank You" for choosing the Thomas product line to fill your transportation needs. This manual should remain with the coach when sold to provide the next owner with important operation and maintenance information. To The Operator Shown below are the safety alert symbols. When you see these symbols and words in this manual, be alert to the potential for personal injury or property damage. Follow the recommended precautions and safe oper- ating practices. The danger message alerts the operator to a haz- ardous situation or unsafe practice that will result in serious injury or death. Danger Warning The warning message alerts the operator to a poten- tially hazardous situation or unsafe practice that could result in injury to the operator and/or damage the coach. Important The message identifies potential problems which could cause minor damage to the chassis and/or body of the coach. Note The message helps to clarify a previous statement. It also identifies "nice-to-know" information. Safety Caution The caution message alerts the operator to a potential hazardous situation or unsafe practice that may result in minor or moderate injury or could result in property damage only. Page 2 Important Notice Your Thomas Built Bus has been manufactured in strict compliance with all the applicable Federal Motor Vehicle Safety Standards (FMVSS). We strongly advise against making any changes or modifica- tions that will in any way violate this compliance. Thomas Built Buses will not be responsible for any change or modification occurring to the coach after its purchase that violates these FMVSS standards. Thomas Built Buses, Inc. is not responsible for any direct or indirect consequence of any modification or alteration made to its products by anyone other than the Thomas factory. Please be advised that such modifications may VOID the Federal and/or State Certification, and the Thomas Body Limited Warranty, the Thomas Chassis Limited Warranty, and/or the Thomas Premiere Protection Plan. The limited warranties of Thomas exclude: "Components or systems which have been altered or modified without the express prior, written autho- rization of the company." Examples of such modifications are, but are not limit- ed to, the following: • After-market alternate-fuel conversions, • Chassis wheelbase changes, • Mounting a Thomas body on a different chassis than the original, • Mounting a different body (than original) on a Thomas chassis, • Any component alteration that affects GAWRF, GAWRR, and/or GVWR, • Any component alteration that affects any FMVSS certification, • Power train replacement or alteration other than original specification, • Steering, braking, or suspension alteration other than original specification, • Seating capacity or configuration modifica- tion, • Addition or deletion of any passenger entrance or exit, • Basic body structural alteration, • Modification of the body-to-chassis mounting system, • Exhaust system alteration or replacement other than original specification, • Use of un-approved fluids, fuels, or lubri- cants, • Electrical system/component alteration, • Addition of after-market components, such as: • Retarder • Air conditioning • Battery disconnect • Traction devices Vehicle Modification Disclaimer Policy Page 3 Introduction Certification and Data Plate The computer generated Certification and Data Plates are attached to the inside roof liner above the driver's window or on the front bulkhead. The Certification Plate certifies compliance with all Federal Motor Vehicle Safety Standards in effect at time of manufacture. Other information included are Date of Manufacture, GAWR Front, GAWR Rear, GVWR, Tire Data, VIN, Vehicle Type, Body ID, and Capacity. Whenever contact is made with a distributor, autho- rized service agent, or Thomas Built Buses concern- ing warranty, parts, or service, these numbers must be given to identify the unit. The three sets of numbers are: 1. Chassis Identification Number - When con- cerning the chassis of a Thomas product. 2. Order Number - The first five-digit number in the Body Identification number. 3. Body Number - The second seven-digit num- ber in the Body Identification number. The Data Plate lists items such as Chassis Yard Number, Model Year, Engine and Serial Number, Transmission and Serial Number, Axles and Model Numbers. The VIN (Vehicle Identification Number) is assigned by the chassis manufacturer and contains information such as manufacturer, engine type, body style, and order number. Vehicle Identification Number (VIN) INC VEH MFD BY: DATE: GVWR: GAWR FRONT: WITH TIRES RIMS PSI COLD GAWR INTERMEDIATE: WITH TIRES RIMS PSI COLD GAWR REAR:WITH WITH TIRES RIMS PSI COLD THIS VEHICLE CONFORMS TO ALL APPLICABLE MAX CAP FEDERAL MOTOR VEHICLE SAFETY STANDARDS SUB TO DESIGN IN EFFECT IN: LIMITS: V.I.N.: CHAS. ID. NO: 11127 VEH. TYPE: EQUIP. CAP.: BODY ID.: 48156 - 9710376 MODEL - (order #) - (body #) HIGH POINT, NORTH CAROLINA WOODSTOCK, ONTARIO MONTERREY, M.L., MEXICO MFD. BY THOMAS BUILT BUSES, INC. DATE: Page 4 HIGH POINT, NORTH CAROLINA WOODSTOCK, ONTARIO MONTERREY, M.L., MEXICO 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 Page 5 Introduction Coach Loading The Thomas coach is designed to provide excellent service if not loaded in excess of either the Gross Vehicle Weight Rating (GVWR) or the maximum front and rear Gross Axle Weight Rating (GAWR). These ratings are listed on the coach certification plate with the tires required to obtain these ratings. GAWR (Gross Axle Weight Rating) is the maximum weight the axle can carry and reflects the combined capacity of axle, brakes, tires, wheel equipment and suspension. GVWR (Gross Vehicle Weight Rating) is the maxi- mum loaded weight of the vehicle. Passenger and cargo loads should be distributed proportionately over both the front and rear axles, and sides of the coach. Caution: Actual loads at the front and rear axles can only be determined by weighing the coach at highway weigh stations or other similar facilities. Warning: Overloading can create the potential for serious safety hazards and places excessive loads on vehicle compo- nents. Coach warranty is void on any vehicle which has been subject to misuse. Overloading the vehicle is misuse. Coach Loading Example: Coach equipped with stan- dard axles and suspension, 10:00 x 20, Load Range G or 11R22.5, Load Range G. Rear GAWR 23,000 lb. 10432.8 kg. Front GAWR 13,200 lb. 5987.52 kg. ________ _______ GVWR 36,200 lb. 16420.32 kg. Rear curb weight, cargo, and passenger load cannot exceed 23,000 lb. (10432.8 kg.). Front curb weight, cargo, and passenger load cannot exceed 13,200 lb. (5987.52 kg.). Maximum total weight cannot exceed 36,200 lb. (16420.32 kg.). Page 6 Each new Thomas bus has been inspected before delivery. Every precaution has been taken to provide the user with a complete and trouble-free bus. There are certain steps that must be taken to contin- ue the assurance of a trouble-free bus. Proper inspec- tion and maintenance of the bus is a necessity from the time of delivery and throughout its service life. If the bus is not processed through a distributor before delivery to the operator, the need to perform the "Delivery Inspection" is greater. Any discrepancies or omissions should be reported to the selling distributor immediately. Delivery Inspection - New Vehicle Federal Clean Air Act Section 203(a) (3) Important: The removal of air pollution control equipment from, or the modification of a certified engine to a non-certified configuration, is prohibited by the Federal Clean Air Act. The following is a direct quotation from Section 203 (a) (3) that covers this part of the Federal Standards: "Section 203 (a) The following acts and the causing thereof are prohibited- (3) for any person to remove or render inoperative a device or an element of design installed on or in a motor vehicle, motor vehicle engine in compliance with regulations under this part prior to its sale and delivery to the ultimate purchaser, or for any manu- facturer or dealer knowingly to remove or render inop- erative any such device or element of design after such sale and delivery to the ultimate purchaser." Thomas Built Buses suggests that you do not make any changes to a certified engine that would result in that engine not matching the certification required to meet Federal Standards. The law provides a penalty of up to $10,000 for each violation. In CANADA, the same conditions apply with one exception. After the coach is sold to a retail customer (end user), emission control devices are controlled by the province in which the coach is licensed. Engine Emissions Page 7 Introduction Condition Report Glass OK Damaged Windshield ___ ________ Side Glass ___ ________ Rear Glass ___ ________ Mirrors ___ ________ Overspray ___ ________ Sheet Metal & Paint Hood ___ ________ Right Side ___ ________ Rear ___ ________ Left Side ___ ________ Lettering ___ ________ Interior Condition Overspray - Dash ___ ________ Overspray - Seats ___ ________ Seats - Cushions ___ ________ Seats - Backs ___ ________ Floors ___ ________ Paint ___ ________ Dash ___ ________ Tires All inflated ___ ________ Cuts, Damages ___ ________ Underhood Oil Level ___ ________ Water Level ___ ________ No. Batteries ___ ________ Identify Plate Body No. _____________________________ Order No. _____________________________ Operational Check System OK Not OK Headlights ___ ________ Turn Signals ___ ________ 8-Way Flasher ___ ________ Warning Buzzers ___ ________ Instruments ___ ________ Brake Lights ___ ________ Tail Lights ___ ________ Back-Up Lights ___ ________ Windshield Wipers ___ ________ Horns ___ ________ Interior Lights ___ ________ Tachograph ___ ________ Heater Motors ___ ________ A/C (must blow cool air) ___ ________ Start Engine Instruments ___ ________ Check the proper blank for the following being in the vehicle. Yes No Fire Extinguisher ___ ____ Fire Axe ___ ____ First Aid Kit ___ ____ Flares ___ ____ Tool box ___ ____ Wrecking Bar ___ ____ Spare Tire ___ ____ Spare Rim ___ ____ Warranty Packet ___ ____ Tire Carrier ___ ____ Jack ___ ____ Data Sticker ___ ____ Thomas Built Buses, Inc. - High Point, NC & Woodstock, Canada VEHICLE ACCEPTANCE FORM Distributor _______________________________________Order No. _____________________________________ Body No. ______________________________________ Yard No. ______________________________________ Every effort has been made to release this vehicle to be acceptable by the selling distributor. This vehi- cle was final inspected on ________________19____ and pronounced ready for shipment with the fol- lowing exceptions: ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ The distributor's representative is advised to inspect this vehicle for deficiencies and/or shortages prior to accepting the vehicle. No Claims will be honored by Thomas Built Buses, Inc. for any deficiencies or shortages unless noted and recorded below. Use the check list as a guide. Damages/shortages list here: ___________________________________________________________________________________ ___________________________________________________________________________________. Released by_______________________________Thomas Built Buses, Inc. Date______________ Pick-up Driver's Signature______________________________Comments: ____________________ ___________________________________________________________________________________. Page 8 In addition to the Delivery Inspection, a one-time pre- ventive maintenance inspection should be performed after the first thirty days of operation. These are areas that should receive attention on any new vehicle. First Thirty Days Body Chassis • Tighten all mounting clips and bolts, then retighten every six months thereafter. • Tighten driver's seat bolts, then retighten every six months thereafter. • Tighten seat leg and wall rail bolts, then retight- en every ninety days thereafter. • Remove heater hose covers and tighten all hose clamps. • Wash bus only with clean water for the first thir- ty days. • Wax bus with a good automotive wax after the first thirty days. • Check toe-in. Reset if necessary. • Check the steering operation. • Tighten power steering items. • Check power steering reservoir level. • Clean and lubricate all fittings. • Inspect front and rear engine mounts and bolt condition. • Tighten front and rear spring U-bolts. • Drain and refill differential lubricant. • Check transmission oil level. Drain and refill if manual transmission. • Change engine oil and filters per PM schedule. • Tighten radiator hoses. Check coolant level. • Tighten steering gear mounting to frame. • Inspect tie rod, pitman arm, and drag link con- nections. • Inspect for correct clutch adjustment, if equipped. • Inspect for correct brake adjustment. • Adjust belt tension (all belts). • Tighten exhaust system. • Gauge tires for correct air pressure. • Inspect for air leaks (air brake models). • Tighten all lug nuts (all wheels). • Check calibration of gas sensor modules. (CNG units) • Check fuel system fittings and components for leaks. (CNG units) Page 9 Operator's Compartment This section provides the operator with important operational and general information. The following divides the Operator's Compartment into four major parts. The first part of this section covers the Instrument Panel. The second part of this section cov- ers the Operator's Compartment Controls. The Side Console Switch Panel forms the third part of this sec- tion. Information about the Driver's Seat completes the section. It is important to carefully read and understand the fol- lowing pages before operating the coach. A proper understanding of component location, function and operation is important to the proper operation of the coach. 1. Speedometer, Programmable 2. Fuel Gauge 3. Indicator Light Panel, 14 Lamp 4. Dual Air Pressure Gauge 5. Tachometer 6. Transmission Shifter, Four Speed 7. Water Temperature Gauge 8. Voltmeter 9. Oil Pressure Gauge 10. Transmission Oil Temperature Gauge 11. Headlight Switch, with Light Dimmer 12. Dome Plug 3/16" 13. Ammeter 14 Heater Control Panel Assembly 15. Blank Switch, Hole Plug V-Series 16. Fresh Air, Outside 17. Fast Idle Switch 18. Ignition Switch 19. Park Brake Valve (Air Brakes) 20. Wiper Switch, LOW-HIGH 21. Blank Gauge (Dummy) 22. Windshield Washer Switch 23. Intermittent Wiper 24. Dome Plug 5/8" Instrument Panel, with MT643 Transmission Page 10 1. Speedometer, Programmable 2. Fuel Gauge 3. Indicator Light Panel 4. Dual Air Pressure Gauge 5. Tachometer 6. Transmission Shifter, Five Speed 7. Pilot Lamp Gauge, ISC 8. Water Temperature Gauge 9. Retarder Switch, ON-OFF 10. Retarder Transmission Pilot Light 11. Auxiliary Switch Pod 12. Switch Blank Switch, Hole Plug 13. Voltmeter 14 Oil Pressure Gauge 15. Transmission Oil Temperature Gauge 16. Dome Plug 3/16" 17. Headlight Switch, with Light Dimmer 18. Ammeter 19. Heater Controller (Webasto) 20. Heater Control Panel Assembly 21. Diagnostics 22. Diagnostic Test (ISB/ISC) Warning Light (CAT) 23. Exhaust Brake 24. Fresh Air, Outside 25. Cruise / Resume 26. Cruise 27. Fast Idle Switch 28. Ignition Switch 29. Park Brake Valve (Air Brakes) 30. Blank Gauge (Dummy) 31. Wiper Switch, LOW-HIGH 32. Intermittent Wiper 33. Windshield Washer 34. Dome Plug, 5/8" Instrument Panel, with MD 3060 Transmission Page 11 Operator's Compartment Instrument Panel, with MD 3060 & CNG Engines 1. Speedometer, Programmable 2. Fuel Gauge 3. Indicator Light Panel 4. Dual Air Pressure Gauge 5. Tachometer 6. Transmission Shifter, Five Speed 7. Blank Gauge (Dummy) 8. Water Temperature Gauge 9. Voltmeter 10. Oil Pressure Gauge 11. Transmission Oil Temperature Gauge 12. Dome Plug 3/16" 13. Headlight Switch, with Light Dimmer 14. Ammeter 15. Heater Controller (Webasto) 16. Heater Control Panel Assembly 17. Blank Switch, Hole Plug V-Series 18. Fresh Air, Outside 19. ECM/Diagnostics 20. GCM / ECM Check Engine Pilot Light (6CG) 21. Fast Idle Switch 22. Ignition Switch 23. Park Brake Valve (Air Brakes) 24. Alarm Detector Lamp Assembly 25. Wiper Switch, LOW-HIGH 26. Intermittent Wiper 27. Windshield Washer Switch 28. Dash Diagnostic Start Switch Page 12 The fuel gauge indicates the amount of diesel fuel in the tank. Fuel Gauge (Diesel) The Instrument Panel is a critical element in monitor- ing the operating condition of the coach. In addition to its monitoring features, the instrument panel enables the operator to perform a variety of tasks necessary for proper coach operation. Various options and specifications dictate the number of gauges and controls installed on our coach. Refer to the specific information about the components. The speedometer indicates coach speed in miles per hour (mph) and kilometers per hour (kph). The odometer registers the total accumulated miles/kilo- meters driven. The odometer can register up to 9,999,999.9 and will then reset to zero. Speedometers must be recalibrated should you change tire size and/or rear axle ratio. Contact your local Thomas dis- tributor. Speedometer/Odometer Fuel Gauge (CNG) Indicates the amount of pressure in the fuel system. Page 13 Operator's Compartment 1. Turn Signal Indicators - Flash when the out- side turn signals are operating or when haz- ard lights are on. 2. Park Brake Light - Indicates park brake is engaged. Caution: To avoid possible damage to the vehicle, do not drive while the parking brake light is illuminated. 3. ABS System Fault Indicator - The warning lamp blinks once, then goes off and stays off, unless the system detects a problem. 4. Engine Compartment Temperature Warning Indicator (Natural Gas Engines only) - Light comes on when temperature in engine com- partment reaches 350 0 F (176.7 0 C). Danger: If Engine Compartment Temperature Warning Indicator comes on, immediate- ly get to a safe stopping area, remove passengers, and check for fire in engine compartment. 5. Low Air Pressure Indicator - This indicator, upon activation, indicates that the air pres- sure in the brake air system (primary-rear, secondary-front, or both) has dropped to 66 psi (46 kPa) or below. The low air pressure indicator becomes red upon activation and is accompanied by a buzzer. As air pressure exceeds 66 psi (46 kPa), the indicator and buzzer are deactivated. The air pressure switches are factory set at 66 +/- 6 psi (46 +/- 4 kPa). Caution: If the air pressure light comes on during normal operation, only a limited number of brake applications will be available, and braking distance will increase. 6. Park Light Indicator - Becomes illuminated when park lights are activated. 7. Check Engine Indicator - When a problem is detected by the engine's electronic system, a diagnostic code is generated and the Check Engine lamp is turned ON. 8. Fasten Seat Belt Indicator - Indicates that dri- ver's seat belt is not buckled. 9. Low Coolant Indicator - The low coolant level indicator lamp becomes illuminated when the coolant level is low. If this lamp comes on while driving, stop the bus and check the level in the cooling system surge tank. Before filling the system with coolant, check for leaks. See Maintenance Section for prop- er fill procedures. 10. Intake Air Heater Indicator - When the ECM is first powered up, the Inlet Air Heater Lamp should come ON for a minimum of two sec- onds. If heater is operating, lamp should turn ON, and then OFF when the cycle is com- plete. 11. Check Transmission Indicator (Allison MD- 3060) - Transmission Fault Indicator. 12 High Beam Indicator - Indicates that vehicle's headlights are on high beam. (Continued on next page.) Indicator Light Panel Page 14 The dual air pressure gauge indicates the levels of air pressure in the primary or rear axle brake system (white needle) and the secondary or front axle brake system (red needle). Both needles should indicate the same pressure reading. Common cut-out pressures are between 105-125 psi (72-86 kPa). Common cut-in pressures are between 90-105 psi (62-72 kPa). The pressure range between cut-in and cut-out is not adjustable. The rear brakes will gradually begin to apply when air pressure drops below 65 psi (45 kPa). At 40 psi (28 kPa) the rear brakes will automatically lock up by actu- ating the PP-1 valve and allowing the air in the spring brake side of the brake chamber to be released. Determine and correct cause of pressure loss before returning coach to service. Warning: In the event that a pressure loss occurs, the operator can identify the affected system by observing the gauge needles. Stop the coach immediately if either of the following conditions occur: Low air warning buzzer sounds and/or indicator light comes on. When the air pressure drops below 60-72 psi (41-50 kPa) the buzzer and light activated. Caution: If one needle suddenly drops pressure and stays below 65 psi (448 kPa), the other system can still safely stop the vehicle, but it may take longer, stopping distances may be increased, and the brakes can only be applied a limited number of times. Have the vehicle repaired immediately if this occurs. Dual Air Pressure Gauge Indicator Light Panel - (continued) 13. Engine Warning Light - If this light remains on while driving, it indicates a potential engine problem such as high engine coolant temper- ature or low engine oil pressure, and a need for service. Caution: Do not run the engine when the engine warning light comes on unless neces- sary to find a safe place to stop the vehi- cle. Running the engine with this light on could cause permanent damage to the engine. Page 15 Operator's Compartment Tachometer The tachometer indicates engine speed in revolutions per minute (rpm). The tachometer aids the operator in preventing excessive engine speed when descending steep grades and using the engine as a brake. The driver should never exceed the maximum governed engine rpm or serious engine damage may result. The hour meter indicates engine service hours and is used to determine engine service and maintenance inter- vals. Caution: Extended operation of engine above rated speed will cause serious engine damage. Page 16 Transmission Shifter (Lever) To put the transmission into gear, move the selector lever from Neutral to the desired drive position. Caution: Do not race the engine when shifting from Neutral into another gear. The available gears are: (R) Reverse - Vehicle must be completely stopped before engaging this gear. (N) Neutral - Use when vehicle is standing for pro- longed periods with engine running. Set the parking brake if you leave the vehicle. Engine may be started in this gear. Caution: Set the gear selector to Neutral, engage the parking brake, and turn off the igni- tion, even momentarily. Never leave the vehicle unattended while the engine is running. Unexpected sudden vehicle movement may occur if these precau- tions are not taken. Do not allow the vehicle to coast in Neutral. (D) Drive - For most city and highway driving. (3) Third and (2) Second - For driving slowly in heavy city traffic or on mountain roads where more precise speed control is desirable, and for climbing and descending long grades. To prevent excess engine speed, do not exceed 45 mph (72 kph) in this gear. (1) First - For driving up very steep hills and engine braking at low speeds - 25 mph (40 kph) or less - when going downhill. To prevent excessive engine speed, do not exceed 25 mph (40 kph) in this gear. Caution: Never depend on the transmission as an engine brake. The transmission will upshift, no matter what gear is selected when the internal pressure reaches a certain level. A shift point will be creat- ed by high engine rpm.