MCi Reliability Driven, J4500 Operator's Manual

J4500 OPERATORS MANUAL

TABLE OF CONTENTS

SUBJECT PAGE

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Daily Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Switches, Warning Lights and Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Steering Column and Floor-Mounted Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Operating Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Wheelchair Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Engine Operation, Fuel and Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Emergency Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Heating and Air Conditioning (HVAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Audio and Video System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

INTRODUCTION

Typical illustrations may be used, therefore minor illustration differences may exist when compared to actual parts or other publications

CERTIFICATION PLATE

The certification plate (Figure 1.) is mounted beside the driver's seat, and certifies compliance with all applicable Federal Motor Vehicle Safety Standards in effect on the date of manufacture. It also lists the date the coach was built, the GVWR, GAWR's, rim size, tire pressures, coach model and coach serial number.

COACH APPLICABILITY

This manual supports the MCI J4500 Coach.

TO THE DRIVER

This manual has been prepared to provide you with the information you need to operate the MCI J4500 Series Coach.

The specifications and information throughout this manual are subject to change without notice.

Report immediately any problem or malfunction that interferes with the operation of the coach, particularly if safety may be affected.

The term “Optional” in this manual pertains to all equipment and features other than basic.

MCI SERVICE NUMBER: 1-800-241-2947

This manual is a permanent part of this vehicle. It must stay with the coach if the coach is sold.

PUBLICATION DATE: July 2015 EFFECTIVE WITH UNIT NUMBER 67310 MCI PUBLICATION PART #.: 03-26-1035B

EMISSION CONTROL DECAL

The emission control decal (Figure 2.) is affixed to the lower panel next to the driver's seat, beside the certification plate shown in

Figure 2.

COACH NAMEPLATE

The nameplate (Figure 3.) is mounted in the engine compartment at the rear of the coach. The vehicle identification number (VIN), model year and date of manufacture are shown on this plate.

Figure 1.

Figure 3.

1July 2015

VEHICLE IDENTIFICATION NUMBER (VIN)

The nameplate and the certification plate both contain the seventeen-character vehicle identification number (VIN).The numbers correspond to the items in the following list.

1. The first three characters identify the manufacturing company:

1M8 = MCI Inc. (U.S.) 2MG = MCI Ltd. (Canada)

2. The fourth character identifies the coach model:

3 = J4500 Intercity

3. The fifth character identifies the series:

J = J-Series

4. The sixth character identifies the type of coach:

M = Intercity (MCI) P = Incomplete Vehicle

5. The seventh character identifies the type of engine:

B = Cummins ISX 8 = Detroit Diesel DD13

6. The eighth character identifies the type of brakes:

A = Air Brake Intercity

7. The ninth character is the check number.

8. The tenth character identifies the year:

G = 2016

9. The eleventh character identifies the manufacturing location:

W = Winnipeg, Manitoba

10.The twelfth through seventeenth characters is the coach's unit number.

July 20152

INTERNATIONAL SYMBOLS

Some of the following international symbols may be on controls and components of this coach (Figure 4.).

1. Parking Brake

2. Anti-Lock Brakes

3. Stop Engine

4. Check Engine

5. Do Not Shift

6. Retarder Hot

7. Protect Eyes By Shielding

8. ECAS Stop

9. Suspension Recover

10. Entrance Door Open

11. Entrance Door Close

12. Fog Lights

13. Window & Aisle Lights

14.Aisle Lights

15. Drivers Light

16. Step Lights

17. Reading Lights

18. Blinds Up

19. Blinds Down

20. Master Power

21. Engine Start

22. Fast idle

23. Engine Brake

24. Retarder

25. Baggage Doors Unlock

Figure 4.

26. Baggage Doors Lock

27. Kneel

28. Spark Could Explode Battery

29.Avoid Sparks Or Flames

30. Drivers Area HV AC

31. Lights Or High Beam

32. Clearance Lamps

33.Turn Signals

34. Hazard Warning

35. Engine Oil Pressure

36. Engine Oil Temp

37. Engine Coolant Temp

38. Windshield Wipers

39.Acid Cause Burn

40. Caution Possible Injury

41. Lighter

42. Battery Charging System

43. Horn

44.Air Pressure

45. Fasten Seat Belt

46. Ventilating Fan

47. Windshield Defrost

48. Windshield Washer

49. Passenger Area HVAC

3July 2015

THIS PAGE INTENTIONALLY LEFT BLANK

July 20154

DAILY INSPECTIONS

The following checks are in addition to the Federal Motor Carrier Safety Administration requirements, not instead of them.

EXTERIOR INSPECTION

1. Ensure that all windows, mirrors an d ligh ts are clean and unobstructed.

2. Ensure that all side windows are closed . A protrusion of 1/4” (6mm) or more indicates that a window in not properly latched.

3. Check that the coach exterior is clear of debris, and that all service doors are secure.

4. Check the tire pressure and inspect the tires for damage. Check that the wheel nuts are tight and inspect the wheels for damage.

5. Look under the coach for fluid leaks, animals or obstructions. Check behind the coach.

6. Check the engine oil level, coolant level, condition of belts and power steering fluid level.

7. Check the engine compartment to ensure that there are no loose or unsecured objects.

8. Check the windshield washer reservoir and fill if required.

INTERIOR COMPONENTS CHECKLIST

1. Ensure that the door(s), hatches and emergency exit windows open, close, seal and latch properly.

2. Ensure that the parcel rack doo rs ar e lat ch ed .

3. Inspect the seats and floor for debris. Clean if necessary.

4. Ensure that the interior and step-well lights work.

5. Ensure that the lavatory door, windo ws and wheelchair access door (if equipped) are closed and latched.

6. Ensure that emergency equipment and contents are in place and properly stowed.

7. Activate the entertainment control module and verify the operation of the driver's and cordless microphones (if equipped). Adjust output volume if necessary.

9. Ensure that the engine compartment remote control box ENGINE ENABLE switch is ON and the STARTER CONTROL switch is set to FRONT.

10. Turn ON the main electrical switch.

Before starting ensure that the fast idle is OFF and the parking brake is applied. Ensure that there is ample distance ahead of and behind the coach in case it moves unexpectedly during starting.

DO NOT rev the engine while starting.

5July 2015

The following checks are in addition to the Federal Motor Carrier Safety Administration requirements, not instead of them.

OPERATIONAL CHECKLIST

1. While the engine is running, look for oil or coolant leaks and listen for air leaks.

2. While the engine is running, check the alternator lights on the remote control box in the engine compartment. The lights should be OFF.

Be very careful when the engine is running and the engine door is open.

If it is necessary to have the engine running for certain inspections or checks, keep a safe distance from moving belts, pulleys, shafts or fans.

Keep hands and limbs away from moving belts and pulleys and also hot areas such as exhaust and turbocharger components and coolant lines.

Do not wear loose, baggy or frayed clothing when working near any moving parts such as pulleys, belts, shafts or fans.

3. Close and secure all baggage and service doors.

4. Ensure that all exterior lights are wor kin g.

5. If the coach is equipped with a wheelchair lift, check the lift operation. For more information refer to the vendor manual.

7. Position the inside and outside mirrors, adjust the driver's seat and fasten the seat belt.

8. Ensure that the tilt steering column is locked.

9. Ensure that the defroster, heater, horn, windshield wipers and washers all function.

Do not move the coach until the front and rear air gauges both read at least 100 psi.

10. Apply the service brakes, release the park brake, then release the service brakes.

11. Apply and hold the brakes and observe the pressure drop. It should not drop by more than 3 psi in 1 minute.

12. Move the coach slowly and bring it to a stop to ensure that the brakes stop and hold the coach.

13. Ensure that brake pedal opera tion feels normal.

14. Ensure that all gauges stay in norma l ran ge.

15. Move the coach a short distance at low speed and check the steering. Ensure that the coach is under full control and handling properly. The steering wheel must turn smoothly without any unusual noises.

6. After the HVAC system has stabilized (10 to 15 minutes), listen for abnormal noises in the compressor and fan motors; check the compressor oil level and check the refrigerant level. Ensure that the self-test has been performed successfully and that there ar e no errors or alarms indicated.

July 20156

DRIVER'S SEAT BELT

MIRRORS

Driver's Seat Belt Adjustment

Using the restraint system can lessen the severity of injury in an accident or sudden maneuver.

While seated straight and well back into the seat, adjust the belt as necessary.

To unfasten the belt, push the release button. If a belt jams, you may be able to release it by

working the belt in and out until the belt rewinds far enough to unlock. If the belt remains jammed or other restraint system parts do not work prop e rly, report the condition to service personnel promptly.

Seat Belt Inspection

Every 30 days, check the belt, buckle, latch plate, retractor and guide loops for proper operation. Check for loose or damaged parts. Keep sharp edges and sharp objects away from belts and other parts of the restraint system.

Inside Rear-view Mirrors (Optional)

The inside rear-view mirrors can be manually adjusted up, down or sideways.

Exterior Rear-view Mirrors

Exterior mirrors have separate upper and lower segments. The convex upper portion is for wideangle view.

Adjust the exterior mirrors so that you can see the side of the coach in part of the mirror. This helps determine the relationship of the coach to objects seen in the mirror.

The roadside and curbside mirror controls are on the lower LH console switch panel. Use the switch in the center of each mirror control to select the upper or lower mirror. Move the switch to the left to adjust the lower mirror and to the right to adjust the upper mirror.

Defrost the mirrors using the mirror heat switch located below the mirror controls.

Keep the belts clean and dry. Replace belts if the webbing appears frayed, cut or damaged. Replace belts that have been involved in an accident. Have parts replaced if there are any questio ns as to their condition. Clean seat belts with mild soap and lukewarm water only; do not bleach or dye.

7July 2015

PRE-TRIP INSPECTION, INTERIOR / EXTERIOR LIGHTING

ANTI-THEFT PRECAUTIONS

Before the Pre-Trip Inspection function is enabled, these functions must be met:

• Position the Master Power switch to the “ON” position,

• Select “NEUTRAL” on the transmission Shift Pad selector,

• Set the Park Brake,

• Position the Reading Light test switch to the “ON” position.

• Apply and hold a service brake application of 60 psi,

Only after these conditions are met, the Pre-Trip Inspection function is enabled, automatically activating all interior / exterior coach lighting and dash tell-tale lights and buzzer will activate for two (2) minutes.

1. Do not leave the coach unattended with the engine running.

2. Park in a lighted spot when possible.

3. Fully close all windows and doors.

4. Keep valuable items out of sight.

5. Lock out the battery disconnect switch



The back-up lights do not illuminate during the Pre-Trip Inspection.

The Pre-Trip Inspection function can be canceled by positioning the Reading Light test switch to “OFF”, or positioning the Hazard switch to “ON”.

July 20158

SWITCHES, WARNING LIGHTS AND GAUGES

1. Instrument Panel, refer to Page 20

2. LH / RH Tell-Tale Cluster, refer to Pages 10-13

3. LH Switch Panel, refer to Pages 15

4. RH Switch Panel, refer to Pages 16

5. Lower, LH Console Switch Panel, Page 17

6. HVAC Display, refer to Page 15

Figure 5. Driver Area

9July 2015

TELL-TALE LAMPS

Left Turn Indicator (Green)

Wait to Start (Yellow) - This tell-tale will

illuminate when the grid heater is ON (pre-heat function).

Check Engine (Yellow) - Engine fault. Refer to vendor manual.

Stop Engine (Red) - Engine is powering down or stopped.

Low Coolant (Yellow) - Tell-tale indicates a low engine coolant level. Do not run engine until condition is corrected.

Not Generating (Red) - Tell-tale indicates that one or both alternators are not functioning.

Regeneration (DPF) (Yellow) - Tell-tale illuminates when a regeneration is required. Tell-tale is OFF during Regen.

High Exhaust Temperatures (HET) (Yellow) - Tell-tale will illuminate when the

coach is moving less than 5 mph (approx.) and the exhaust outlet temperature exceeds the predetermined level.

Diesel Exhaust Fluid (DEF) (Yellow) - Telltale illuminates indicating the DEF level is low. Correct by refilling the DEF tank.

DEF tell-tale flashes indicating the DEF level has fallen below a critical level. Correct by refilling the DEF tank.

DEF tell-tale flashes and Check Engine illuminates indicating the DEF level is critically low and power loss will occur. Normal engine power will be restored by refilling the DEF tank.

DEF tell-tale flashes and Check Engine and Stop Engine illuminates indicating the DEF tank has been run dry . Engine will De-rate and limit speed to 5 MPH. Normal engine power and coach speed will restored by refilling the DEF tank.

Tell-tales indicate various conditions by lighting. In general, yellow indicates system status and red indicates a fault or warning. Tell-tales are located in RH and LH clusters, in the instrument cluster. Some tell-tales are accompanied by a buzzer or bell. At system start-up, tell-tales light briefly to show that the LEDs work.

LEFT-HAND TELL-TALE CLUSTER (Figure 6.)

Figure 6. ACTIA LH Tell-tale Cluster

July 201510

MIL (Yellow) - Malfunction Indicator Tell

tale Lamp (on DD13 engines ONLY). Telltale indicates a failure of an emission system component.

Blank

Water in Fuel (Yellow) - Tell-tale indicates

water in the fuel filter.

Park Brake Applied (Red)

Trailer Park (Red) - Tell-tale is disabled.

ABS (Yellow) - Tell-tale indicates anti-lock

braking system malfunction.

Electronic Stability Control / Automatic Traction Control (Yellow) - Tell-tale

indicates an Electronic Stability Control (ESC) or an Automatic Traction Control (ATC) event.

Brake Lights (Green) - Tell-tale illuminates throughout the service brake application.

Engine Brake (Yellow) - Tell-tale indicates the engine brake is activated.

Check Transmission (Yellow) - Move the coach to a safe location and turn OFF ignition. DO NOT change gear.

Stop Transmission (Red) - Tell-tale is disabled.

Retarder Temperature (Red) - Tell-tale illuminates when retarder oil temperature is above 168 degrees Celsius for more than ten (10) seconds.

Brake Wear (Yellow) - Tell-tale is disabled.

Fuel Filter Restriction (Yellow) -

Indicates the fuel filter has been clogged.

T ag Lock Fault (Red) - Tell-tale illuminates when coach speed reaches 15 mph and the tag cylinder does not lock.

Tell tale is OFF when coach speed returns to 10 mph.

No Hill Start (Yellow) - Tell-tale is disabled.

11July 2015

RIGHT-HAND TELL-TALE CLUSTER (Figure 7.)

Driver Seat Belt (Red) - Tell-tale lights

when park brake is released and the driver's seat belt is not buckled.

Check Info (Yellow) - Tell-tale indicates message on alphanumeric display of speedometer. Refer to next page for further information.

Low Fuel (Yellow)

Cruise Enabled (Green) - Tell-tale

indicates that the cruise control is activated.

High Beams (Blue) - Hi-beam tell-tale will illuminate when the main headlamps are on HIGH intensity.

Right Turn Indicator (Green)

Rear Rise (Red) - Tell-tale illuminates and

a buzzer sounds when the Rear Rise switched is pressed.

High Ride (Red) - Tell-tale will illuminate and a buzzer sounds when the coach is in transition and is maintained in HIGH RIDE.

Low Ride (Red) - Tell-tale flashes when the coach is in transition to and is maintained in LOW RIDE.

Ride Fault (Red) - Tell-tale illuminates when a fault has occurred in the MDSS. Report problem to maintenance personnel.

Kneel (Red) - Tell-tale flashes and a buzzer sounds when the coach is kneeling or recovering. When kneel is reached, the lamp stays on and the buzzer stops.

Tag Unload (Red) - Tell-tale Illuminates when the tag axle is unloaded.

WCL Door Open (Red) - Tell-tale will illuminate indicating door ajar or unlocked condition.

Figure 7. ACTIA RH Tell-tale Cluster

July 201512

CHECK INFO TELL-TALE

WCL Interlock (Red) - Tell-tale illuminates

when the wheelchair lift interlock is activated. The wheelchair interlock system, when activated, disables the transmission shift and throttle, sets the park brake solenoid, and begins engine fast idle.

Front Door Open (Red) - Tell-tale light illuminates when the entrance door is open.

WCL Stop Request (Blue) - Illuminates when a passenger in the wheelchair area presses the stop button.

Stop Request (Yellow) - Tell-tale lights when a passenger presses the stop request button.

Aux. Heat (Yellow) - Illuminates when the auxiliary heater has been activated.

Fire Alarm (Red) - Illuminates when the temperature sensors sense heat from a fire in the engine compartment.

Emergency Lights (Yellow) - Tell-tale is disabled.

Dock Lights (Blue) - Tell-tale is disabled.

Service Lights (Yellow) - Tell-tale

indicates engine compartment. light is ON.

Bike Rack (Yellow) - Tell-tale is disabled.

Check Lube (Yellow) - Tell-tale is

disabled.

Back-up Alarm Off (Yellow)- Tell-tale is disabled.

Lavatory Emergency (Yellow)- Tell-tale illuminates when a passenger presses the emergency button in the lavatory.

The CHECK INFO tell-tale illumination indicates that a message regarding additional tell-tale information is displayed on the alphanumeric disp lay of speedometer. Dependant of the message displayed, a buzzer may accompany the message.

Move the coach to a safe parking area to view the message displayed on the alphanumeric display of speedometer. After the message has been recorded, the operator can press the TRIP button (RH side of the speedometer, refer to Figure 8.) to dismiss the message. The CHECK INFO tell-tale will remain illuminated, but the message will not appear in the alphanumeric display of speedometer until the system re-broadcasts the signal.

The tell-tale information displayed on the alphanumeric display of speedometer are Lavatory Emergency (displayed as LAVTORY), Baggage Lights (BAG LTS), Low Ride (LOWRIDE), Digital Wheel End Sensor (WHL END) and Fire Alarm.

Figure 8. Speedometer Alphanumeric

display

13July 2015

Figure 9. 4 in 1 Gauge

4 IN 1 GAUGE TELL-TALES (Figure 9.)

1. Front Air PSI

The low air warning tell-tale illuminates when the air pressure drops below the pre-determined level.

In the event of a low air warning, stop the coach and determine the cause of air loss before proceeding.

2. Rear Air PSI

The low air warning tell-tale illuminates when the air pressure drops below the pre-determined level.

In the event of a low air warning, stop the coach and determine the cause of air loss before proceeding.

3. Water Temperature

The tell-tale illuminates when the coolant

temperature is above normal. Obtain service as

soon as possible.

4. Oil Pressure

The tell-tale illuminates when the oil pressure is too

low.

Low air pressure will illuminate the LOW AIR lamp and a buzzer will sound, indicating that the air pressure is too low. Stop coach and determine reason for pressure loss. DO NOT operate the coach under 100 psi air pressure.

July 201514

5. Override - Press to override an emergency engine shutdown for 30 seconds. Press as often as necessary to move coach to safe parking.

This switch allows the operator to override an emergency shutdown due to an engine malfunction. Pressing the switch allows the operator to run the engine for an additional 30 seconds so that the operator can move the coach to a safe parking area.

In a driving situation, the override switch should be utilized only to safely move the coach to a safe parking area.

The engine overrule feature is not intended to provide a”limp home” capability. This feature should not be utilized to extend coach driving to a garage or other destination, as engine damage may result from over-extension of the safety feature limitations.

Figure 10. - LH Switch Panel

LEFT-HAND SWITCH PANEL (Figure 10.)

1. Fog Lights Switch

2. Mirror Heat Switch - Press this switch to clear

the mirrors of fog and frost.

3. Parcel Rack Blower Switch - The PARCEL RACK switch turns the parcel rack blowers ON and OFF

To turn the Proheat OFF, push the switch back. It

will purge for 2 to 3 minutes. If the coach is started during preheating, the temperatureDependant control overrides the timer.

6. Master Power Switch - Pressing this switch to the ON (upper) position will enable all of the multiplex modules and turn on the coach's electrical system.

7. Engine Start Switch - Used to start the coach using the rocker switch ignition.

To START the coach using the rocker switch

ignition, place the master power switch in the ON (upper) position. Press the upper portion of the engine start momentary-on spring return switch to engage the starter. Release the switch once the coach has started.

Allow the coach to idle for 30 seconds. To STOP the engine, place the master power

switch in the OFF (lower) position.

15July 2015

Figure 11. RH Switch Panel

RIGHT-HAND SWITCH PANEL (Figure 11.)

1. Interior Light

2. Reading Lights - Turns reading lights ON and

OFF.

3. Blank Switch

4. Baggage Bay Lights - Turns the baggage bay

lights ON and OFF. The baggage bay lights have a timer feature that automatically shuts OFF the lights after 30 minutes, if the switch is left in the ON position.

5. LH Baggage Lock - Locks and unlocks the lefthand baggage doors.

6. RH Baggage Lock - Locks and unlocks the right-hand baggage doors.

7. Kneeling - With the park bra ke ap p lied , the transmission in Neutral and the entrance door closed, press and hold the KNEEL half of the switch to lower the front of the coach 5" (127 mm).

8. Entrance Door Open/Close - Press and hold the upper half of the switch to open the door. Press and hold the lower half of the switch to close the door. Door movement stops if the switch is released.

9. Panel Lights

10. Driver's Light - Turns lights on in the driver's

compartment.

11. Step-well Lights - When this switch is ON, the step-well lights turn ON whenever the entrance door opens.

12. Blue LED Light

13. Blank Switch

14. Hazard/W arning Lights - Flashes all front, rear

and side-mounted turn signal lights and both telltales simultaneously.

July 201516

Figure 12. Lower LH Console Switch Panel

LOWER LH CONSOLE SWITCH PANEL (Figure 12.)

1. Cup Holder

2. Headlight Switch

3. Mirror Controls - Adjust the RH and LH exterior

mirror heads (upper and lower).

4. 110 Volt

5. Tag Lock / Auto Switch

Press the upper half, LOCK, of the momentary switch to lock the tag cylinder. The CHECK INFO tell tale flashes and the alphanumeric display on the speedometer will display TAG LOCK.

When coach speed reaches 15 mph, the alphanumeric display on the speedometer will stop displaying the TAG LOCK message.

When coach speed reaches 10 mph and lower, the tag cylinder will remain locked and the alphanumeric display on the speedometer will display the TAG LOCK message.

The tag cylinder can only be unlocked by pressing the lower half, AUTO, of the momentary switch or by cycling the ignition.

6. Mud/Snow - On extra soft surfaces (snow, mud or gravel), press the MUD/SNOW switch to increase traction by slightly increasing permissible wheel spin. The LOW TRACTION or ESC / ATC telltale will blink continuously when MUD/SNOW is active. Press the switch again to turn off MUD/SNOW. (Turning off the ignition also resets the MUD/SNOW feature.)

7. Fast Idle - Place the transmission in Neutral, apply the parking brakes and turn FAST IDLE on to increase engine idle speed for engine warm-up, air pressure build-up or A/C op erati on when the coach is parked. Return the switch to normal when fast idle is not required.

8. Tag Axle Unload - Press to unload the tag axle to improve traction on the drive axle. Press again to transfer the load back to the tag axle.

Only unload the tag axle in low traction situations.

17July 2015

LOWER LH CONSOLE SWITCH PANEL Cont’d

9. Rear Rise

10. Level Control Switch - Press the UPPER half

of the switch to raise the front and rear suspension to the High Ride parameter height. Press the LOWER half to lower the front and rear suspension to Low Ride parameter height.

11. Normal Ride / Recover - Press switch to change front and rear suspension to Normal Ride height.

12. LH Blind Switch

13. RH Blind Switch

14. 12-Volt Power Source

15. Automatic Transmission Control

16. Wheelchair Master Switch (Optional)

17. Emergency Park Brake Release

Figure 13.

18. Front Service Compartment Door Release

July 201518

Regeneration Switch

The regeneration toggle switch is located in the

rear, side service compartment (Figure 14.).

To avoid serious personal injury or property damage, ensure that no persons or objects are at or within two feet of the exhaust outlet at any time during a regeneration. Ensure that exhaust and outlet are clear of any trash, grasses, or other vegetation or debris.

Use extreme caution during a stationary regeneration, as exhaust gas tail pipe outlet temperatures can exceed 900 degrees F (482 degrees C). Stationary regenerations are to be performed outdoors only.

DO NOT leave the coach unattended during a stationary regeneration.

DO NOT perform inside a garage or maintenance facility.

DO NOT attach an exhaust extraction hose to the exhaust outlet.

PARKING BRAKES

The coach has air-operated spring parking brakes. The PARKING BRAKE control is a black, button located under the LH switch panel (Figure 15.).

Do not leave the coach without applying the parking brake.

Figure 15. Parking Brake Knob

Normal Park Brake Operation

1. Stop the coach, put the transmission in neutral.

2. Pull the park brake knob out (Figure 15.) to set the park brake. The valve will latch in this position.

3. Ensure that the air pressure gauge shows 100 psi (689 Pa) or more.

4. Push the park brake knob fully in to release the brakes. The valve will latch in this position.

Emergency Park Brake Release

In an emergency, where there is no pressure or low pressure in the air system, the parking brake can be released by pushing and holding down the Emergency Park Brake Release.

Figure 14. Regen Switch

Park Brake Interlocks

The parking brake is interlocked with and affects

the operation of kneeling and cl as follows:

• Kneeling - The park brake must be applied to kneel. Releasing the park brake cancels kneeling and returns the coach to normal ride height.

• Wheelchair Lift - The park brake is

interlocked by the wheelchair lift key switch. The park brake must be set before turning the wheelchair lift master key switch on. Opening the wheelchair lift doors also sets the parking brake.

The park brake emergency release air tank has only enough air to release the parking brake three times.

The Emergency Park Brake Release is a green, circular button located on the lower LH console switch panel (Figure 16.).

Figure 16. Emerg. Park Brake Release

19July 2015

Figure 17. J4500 Instrument Panel

INSTRUMENT PANEL/GAUGES(Figure 17.)

1. Speedometer - The speedometer, which

features an alphanumeric message dis pla y, reads the forward speed of the coach in miles per hour or kilometers per hour. The speedometer features a MODE and TRIP button allow the driver to select, set/ reset displays and scroll through active system warning messages, when the coach is at a complete stop.

The MODE button is utilized to select the mode of operation for the message display and to clear priority messages.

The TRIP button is utilized to change what is displayed on the lower line of the alphanumeric message display.

The following settings can be selected on the main screen by utilizing the MODE and/or TRIP buttons (Figure 18.):

- Imperial / Metric Units,

- Contrast Adjust,

- Display Language (English, Spanish or French)

- Diagnostics Menu.

2. 4-in-1 Gauge:

Front Air Pressure - The secondary air pressure

gauge reads front brake air reservoir pressure in pounds per square inch or kilo-pascals. If the pressure is low during start-up, the LED lights and a buzzer sounds. The alarms stop when the pressure builds up to operating level. Do not operate the coach under 100 psi (690 kPa).

Rear Air Pressure - The primary air pressure gauge reads rear brake air reservoir pressure in pounds per square inch or kilo-pascals. If the pressure is low during start-up, the LED lights and a buzzer sounds. The alarms stop when the pressure builds up to operating level. Do not operate the coach under 100 psi (690 kPa).

If a low air warning activates during driving, stop the coach immediately and find the cause of the air loss. If brake reservoir pressure drops significantly, the parking brakes apply automatically.

Figure 18.

July 201520

4-in-1 Gauge: (cont'd)

Oil Pressure - The oil pressure gauge reads engine

oil pressure in pounds per square inch or kilo Pascals. Oil pressure should be between 50 - 70 psi (345 - 483 kPa). The LED lights when the oil pressure is too low.

Coolant Temperature - The coolant temperature gauge reads engine coolant temperatu re in degrees Fahrenheit or Celsius. The normal operating range is 160-226F (71-108C). The LED lights when the temperature is above normal. Obtain service as soon as possible.

3. 3-in-1 Gauge:

Fuel - The fuel gauge reads the fuel level

in the tank. Diesel Exhaust Fluid (DEF) - The DEF

gauge reads the fluid level in the tank. Engine Tachometer - The engine

tachometer reads engine revolutions per minute.

4. Voltmeter - The voltmeter reads the condition of the 24-volt electrical system. The gauge is calibrated in volts. The needle should be from 27 to 29 volts. If below 27 volts, the batteries are undercharging. If above 29 volts, the batteries are overcharging. Have the system checked if over- or undercharging. The LED lights when voltage is too low.

5. Transmission Temperature

6. Plug

7. Vent

8. SmarTire SmartWave Full Fu nction Display -

The SmartWave tire monitor system provides tire pressure deviation alert, low pressure warning and high temperature alert for all tire positions.

SmartWave display functions:

1. ALARM tell-tale light to alert driver.

2. Display screen shows alert icons, tire location and numerical unit of pressure or temperature.

3. Control buttons to scroll through display.

21July 2015

Bendix Wingman System (Optional)

Figure 19.

The Driver is always responsible for the control and the safe operation of the vehicle at all times. The Bendix Wingman Advanced (or ACB) system does not replace the need for a skilled, alert professional driver, reacting appropriately and in a timely manner, and using safe driving practices.

Any audible and/or visual alert by the system means that your vehicle is too close to the vehicle ahead, immediately act to potentially avoid, or lessen the severity of, a collision.

Improper use of the Bendix Wingman Advanced (or ACB) system can result in a collision causing property damage, serious injuries, or death.

Active Cruise with Braking (ACB)

The Wingman system (Figure 19.) is engaged by turning cruise control ON and setting the vehicle speed. The system helps maintain a set distance between the operated vehicle and a detected vehicle ahead. To disengage the system, turn the cruise control OFF or press the brake pedal.

The Wingman Advanced (or ACB) system is

automatically ready when the cruise control is set. However, cruise control must be used only in the same conditions that are normally recommended for ordinary cruise control. As noted below, there are certain situations when cruise control should NOT be used. Do not use cruise control in the following conditions or situations:

• Inclement weather (rain, snow, fog, ice or other severe weather conditions)

• Dense Traffic

• Sharp curves and winding roads

• Entrance or exit ramps

• Downhill grades

• Construction zones

• Smaller forward vehicles - Smaller vehicles, such as motorcycles, may be difficult for the radar to identify. It is the driver’s responsibility to be aware of these types of vehicles and to slow down if necessary.

Any vehicle trouble code that disables vehicle cruise control will also cause a diagnostic trouble code in Wingman Advanced (or ACB). The Wingman system will not operate until the DTC is cleared.

Collision Mitigation (Advanced)

Audible and visual alerts are provided to the operator through a Driver Interface Unit (DIU). All the alerts are always active regardless whether cruise control is engaged or not. Any alert means your vehicle is too close to another vehicle or object. These alerts will change as the distance between the two vehicles decreases alerting the operator of the impending hazard. As the distance closes, the system will automatically intervene and slow the vehicle.

July 201522

The radar system only senses metallic objects. Non-metallic or limited metallic objects such as people, animals, RVs, motorcycles, horse drawn buggies, logging vehicles, or cross- traffic will not trigger the system.

Due to inherent limitations of radar technology, the collision mitigation technology on rare occasions may not detect moving vehicles or stationary objects in your vehicle’s lane of travel.

Road curvature may impact the radar’s ability to track vehicles ahead in the same lane.

Operator alerts, warnings, or brake interventions may not occur. In addition, the system may react to moving vehicles not in your vehicle’s lane of travel. Operator alerts, warnings, or brake interventions may occur.

Following Distance Alert (FDA)

A FDA is generated through the DIU using vehicle speed, forward vehicle speed, distance and driving scenarios.

These alerts indicate that the time between your vehicle and the detected forward vehicle ahead is less than one and a half (1.5) seconds and decreasing. Once the audible alert is heard, the driver should increase the distance between their vehicle and the vehicle ahead until the audible alert stops.

Single, Yellow Illuminated LED

The forward vehicle is within a 1.5 seconds range and traveling at the same speed or slower.

The screen will visually show the distance between the vehicles, closing.

Two, Yellow Illuminated LEDs

The forward vehicle is much too close and traveling at the same speed or slower. The screen will visually show the vehicles slightly closer to each other.

Figure 20.

Bendix Wingman Driver Interface Unit (DIU)

1. Three Red LEDs

2. UP Button

3. OK Button

4. Down Button

5. Orange LED

6. Blue LED

7. Three Yellow LEDs

8. LCD Display

All Three, Yellow Illuminated LEDs

This is the closest and most urgent Following Distance Alert. The forward vehicle is in this zone and traveling at the same speed or slower. The screen will visually show the distance between the vehicles as very close.

All Three, Red Illuminated LEDs

This alert is the most severe warning. A loud solid tone is generated, and the screen will flash. The system will automatically slow down the vehicle. The operator must apply additional braking to maintain a safe distance from the vehicle ahead. If a collision is likely to occur, and the collision mitigation feature activates the brakes, the tone of the alert will change and the screen will flash between two displays.

This alert indicates that a collision with the detected forward vehicle is likely and the driver must immediately act to potentially avoid, or lessen the severity of a collision.

23July 2015

Stationary Object Alert (SOA)

This alert does not provide any automatic intervention at all, active braking or vehicle deceleration. Operator must take appropriate braking and/or avoidance measures. This alert indicates that a collision with a stationary object is likely and the operator must immediately act to potentially avoid, or lessen the severity of, a collision. System will provide up to a three (3) second alert when approaching a detected, sizable, metallic stationary object in vehicle’s current lane of travel.

Solid Blue LEDs

If the operator doesn't take action within 15 seconds, the system will shut off and a DTC (Diagnostic Trouble Code) will be generated. All intervention features of the system will remain off until the next ignition cycle. If the operator does intervene within the 15 seconds, the system will remain unavailable for 20 minutes. After 20 minutes the displayed ACB Braking Overuse message will disappear and the blue LED will turn off.

All three types of alerts (FDA, IA, and SOA) will continue to be provided during the brake overuse alert.

Two Yellow Illuminated LEDs

The radar detects a sizable, non-moving, metallic

object in the vehicle's path of travel.

Brake Overuse Alert

This alert is provided when the system is intervening and using the brakes excessively . Brake overuse can lead to overheating and a potential loss of braking performance (brake fade).

Using cruise control on downhill runs will cause this alert. Do not use cruise control on downhill grades.

Blinking Blue LEDs

When brake overuse is detected, a text message and audible alert/alarm is generated and the DIU blue LED will illuminate. The operator has 15 seconds to take action (turn cruise control OFF or apply the brakes).

False Alerts

In certain unusual traffic or roadway conditions, Wingman Advanced (or ACB) may issue a false alert. While eliminating all false alerts is not possible, if false alerts occur too frequently (more than twice a day), this may indicate sensor misalignment. Service the system at the earliest opportunity.

Front Bumper Radar Sensor

The sensor relaying information to the DIU is located on the front bumper of the coach (Figure 21.).

Figure 21.

Radar sensor inspection for obstruction/ damage must be monitored routinely.

July 201524

STEERING COLUMN & FLOOR-MOUNTED CONTROLS

Figure 22. Steering Wheel

STEERING COLUMN

Ensure that the column is firmly locked before driving. Do not adjust the steering column while driving; steering control could be lost.

The tilt and telescoping steering column is basic. It has a molded polyurethane steering wheel with fingertip cruise control and Jake brake.

The tilt/telescoping control lever is on the LH side of the steering column (Figure 23.). Pull on the adjustment lever and tilt the steering wheel to the desired position. Push on the adjustment lever and raise or lower the assembly as necessary. Release the lever to lock. Ensure that the column is securely latched.

Figure 23.

25July 2015

“SMART STICK” CONTROLS

The “Smart Stick” (Figure 24.), on the LH side of

the steering column, controls the turn signals, air

horn, headlamp dimmer, windshield washer and

windshield wipers.

Turn Signals

Move the lever up for right turns, and down for left

turns. The corresponding telltale will flash.

Air Horn

Press the button on the end of the turn signa l lever

to activate the air horn.

Headlamp Dimmer

Pull the turn signal lever forward and release it to change from one setting to another. The HIGH BEAM telltale lights when the headlights are on high beam.

Windshield Washers

Push the sleeve towards the steering column. Activating the washer turns the wipers ON for four seconds on low speed.

Windshield Wipers

There are four rotary positions that operate the wipers: OFF, intermittent, low speed and high speed.

1. Windshield Washer

2. Windshield Washer

3. Turn Signals

4. Air Horn

Figure 24.

July 201526

CRUISE CONTROL

Do not use cruise control in heavy traffic, on icy roads or in any other driving condition that does not permit a constant speed.

Setting Vehicle Speed

Press the ON switch to turn on the cruise control.

Accelerate to the desired speed, press the Set

switch, then release the accelerator pedal. The

CRUISE ENABLED telltale on the RH cluster stays

on until the cruise control is turned off.

Note: Cruise control will not operate under 20

mph (32 km/h).

Increasing Set Speed

1. Press and hold the RES switch until the desired

speed is reached,

2. Press the accelerator pedal until the desired

speed is reached, then press and release the SET

switch.

Figure 25.

JACOBS (JAKE) ENGINE BRAKE

The Jake brake controls are mounted on the RH side of the steering wheel.

The four controls are: OFF, LOW, MEDIUM and HIGH.

NOTE: When driving with cruise control, speed

may be increased (for passing, etc.) by

pressing the accelerator in the usual way.

Releasing the accelerator returns the coach to

the set speed.

Decreasing Set Speed

1. Press and hold the Set switch until the desired

speed is reached,

2. Lightly press the brake to disengage the

system. Allow the vehicle to coast to the desired

speed, then press and release the Set switch.

NOTE: The transmission may be shifted in the

normal way without disengaging the cruise

control.

Canceling the Set Speed

1. Press the OFF switch or the CANCEL button,

2. Make a slight brake application.

NOTE: When automatic operation is canceled,

Res may be used to return to cruise control.

Figure 26.

The button located at the top of the RH control features a “courtesy light” that momentary flashes the coach marker lights to acknowledge passing vehicles.

27July 2015

ELECTRIC HORN

Press the horn bar on the steering wheel center hub to activate the electric horn.

ACCELERATOR PEDAL

The accelerator pedal is to the right of the service brake pedal.

SERVICE BRAKES

Do not apply the parking brakes until the coach has come to a complete stop.

The coach has air-operated service brakes that are applied with the foot pedal to the left of the accelerator pedal.

ANTI-LOCK BRAKES (ABS)

The anti-lock brake system (ABS) minimizes brake

lock-up at each wheel.

DO NOT pump the brake pedal.This defeats the purpose of the ABS.

The ABS telltale on the LH telltale cluster is used for blink code diagnostics and lets the driver know the status of the system. The telltale lights briefly at ignition. If it lights at any other time, the system requires service. Full regular braking remains, and partial ABS may be present (refer to Figure 27.).

Stop lamps on the rear of the coach light when the brake pedal is pressed. The STOP LAMPS telltale on the RH telltale cluster lights.

ABS Telltale

If an ABS malfunction is indicated by the ABS telltale lamp, the driver must safely stop the coach and safely check all six (6) wheel ends for an overheat condition.

If an overheat condition exists, the coach must NOT be driven until inspected by a qualified technician.

In the event of an ABS malfunction, the braking system will default to a normal braking system. Exercise caution to avoid potential wheel-lock conditions.

Figure 27.

July 201528

ENTRANCE DOOR

OPERATING FEATURES

The entrance door is controlled by a switch on the RH switch panel on the instrument panel, or by an exterior switch located rearward of the door (Figure 28.).

Figure 28. Exterior Entrance Door Switch

The DOOR OPEN telltale turns ON when the door

is open.

To operate, hold the switch until the door is fully

opened or closed. The door may be stopped

anywhere in its travel by releasing the switch. The

door catch will engage when the door is in the fully

closed position only, with the ignition ON.

KNEELING

The coach has a kneeling feature that allows the operator to lower the front of the coach five (5) inches (127 mm) for ease of boarding.

To activate the kneeling feature, the park brake must be set, the transmission must be in Neutral and the entrance door must be closed.

sound. When the coach reaches kneel height, the telltale remains lit, but the exterior lamp and buzzer(s) go off (Figure 28.).

To return to normal ride height, press and release

the RECOVER half of the switch.

If the KNEEL switch is released before the coach is fully knelled, the coach stops lowering. To resume kneeling, press and hold RECOVER to return to normal ride height, then press and hold KNEEL to reactivate kneeling.

The coach automatically returns to normal height if the park brake is released or the transmission is shifted out of Neutral.

REAR RISE

The coach may be equipped with the rear rise

option, which prevents rear bumper scuffing in off-

highway situations by raising the rear bumper

approximately three (3) inches (76 mm) above

normal ride height.

The Rear Rise switch is located on the RH switch

panel. When the coach is traveling under 20 mph

(30 kph) and the RAISE half of the switch is

pressed, the rear of the coach rises, the HIGH

RIDE telltale lights and a buzzer sounds.

Pressing LOWER or traveling above 20 mph

(30 kph) returns the coach to normal ride height.

To avoid personal injury and property damage, ensure that nothing is under the coach when kneeling.

To lower the coach, press and hold the KNEEL half of the switch in the RH switch panel. While the coach is lowering, the KNEEL telltale and exterior kneel lamps flash, and interior and exterior (optional) buzzers

Do not operate the coach in the high position for extended periods. Lower the rear rise system before any suspension maintenance or inspection.

29July 2015

TAG AXLE UNLOAD, ELECTRICAL

(OPTIONAL)

The electrical tag axle unloading feature allows the operator to partially unload the tag axle using a dashmounted switch. When the coach cannot get traction, this transfers weight to the drive axle. The operator should refill the tag as soon as the coach has regained traction. It is unsafe to drive the coach with the tag axle air springs unloaded.

Only the tag axle unloading feature in low traction situations.

Do not use it for normal driving. Reduce coach speed when the tag axle air springs are unloaded.

To unload, press the TAG AXLE switch located on

the LH switch panel. The TAG UNLOAD telltale will

light and a buzzer will sound.

To re-load, press the TAG AXLE switch again or

drive above 17 mph.

Applying the service brake prevents MDSS from

self-leveling the coach when the tag axle is

unloaded.

IN-STATION LIGHTING/BATTERY CHARGER

(J4500) (OPTIONAL)

An optional 110V AC receptacle in the battery

compartment provides for in-station lighting and

battery charging.

AUTOMATIC TRACTION CONTROL (ATC)

This system improves traction when the coach is on slippery surfaces by reducing drive wheel spin. If one drive wheel starts to spin, ATC applies the brake to transfer engine torque to the wheel with better trac tion. If all drive wheels spin, ATC reduces engine torque to improve traction.

ELECTRONIC STABILITY CONTROL

Coaches are equipped with a stability c ontr ol system that features Electronic Stability Control (ESC) combined with Roll Stability Control (RSC). ESC is a computerized technology that improves the safety of a vehicle's handling by detecting and potentially preventing skids by automatically applying brakes to help steer the vehicle where the driver wants to go.

ESC is automatic in that these systems become active when the system Electronic Control Unit (ECU) senses conditions that could produce imminent roll or directional instabilities. Rapid lane changes or cornering at excessive speed on dry or slippery surfaces can create the potential for spin-out or drift out, often before the operator is aware. The ESC system uses a lateral accelerometer, a steer angle sensor in the steering column and a yaw rate sensor to enhance the operator's control in these conditions.

The stability control system is designed to assist the operator, not to replace the operator.

The operator will notice a difference in the coach when the ESC system becomes active, but should continue to drive as normal and provide any additional needed corrections. In an ESC event, the operator may first sense a decrease in engine power as the system ECU overrides the accelerator pedal, and may then sense additional deceleration from an engine brake application and service brake applications on the steer axle brakes or all axle brakes, depending on whether the conditions suggest the possibility of a directional control or a rollover event.

The telltale comes on when the drive wheels spin during acceleration. It goes out when the drive wheels stop spinning. ATC is always active; the operator does not have to select it.

The MUD/SNOW switch is included with ATC. On extra soft surfaces, such as mud, deep snow or gravel, this feature increases traction by slightly increasing wheel spin. When MUD/SNOW is active, the LOW TRACTION telltale blinks continuously.

July 201530

WHEELCHAIR LIFT (OPTIONAL)

GENERAL DESCRIPTION

A wheelchair lift is installed in the storage compartment on the curbside rear of the coach, between the wheel housing and the rear ser vice doo r. The lift provides safe on-loading and off-loading of wheelchair passengers with easy ground level access. The platform raises to coach floor level where the passenger enters the coach through the cabin access door.

The lift is powered by an electrically operated hydraulic pump, with emergency manual back-up, and operated with a hand held WCL controller. Keyed operation and a safety interlock prevents unsafe deployment.

The wheelchair lift platform features:

• folding handrails,

• a manually operated front barrier,

• a powered rear barrier that acts as a bridge between the platform and the coach floor.

A cabin access door is located directly above the wheelchair lift storage compartment. The door has a forward hinge and a positive lock mechanism to prevent accidental closing. The cabin access door is operated manually.

Two wheelchair parking spaces are available next to and across from the lift platform. Special sliding and folding seats can be repositioned to provide wheelchair parking area.

A seven point wheelchair and passenger

restraint system is included at both wheelchair locations.

The electric pump, emergency hand pump (Figure 29.) and reservoir assembly are located in the rear service compartment.

WHEELCHAIR INTERLOCK SYSTEM

This system prevents the WCL controller to be

enabled until the following functions occur:

• the main battery disconnect switch is in the ON position,

• the engine is running,

• Neutral is selected on the transmission shift pad,

• the Park Brake is set,

• the master wheelchair lift key switch (located on the lower, LH switch panel) is turned to the ON position.

Only after these conditions are met, the following functions occur:

• the vehicle assumes normal ride height,

• the throttle is disabled,

• the WCL INTRLK dash telltale illuminates,

• the engine is running at fast idle,

• the Hazard/Warning lights automatically activate,

• the audible back up alarm automatically activates,

• the transmission shift inhibit and MDSS inhibit are energized,

• the park brake lock valve is energized,

• the wcl interior light illuminates,

• the wcl controller is enabled,

• the key will release from the master wheelchair lift key switch, eliminating the possibility of theft or engaging the coach during wheelchair operation.

Figure 29.

31July 2015

THRESHOLD WARNING SYSTEM

The threshold warning system is located above the wheelchair parking (threshold) area (Figure 30.). The module status indicator light illuminates when the wheelchair lift is powered, indicating that the module is activated.

Two acoustic sensors monitor the doorway threshold area. If the acoustic sensors detect a passenger in the threshold area; when the lift is below coach floor height and the cabin access door is open, an audible buzzer and flashing light are actuated.

Figure 30.

July 201532

BRAUN WHEELCHAIR LIFT OPERATION

1. Stop the coach, ensuring that there is adequate clearance to deploy the lift and to allow the passenger to maneuver onto the platform.

2. Place the transmission in Neutral and set the Park Brake.

3. Turn ON the wheelchair lift master switch key on the lower, LH switch panel (Figure 31.). The alarm will sound and the WCL INTRLK dash telltale in the RH telltale cluster will illuminate.

Deploying The Lift From Compartment

7. Lift to remove control pendant from lift storage clip.

8. Press POWER switch on the pendant to ON (POWER button illuminates only when the lift is operating and receiving power).

Figure 33. Braun WCL Pendant

Figure 31. WCL Master Switch

4. Fold and position passenger sliding seats to provide wheelchair parking area.

5. Remove the key and exit the coach.

6. Open the wheelchair lift compartment door. Place the steel pin through the two holes, securing the door in the open position

Figure 32.

1. WCL control pendant

2. Pin location

1. Up Button

2. Down Button

3. Stow Button

4. Power Enable Switch4

9. Stand clear. Press and hold the UP switch until lift stops (extends fully).

10. Lift the RH ha ndrail and swing out. Lower the handrail to the locked position.

11. Lift the LH handr ail an d swin g ou t. Lower the handrail to the locked position

12. Securely support platform with right hand and rotate yellow platform latch (Figure 34.) up to Unlock platform.

Figure 34.

33July 2015

13. Grab the top of the platform and apply enough force to pull down platform to horizontal position, ensuring that it engages on the pin of the handrail assembly. (Figure 35. and Figure 36.)

Figure 35.

Figure 38.

15. Exhaust the door locks an d actuating cylinder on the cabin door by placing the air dump valve to the release position (Figure 39.).

16. Reach into the compartment and push the manual latch handle upwards to release the cabin door (Figure 39.).

Figure 36.

14. Grip outer barrier and pull outer platform out fully, ensuring the center transition plate engages (locks) outer platform.

Figure 37.

The platform will not raise or lower unless the outer barrier is in the vertical and locked position.

Figure 39.

1. Latch handle location

2. Air dump valve

17. When the passenger is ready to board, grasp the edge of the cabin door to open it fully, and secure in full open position. using rocker switch on door (Figure 40.).

Figure 40.

July 201534

TO LOAD PASSENGER:

1. Load passenger onto platform, lock wheelchair brakes.

2. Latch handrail belt.

3. Press UP switch on the pendant to fold outer barrier up. Raise platform to floor level. At coach floor level, the inner roll stop will automatically unfold as a ramp.

4. Carefully unlock wheelchair brakes and unload passenger from platform.

5. Position and securely restrain wheelchair in the wheelchair parking area using the proper restraints.

TO UNLOAD PASSENGER:

1. Latch handrail belt.

2. Press UP button on the pendant until lift stops (raises to floor leve l), and inne r roll stop unfo lds to floor level.

TO STOW HANDRAILS:

1. Lift the LH handrail and swing in.

2. Lower handrail to locked position.

3. Lift the RH handrail and swing in.

4. Lower handrail to locked position.

Ensure handrails are locked together (Figure 41.).

3. Carefully load passenger onto platform and lock wheelchair brakes.

4. Latch handrail belt.

5. Press DOWN button on the pendant until entire platform reaches ground level and outer barri er unfolds fully.

6. Unlatch handrail belt, unlock wheelchair brakes and unload passenger from platform.

TO STOW PLATFORM:

1. Press STOW button on the pendant until platform reaches stow level (stops).

2. Using strap, lift center transition plate and push outer barrier in fully .

3. Manually stow (fold) platform to vertical position.

4. Support platform with right hand and rotate yellow platform latch to Unlock position (up).

5. Push platform in and rotate yellow platform latch to Lock position.

Figure 41.

TO STOW LIFT (IN):

1. Press STOW button until lift stops (retracts fully).

2. Release the cabin door by placing the LOCK/ UNLOCK switch at the end of the heat duct to UNLOCK.

The cabin door must be closed before the lift key is switched OFF . This action controls both the pneumatic door locks as well as providing power to the lift.

3. Press POWER switch to OFF.

4. Store hand-held pendant in lift storage clip.

5. Remove pin from lower door hinge. Insert pin in storage clip.

6. Close door.

7. Turn wheelchair lift key switch on the lower, LH switch pane to OFF.

35July 2015

MANUAL WHEELCHAIR LIFT OPERATION

In case of an electrical or other malfunction, passengers may be unloaded by manually operating the lift. The manual bypass valves and hand pump are located in the side service compartment directly to the rear of the w/c compartment.

Manual operation should only be used for unloading passengers during a malfunction. DO NOT use the manual operation feature to load passengers.

Refer to the BRAUN manual provided with your coach and the decal on wheelchair lift door (Figure 42.) for information on manual wheelchair lift operation.

Figure 42.

July 201536

WHEELCHAIR PASSENGER SEATING

Figure 43.

Positioning The Wheelchair

Since the QRT Retractable System consists of self-locking and self-tensioning retractors which retract and lock automatically, the driver can position the wheelchair anywhere within the clear floor space which will allow for convenient access to securement points on the wheelchair.

Securing The Passenger

The self-locking and self-tensioning features of the QRT enables the driver to secure the wheelchair beginning with either the front or rear retractors or if standing on the lift with the wall side front and rear retractors if this is more convenient.

Explain to the passenger what you are doing to make them feel comfortable with the process.

Figure 44. QRT Instruction placard mounted on cabin access door

37July 2015

Securing The Passenger (cont'd)

Care and Maintenance

1. Ensure a straight line from anchorage to wheelchair attachment.

2. Select the appropriate attachment points on the wheelchair. Look for frame members that are welded or securely bolted to each other.

NOTE: DO NOT use removable armrests, footrests, wheels of the crisscross supports on folding wheelchairs.

3. The rear attachment points should be a solid frame member as near as possible to where the seat and the back meet. The front attachment points should be a solid frame member, which will create an angle between 30 and 45 degrees to the retractor.

4. Attach the “J” hooks on all four retractor belts to solid frame members.

5. Ensure that the belts are prope rly tensioned.

NOTE: DO NOT allow the webbing to be twisted inside the retractor.

6. Extend the shoulder belt from the retractor and attach the female pin connector end to the male pin connector on the lap belt. The belt will remain comfortable on the passenger and lock only in an emergency when an inertial force is applied.

1. Clean the webbing periodically with mild soap and water. After cleaning, fully extend the belts and position them to prevent water from entering the retractor until completely dry. Take care to prevent contamination of the webbing with polishes, oils and chemicals, particularly battery acid.

2. Webbing and components should be inspected, cleaned and maintained regularly.

3. Frayed, contaminated and damaged webbing should be replaced.

4. Broken and worn parts should be replaced.

5. Components, including anchorages, that are suspected to have been in use during an impact from which the vehicle must be towed, should be replaced.

6. Clean bolt threads and re-apply permanent thread locker if bolts are adjusted.

Do not use the wheelchair life for lifting freight. The warranty will be void. Do not use the wheelchair life for lifting

NOTE: When positioned properly, the shoulder belt should lay across the torso and angle up from the mid-point of the shoulder to the wall.

NOTE: Adjust the belt as firmly as possible consistent with user comfort.

DO NOT twist the belt.

7. Engage the wheel locks on the wheelchair.

Ensure all passengers and wheelchair equipment is secured correctly. Failure to do so can result in property damage, personal injury or death.

July 201538

ENGINE OPERATION, FUEL AND EXHAUST

Starting the Engine

The controls necessary to starting and stopping the engine from the driver's area or engine compartment are mounted on the instrument panel in front of the driver and on the remote box in the engine compartment. These controls and a description of their operation and function follow:

Do not engage the started for longer than 15 seconds at a time. Wait 30 seconds before cranking again. Continuous use can damage the starter motor.

Front Start Procedure

Figure 45.

1. Master Power / Ignition Switch - Pressing this switch to the ON (upper) position will enable all of the multiplex modules and turn on the coach's electrical system (Figure 45.).

Rear Start/Remote Engine Operation

This feature is primarily for maintenance purposes. Before attempting to start engine from rear of coach, make sure transmission is in Neutral and parking brake is applied.

The remote electrical control panel is located at the LH side in the engine compartment. To gain access to the panel, open rear engine compartment doors.

1. Ensure the ENGINE ENABLE switch on the remote engine control box (located in the engine compartment) is set to ON.

Be very careful when the engine is running and the engine door is open. If it is necessary to have the engine running for certain inspections or checks, keep a safe distance from moving belts, pulleys, shafts or fans. Keep hands and limbs away from moving belts and pulleys and also hot areas such as exhaust and turbocharger components and coolant lines. DO NOT wear loose, baggy or frayed clothing when working near any moving parts such as pulleys, belts, shafts or fans.

2. Actuate the “REAR START” switch to start engine. The start switch is a momentary-on spring return type and must be held in the depressed position to engage the starter.

2. Engine Start Switch - Used to start the coach using the rocker switch ignition (Figure 45.).To STAR T the coach, place the master power / ignition switch in the ON (upper) position. Press the upper portion of the engine start momentary-on spring return switch to engage the starter. Release the switch once the coach has started. Allow the coach to idle for 30 seconds. To STOP the engine, place the master power switch / ignition in the OFF (lower) position.

Do Not engage the starter for longer than 15 seconds at a time.Wait 30 seconds before cranking again. Continuous use can damage the starter motor.

Engine Warm-Up

Activate the FAST IDLE switch to warm up the engine, fill the air system quickly, and to increase electrical and HVAC output. Parking brake must be applied. Watch gauges and telltales. If abnormalities arise, stop engine and find cause.

39July 2015

Stopping the Engine

1. Bring coach to a complete stop.

2. Place the transmission in Neutral.

Shutting down the engine from high idle can damage the turbine bearings.

3. Apply the parking brake.

4. Idle the engine at low rpm for 30 seconds, then turn the ignition OFF.

Regeneration Switch

The regeneration toggle switch is located in the

rear, side service compartment (Figure 14.).

To avoid serious personal injury or property damage, ensure that no persons or objects are at or within two feet of the exhaust outlet at any time during a regeneration.

Ensure that exhaust and outlet are clear of any trash, grasses, or other vegetation or Use extreme caution during a stationary regeneration, as exhaust gas tail pipe outlet temperatures can exceed 900 degrees F (482 degrees C).

Stationary regenerations are to be performed outdoors only.

DO NOT perform inside a garage or maintenance facility. DO NOT attach an exhaust extraction hose to the exhaust outlet.

Multiplex Bypass Circuit

If the engine cranks but does not start because the ignition module fails, the engine ignition bypass switch, located in the rear junction box, provides emergency power to start the engine.

NOTE: In this mode, the coach should be driven straight to a service facility.

1. Open the rear junction box compartment door (baggage bay compartment #3) (Figure 47.). Locate the emergency engine switch on the upper section of the junction box (Figure 48.).

Figure 47.

Figure 46.

Figure 48.

2. Lift the red self-canceling cover and position the

toggle switch ON.

3. Get service assistance as soon as possible.

July 201540

ENGINE CODE RETRIEVAL

Using the touch screen diagnostic interface (Optional), the operator can retr ieve coach electrical or drive train diagnostics to notify the garage. (Figure 49.).

There are three (3) interface port connections on

the coach:

1. underneath the instrument panel,

2. in the rear junction box located in baggage bay compartment #3, and,

3. the bottom face of the engine compartment remote control box.

Figure 49. LCD diagnostic interface connected underneath the instrument panel.

41July 2015

IMMERSION HEATER - Engine Block

(Optional)

Use the engine block heater when the coach is parked for an extended period in cold weather. The plug is in the curb-side rear service door (Figure 50.)

Figure 50.

FUELING

Two (2) diesel (ULSD) fuel fillers are installed on the coach. One is located behind a filler door in the fuel tank compartment door on the curbside (Figure 51.). The second location is on the roadside behind a filler door in the A/C condenser door.

DO NOT put anything but DEF in the DEF tank ( blue cap ).

One (1) diesel exhaust fuel (DEF) filler door is provided next to the curbside diesel (ULSD) filler door (Figure 52.).

Figure 52. DEF Tank Door

Diesel Fuel Specification

Engines must comply with EPA mandated low

emission guidelines by using ULSD (ultra low

sulfur diesel) fuel.

Figure 51. Diesel (ULSD) Fuel Door

The fuel tank is equipped with a whistle that stops when the tank is full. Close filler and latch it securely after filling.

Do not fill the tank from both necks at once or have both fill caps open; the tank will over-fill and overflow.

Failure to use ULSD fuel in 2015 EPA engines will result in component damage.

Diesel Exhaust Fuel (DEF) Specification

DEF must meet ISO standard 22241-1.

Diesel Fuel System Maintenance

The fuel filter(s) require(s) periodic maintenance, and fuel lines and connections must be inspected regularly for evidence of leaks. When filling the tank, take care to prevent the entry of dirt and water. See the MCI Maintenance Manual and the Service and Maintenance section of this operator's manual for further information.

Do not smoke while handling fuel.

July 201542

Diesel Fuel Contamination

Water is the most common contaminant. It can be introduced through poor maintenance (loose or open fuel tank cap), a contaminated fuel supply or condensation.

A fuel filter with water separator is located on the curb side of the engine. Inspect the bowl for water accumulation and drain as required. The auxiliary heater also has a fuel filter. Inspect and drain regularly.

Lubricant Additives

Do not use any lubricant additives.

Failure to use CJ-4 engine oil in 2015 EPA engines will reduce component life.

EXHAUST

Exhaust gases contain carbon monoxide, which can cause unconsciousness and death. Strictly follow safety guidelines:

1. Do not inhale exhaust fumes.

2. If you suspect that exhaust fumes are entering the coach, discharge passengers and do not drive the coach. Have the cause determined and corrected immediately.

3. The exhaust system, body and ventilation system must be inspected and maintained regularly.

4. Keep the tailpipe area clear of snow and other material.

FUEL PRO FUEL FILTER

The Fuel Pro extends filter change intervals and features a clear cover that provides visual identification of the fuel level (Figure 53.). When the fuel level reaches the change filter line on the filter cartridge, the element should be replaced at the next sched u led maintenance interval. Fuel filters should be replaced as a set.

5. The exhaust system and coach body must be inspected any time the exhaust system or coach are damaged, or when the exhaust system sounds different.

6. Keep the engine air inlet grille clear of snow, dirt and other obstructions.

7. Do not run the engine inside confined areas without using an exhaust removal system.

8. Do not run the engine while parked in narrow alleys.

9. If the coach must be parked with the engine running for an extended period and is in an unconfined area, turn the HVAC system on.

Figure 53.

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July 201544

TRANSMISSION OPERATION

- Used to select gear ranges manually. The display will show the highest gear in the selected range. Lower gears can be selected to provide engine braking on steep grades.

GEN V AUTOMATIC TRANSMISSION

The B500 series GEN V is an electronicallycontrolled hydraulic auto-shifting six-speed transmission. This transmission controls all aspects of the shift function once placed into the desired drive range. Shift range selections are made with the touchpad module located on the side console.

A two-character digital display is located at the top of automatic transmission shift selector. The left character of the display, SELECT, designates N, R, or the highest gear available of the selected forward range. The right character of the display, MONITOR, designates the actual gear which is being commanded by the transmission control module (TCM).

Two-character diagnostic codes can be accessed using the touch-pad on the pushbutton shift selector.

The MODE button, can be utilized to invoke a special function that has been programmed into the TCM. A small red light is illuminated on the MODE button when the function is activated.

1. Two Character Digital Display

2. Mode ID

3. Mode ON Indicator

4. Mode Button

5. Manual Shift Up / Down

Shift Selection Controls

D - DRIVE is used for normal driving. All shifting is

automatic.

N - NEUTRAL R - REVERSE

NOTE: The gear selector should always be in the NEUTRAL position when the coach is parked.

The transmission may select a gear range higher than the selected range if damage due to engine over-speed is possible.

There is no PARK position on the transmission touch-pad. Select N (Neutral) and apply the parking brake. When shifting from Drive to Reverse or Reverse to Drive, select Neutral first. The engine must be at normal idle before shifting. If the coach is at fast idle, turn fast idle off and wait for the idle speed to slow before shifting.

Figure 54. GEN V pushbutton shift selector

45July 2015

GEN V Diagnostic Code Retrieval

Diagnostic codes, displayed as two digit numbers,

indicate a transmission malfunction. Diagnostic

codes can be accessed through the pushbutton

shift selector. These codes are logged in the TCM /

ECU with the most severe or recent code listed

first.

A maximum of five codes, identified as d1 to d5,

can be listed at one time. As codes are added, the

oldest non-active codes are dropped from the list. If

all codes are active, the code with the lowest

priority not included on the severity list is dropped.

If the displayed code is active, the red light is

illuminated on the MODE button. If the displayed

code is non-active, the red light will not illuminate

on the MODE button.

The display will show two dashes (--) if diagnostic

cycle was performed and no problems were found.

Pressing the N key on the touch-pad, with the

ignition turned ON (engine can be running), will

allow the user to retrieve the transmission codes.

Observe the two digit display for codes. Press the

MODE button to view the next code.

Record all codes.

Diagnostic Code Example

Code - P0722. Displayed as: d1, P, 07, 22.

d1 is the diagnostic code list position. P is the main diagnostic code. 07, 22 are the sub codes. Each item is displayed for about one second.

Clearing a Fault Code

Record all codes prior to clearing.

LED flashes when the code clears.

July 201546

ALLISON GEN V

2. Simultaneously press the buttons once. There may be a short delay while the fluid and temperature stabilizes.

TRANSMISSION FLUID LEVEL CHECKS

Automatic Transmission Fluid

Access the transmission dipstick and fill tube from

the rear engine door.

Electronic Fluid Check

1. After reaching normal operating temperature [140F - 220F (60C - 104C)], park the vehicle on a level surface, select Neutral and allow the engine to idle (500-800 rpm).

NOTE: Coach should be stationary for approx. two minutes to allow the fluid to settle. NO fast idle during electronic fluid check.

3. The fluid level will display:

If correct, OL-OK. If low, OL-LO-# (number of quarts of

transmission fluid required). If high, OL-HI-# (number of quarts overfilled).

4. Confirm with a manual fluid level check.

Manual Cold Fluid Level Check

Do a cold check to ensure that the transmission has enough fluid for safe operation until a hot check can be done. Check the reading at least twice.

1. Park the coach on a level surface and apply the parking brake.

2. Run the engine for at least 1 minute.

3. Apply the service brakes, shift the transmission to drive (D) and operate the engine at 1000 to 1500 rpm for 30 seconds. Shift to reverse (R) to clear air from the hydraulic system. Shift to neutral (N) and idle the engine at 500-800 rpm.

4. With the engine running, remove the dipstick from the tube and wipe it clean.

5. Insert the dipstick into the tube and remove it. Check the level reading.

6. Repeat to verify the reading.

7. If the fluid level is within the COLD RUN band, the transmission may be operated until the fluid is hot enough to perform a hot check. As required, add fluid to bring the level to the middle of the band.

8. Perform a hot check as soon as the coach reaches normal operating temperature [140F 220F (60C - 104C)].

Low and High fluid levels cause overheating and irregular shift patterns. If not corrected, transmission damage can occur.

Dipstick checks may not agree exactly with sensor checks, because the oil level sensor compensates for fluid temperatures.

47July 2015

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July 201548

EMERGENCY CONDITIONS

Check gauges and telltales at start-up and regularly during operation. If abnormalities arise, take action at once.

If the following telltales light, action is required

Regeneration (DPF) Telltale Regeneration required for 2015 engines High Exhaust Temperature

(HET) Malfunction Indicator (MIL) Telltale Failure of an emission component on DD13 engine Not Generating Telltale Alternator(s) not functioning, Alternator belt broken Tag Unloaded (Optional) Telltale Tag axle is unloaded ABS Telltale Anti-lock braking system malfunction Check Transmission Telltale Transmission problem, Do not change gear. Check Engine Telltale Engine fault Stop Engine Telltale Engine is powering down or stopped

Low Coolant Telltale Supply Air Low Telltale System air pressure is low

Fire Alarm Telltale Fire in the engine compartment Lavatory Emergency Telltale Passenger has pressed buzzer in lavatory Digital Wheel End Sensor Speedometer High temperature warning in rear wheel Voltmeter Gauge LED Instrument Voltage too low Oil Pressure Gauge LED Instrument Oil pressure is too low Temperature Gauge LED Instrument Engine coolant temperature too high Tachometer Gauge LED Instrument Engine RPM too high Air Pressure Gauge LED Instrument Front or rear brake pressure too low Fuel Gauge LED Instrument Low Fuel

Telltale Exhaust outlet temp exceeds predetermined level

Add coolant. Check for leaks in the engine compartment

49July 2015

EMERGENCY ESCAPE

Roof Hatch

Two escape hatches are located in the roof for emergency exiting (Figure 55.). To open in case of an emergency, follow the instructions on the applicable roof hatch.

Figure 55.

A prop rod is located in the hatch opening.

Side Windows

Select side passenger windows can be opened from inside for emergency escape purposes. These non-bonded side windows are top hinged, and open from the inside.

To open, lift the release bar at the lower edge, disengaging the safety latches. Push the window out.

Emergency instructions decals are attached to the release bars (Figure 58.). Inspect regula rly to assu re the decals are legible.

Figure 56.

The roof hatch may be partially propped open by the operator for ventilation purposes when it is safe to do so.

Before doing so, the operator should ensure that the coach will have adequate roof clearance with the partially opened hatch throughout the operator’s intended route of travel. The partial opening should not be performed while the coach is in motion.

In no event should the roof hatch be fully opened for ventilation or any other purpose while the coach is being operated.

Figure 57.

Figure 58.

Do not open the side windows while the coach is moving.

Windows close with enough force to cause injury. Ensure that hands are clear.

July 201550

EMERGENCY STARTING

If the coach has dead batteries, it can be jump started.

Negative and positive boosting posts are in the

curb-side rear service compartment.

Follow procedures exactly or personal injury or property damage may result, and the starting or charging system of the booster or immobilized vehicle may be damaged.

Do not jump start a vehicle with a frozen battery. Frozen batteries can rupture or explode. Examine the fill vents for ice. If ice is visible, do not jump start.

Connect and disconnect jumper cables as described.

Connecting Booster Cables (Figure 59.)

1. Set the parking brake, turn off lights, heater and all electrical accessories.

5. Attach the other end of the same cable to the positive booster post on the upper frame rail below the lavatory tank.

Figure 59.

6. Attach one end of the remaining negative cable to the negative terminal of the booster battery.

7. Attach the other end to the negative booster post on the lower coach frame rail.

1. Positive Boost Post

2. Negative Boost Post

Disconnecting Booster Cables (Figure 59.)

To reduce the chance of an explosion, take steps to prevent hydrogen buildup. Remove the vent caps from the booster and the dead batteries. Ensure the battery compartment is well ventilated.

Do not permit vehicles to touch each other. Take care that clamps from one cable do not touch clamps on the other cable.

2. Remove the vent caps from the booster and the discharged batteries.

3. Remove the rubber boot that covers the positive booster post located on the upper frame rail below the lavatory tank.

4. Attach one end of one jumper cable to the positive terminal of the booster battery.

Do not lean over the booster battery when disconnecting the ground lead. Take care that clamps from one cable do not touch clamps on the other cable.

1. Disconnect the jumper cable from the ground stud.

2. Remove the remaining end of the negative jumper cable from the booster battery.

3. Remove one end of the remaining jumper cable from the positive booster post on the upper frame rail.

4. Remove the other end of the same cable from the positive terminal of the booster battery.

5. Install the rubber boot over the positive booster post.

6. Install the vent caps on the batteries.

POWER STEERING SYSTEM

If the power steering system fails, the coach can be

steered, but much greater effort is required.

51July 2015

BRAKES (EMERGENCY OPERATION)

Parking Brake (Emergency Operation)

If the front and rear brake system air pressure falls below approximately 50  5 psi (345  35 kPa), the parking brake will automatically apply.

An isolated emergency release reservoir has enough air to release the parking brake three times. Press and hold the emergency parking brake release button (lower LH console switch panel). The parking brake springs will reapply as soon as the knob is released.

The parking brake emergency release button allows the coach to be moved to safety when both brake reservoirs are depleted and the parking brake has applied automatically.Do not use this feature other than to move the coach to a safe parking location.

Do not drive the coach until the air loss problem is fixed and the brake reservoirs are fully charged.

Service Brakes (Emergency Operation)

This coach has a dual-circuit service brake system with separate reservoirs for rear and front brakes to ensure that brakes are available if one circuit fails.

If low air pressure occurs in both brake circuits at the same time, an alarm sounds. The brakes will remain operable until air pressure falls to 50  5 psi (345  35 kPa) and the parking brakes apply automatically to stop the coach.

Brake System Emergency Fill

Emergency fill provisions allow the primary or secondary service reservoirs to be filled independently. The fill provisions are in the front roadside service compartment (Figure 60.).

Figure 60.

Coach Air Service Fill

A service fill provision is located behind the curbside rear service door (Figure 61.) allows filling the coach air system from an external source, provided the air system is intact.

Figure 61.

July 201552

TOWING

Only operators authorized to and experienced in towing intercity coaches may tow coaches.

Towing Airline Connections

The towing air connections are in the roadside front

service compartment, along the rear wall (Figure 62.).

Figure 62.

Towing Procedures

Route the hoses away from the steering gear and linkage.

Ensure that the tow hoses will not be pinched or damaged during towing

3. Use the TOW SUPPLY connection for the supply line from the tow vehicle.

4. Use the TOW BRAKE connection for the line from the tow vehicle that operates the service brakes.

If this line accidentally detaches or is severed while towing, the parking brake will activate.

5. Connect the coach to the tow vehicle.

Disconnect the drive shaft or remove the axle shafts, before towing the coach. See Section 3F – Towing, in the Maintenance manual for axle shaft removal procedure.

Highway towing must be from the front. Only tow from the rear to extract the coach from ditches or snowbanks.

Only operators authorized to and experienced in towing intercity coaches may tow coaches.

DO NOT INSTALL SOLID PLUGS.

1. Remove the 1/4 NPT threaded mufflers to install the fitting style required by the tow truck.

2. Route the tow vehicle hoses to the coach connection points.

Reinstall the muffler when towing is completed. The connections must vent to atmosphere for the parking brakes to release properly.

If it is necessary to cage the spring brakes, see Section 4 of the Maintenance Manual. Always use extreme caution around spring brakes.

53July 2015

EMERGENCY STOPS

If you must stop the coach because of a breakdown or unsafe condition, ensure that it is safely parked.

1. Pull the coach as far out of traffic as possible.

2. Turn on the hazard lights.

3. Place reflector triangles in front of and behind the coach (refer to Figure 63. for storage location).

Figure 65.

Pull the entrance door knob to dump the air, allowing the entrance door to be manually pushed opened (Figure 66.).

Figure 63.

ENTRANCE DOOR OVERRIDE VALVE

The entrance door override valve (Figure 64.) allows air to be dumped from the entrance door actuating air cylinder, door claw and header locking devices. After dumping air, the entrance door can be manually pushed open.

Figure 64.

In addition to the valve, there is a provision for release of the front service compartment door, beside the windshield washer reservoir. This allows the compartment door release to be operated from outside the coach. Push upwards on mechanism, threw hole opening, to release compartment door latch (Figure 56.)

Figure 66.

TOOLS AND SAFETY EQUIPMENT

• A fire extinguisher is installed under the #2 curbside passenger seat.

• Three reflector triangles are provided in a container mounted in the upper corner of the #1 curbside baggage bay compartment. A container of fusees are mounted in the battery compartmen t.

• A lug wrench, hydraulic jack with handle and wooden run-up block (used for raising the axle when changing tires) are located in the front side service compartment (Figure 67.).

Figure 67.

July 201554

ENGINE DOOR RELEASE LEVER

The engine compartment door release lever is in

the rear curbside service door (Figure 68.).

Figure 68.

MAIN BATTERY DISCONNECT SWITCH

Activate the disconnect feature of the main battery disconnect (MDS) system by turning the rotary switch 45 degrees counter-clockwise to OFF (located in the battery compartment) (Figure 69.).

To turn ON (wake up) power from the exterior of the coach, press the exterior entrance door open switch. To turn ON (wake up) coach power from the interior of the coach when the coach is in sleep mode, press the entrance door open rocker switch or position the ignition rocker switch to the RUN position.

CIRCUIT BREAKERS AND FUSES

Self-resetting circuit breakers, located in the battery compartment on the curb side of the coach, provide overload and short circuit protection for the main HVAC blowers, condenser fans, driver's evaporator blowers and 12 and 24 volt relay modules. Three self-resetting circuit breakers for the driver's blowers are in the control box for the driver's evaporator, and two self-resetting circuit breakers for the parcel rack blowers are located in the fuse box.

Fuses, provided for the auxiliary heater, engine ECM, transmission ECU, interlock modules, door sensors and HVAC controllers, are located in the battery compartment fuse box.

Figure 69.

The multiplex modules installed on MCI coaches have been programmed with a system sleep mode. After thirty (30) minutes of no coach system activity, the power management supply module will remove electrical power from all the components connected to the main disconnect switch (now a rotary switch, located in the battery compartment). When the coach goes into sleep mode after thirty (30) minutes, coach power is turned OFF which allows the coach systems to conserve coach power, (providing that the hazard lights and master power switch are in the OFF position).

LAVATORY EMERGENCY

A momentary ON lavatory emergency button is located in the lavatory compartment (Figure 70.). Pressing this button will illuminate the LAV EMERG tell-tale and activate a buzzer. Releasing the button cancels the tell-tale and buzzer.

Figure 70.

55July 2015

AMEREX FIRE SUPPRESSION SYSTEM

The AMEREX fire suppression system is an automatic system that continuously monitors the engine compartment for fires. The system uses thermo-sensors connected to an electronic circuit monitor/control panel to electrically trigger the release of the dry chemical (ABC) extinguisher.

Figure 71.

Control Panel

The control panel is responsible for driver alerts and for the automatic activation of the system during fire hazards. The control panel has both audible and visual alarms.

Normal Operation

During normal operation, a green System OK LED is illuminated on the front of the control panel. This indicates that all circuits are intact and functioning.

Fire Hazard Conditions

In the event of fire, the green System OK LED will go out and the red FIRE LED will come on. The system will force chemical fire suppressant through four spray nozzles located in the engine compartment.

In the event of a fire, the engine will shutdown 15 seconds after the fire system is activated. If more than 15 seconds are required to move the coach to a safe parking area, the operator can push the ENGINE OVERRULE switch, located on the second row of the LH Switch Panel. Push the button at approximately 1012 second intervals to delay shutdown for another 15 seconds.

An audible buzzer will sound continuously during fires. This alarm will operate until the Alarm Silence button is pushed. When the Alarm Silence button has been pushed, the LED will be illuminated.

As a safety provision, the silence feature cannot be operated in advance of a fire or fault condition.

When the fire is extinguished and the thermosensor cools, the red FIRE LED will remain illuminated until the system is serviced and the monitor is reset.

Fault Condition

If a fault occurs in the actuator circuit, the Service System LED will be illuminated and will remain so until the condition is repaired.

Manual Operation

The manual function is used when a fault exists that could inhibit auto/electrical actuation via the control panel. During a fire emergency, the driver must manually pull the disarming pin that retains the actuator switch and push the button (Figure 72.). The manual fire button is located behind the drivers seat, on the LH side.

The Relay Reset button on the Amerex control panel is disabled (Figure 71.).

Figure 72.

July 201556

HEATING AND AIR CONDITIONING

MICROMAX HVAC DISPLAY

5. Micromate Control Panel - The Micromate

Control Panel displays the set point temperature, interior (return air) temperature and exterior temperature. To read interior or exterior temperature, press the TEMPERATURE display button to illuminate the indicator light. After a short delay, the display will return to the default set point temperature.

Set point temperature may be changed by pressing the UP or DOWN arrow button. The UP button will increase the set point temperature and the DOWN button will decrease the set point temperature. The set point temperature can be adjusted from 60F to 80F (15C to 27C).

KEY FUNCTIONS

Figure 73.

MICROMAX HVAC SWITCHES

1. Driver's Fan (Defrost) Control - Controls

driver's defroster fan speed from OFF, LO, MED, HIGH.

2. Driver's Heat Control - Controls driver's heat and cooling.

3. Parcel Rack Ventilation Switch - The PARCEL RACK switch turns the parcel rack blowers ON and OFF.

4. Auxiliary Heater Switch - Whe n th e en gin e is OFF, the engine can be preheated by pushing the AUXILIARY HEA TER switch forward, which activates a 90 minute timer in the Proheat unit. When the Proheat burner is ON, the HEATER ON telltale lights. To turn the Proheat OFF, push the switch back. It will purge for 2 to 3 minutes. If the coach is started during preheating, the temperaturedependent control overrides the timer.

57July 2015

START-UP AND SETTINGS

Alarms

The HVAC system self tests and starts automatically after the engine speed reaches idle. If the coach ignition key is ON, but the engine does not start by the end of the self test, the display will indicate “No Data” and the system will wait for the engine to start.

The main HVAC system will start at the same setting as when it was turned OFF.

When heating, the main fans will not start until the engine coolant temperature exce ed s 12 0F (4 9C) .

The fans start immediately when cooling.

The fans operate automatically at high, medium or low, depending on the heating or cooling requirements.

NOTE: Turn fast idle ON if running the air conditioning while stopped.

PARAMETERS and ALARM CODE RETRIEVAL

Pressing the UP and DOWN arrow buttons for 3 - 5 seconds will allow the user to scroll up or down through the parameters and alarms.

When scrolling through the parameters, the current parameter will be displayed for 2 seconds. When the last parameter is reached, the list will wrap back. Pressing the ON/OFF key at any time, or if no key is pressed for 30 seconds the mode will exit and will revert back to the default display.

Lights indicate alarm codes. Each alarm code is a 2 digit number. The first display is the first digit, and after a slight pause the second display is the second digit. When the end of the alarm is reached the display will show “---”. If the AUTO key is held down for 5 seconds while“---” is displayed, all inactive codes are cleared. Record all codes prior to clearing.

PASSENGER ZONE

The display will toggle between an alarm and the temperature setting when there is a system malfunction. The system may shut down if the malfunction is serious.

NOTE: To turn the heat OFF in an emergency, use the valves located in the engine compartment or the valve located under the driver's area. Refer to Section 6 of the Maintenance Manual.

HVAC PRE-TRIP INSPECTION

After starting system operation, allow the system to stabilize for ten to fifteen minutes, then check the following:

1. Listen for abnormal noises in the compressor or fan motors.

2. Check compressor oil level.

3. Check refrigerant level.

4. Ensure that the self-test has been performed successfully and that there are no errors or alarms indicated.

5. View compressor drive belt for excessive belt flap. (Refer to Section 16 of the Maintenance Manual.)

Back-lit Function

The back-lit function of the Micromate control panel is actuated when the headlight or clearance lights are turned ON (Figure 74.).

Default Settings

The default setting for the passenger zone is 70F (21C). The fans operate at high until the interior temperature reaches the set point.

Manual Settings

Temperature Settings

The temperature setting will be visible on the display. Pressing the AUTO key returns settings to auto control.

Fan Settings

The fans can be set at LOW or HIGH.

Figure 74.

July 201558

AUDIO AND VIDEO SYSTEMS

The REI Dual Zone system has the following features:

• DVD/CD/MP3/MP4/Radio/MIC Player with USB Input,

• Aux / IPod/ USB Playback

• Bluetooth Hands Free Calling and Wireless Audio Streaming

• The CD/AM/FM radio has built-in amplifier for powering driver’s speakers

• Six station pre-sets.

• Separate tone control (Dual Zone) for driver and passengers,

Figure 76.

Figure 77.

Figure 75.

1. REI EC-750 Dual Zone Player

REI ECD-5500 Dual Zone Player

3. REI DVD Player

4. Wireless Microphone (Optional)

5. Media Hub (Optional)

Figure 78.

MP-1000 Media Player (Optional)

• Passenger Safety Announcements

• Custom Video Playback

• Rolling Text

59July 2015

Figure 79. REI EC-750 Dual Zone controls.

July 201560

Figure 80. REI DVD Player Dual Zone controls.

61July 2015

Figure 81. REI ECD-5500 Dual Zone controls.

July 201562

REI Video Monitors

Six (6) 15.4 inch LCD monitors are installed throughout the coach cabin. The LCD monitors have a self protection feature against extreme climate temperatures.

Figure 82.

Figure 83.

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July 201564

SERVICE AND MAINTENANCE

Take care when inspecting or servicing the coach to avoid being injured. Some components may be hazardous if handled improperly. Poor maintenance could also lead to malfunctions, which could cause personal injury or damage to the coach.

Figure 84. J4500 Exterior Components

EXTERIOR COMPONENTS (Figure 84.)

1. Entrance Door

2. Entrance Door Exterior Switch

3. Baggage Compartment

4. Battery Compartment

5. A. Diesel Exhaust Fuel (DEF) Tank Filler Door B. Diesel (ULSD) Fuel Tank Filler Door

6. Wheelchair Lift Compartment

7. Rear Side Service Compartment

8. Rear Engine Service Compartment

9. Front Junction Box

10. Front Service Compartment

11. A/C Condenser Compartment

12. Radiator Compartment

13. Spare Tire Compartment

14. Roof Hatch

65July 2015

EXTERIOR LIGHTING (Figure 84.)

a. Headlights b. Multi-function LED (sweep style),

Directional Light / Hazard Light /

Daytime Running Light c. Reflectors d. Identification Light e. Marker Light f. Supplemental Stop Light g. LED Directional Light h. LED Backup Light i. LED Stop Light j. License Plate Light k. LED Cornering Light l. l. Directional Light

COMPARTMENT ACCESS (Figure 84.)

Engine Compartment

The engine service compartment door release is in

the rear, curbside, side service compartment.

Front Service Compartment

The T-handle, located at the rear of the drivers lower, LH console, is utilized to release the front service compartment door.

In addition to the T handle, there is a provision for release of the front service compartment door, beside the windshield washer reservoir. This allows the compartment door release to be operated from outside the coach. Push upwards on mechanism, thru hole opening, to release compartment door latch (Figure 86. and Figure 87.).

Stand clear when opening the rear engine door. It swings up. Turn OFF the engine enable switch any time the engine compartment is opened.

Condenser Compartment

The latch is located in the roadside fuel fill door.Radiator Compartment

Open with a handle located on the road side of the rear engine compartment.

Spare Tire Compartment

The bumper release handle is in the roadside front service compartment. Ensure sufficient clearance prior to releasing the compartment door (Figure 85.).

Figure 86.

Figure 87.

Figure 85.

July 201566

Fuel Tank

Access the fuel tank assembly through the fuel tank door on the curb side.

Fuel Tank Filler Doors

Two diesel (ULSD) filler doors are provided: one through the condenser door on the roadside and one through the fuel tank door on the curbside.

One diesel exhaust fuel (DEF) filler door is provided next to the curbside diesel (ULSD) filler door (Figure 88.).

COOLING SYSTEM

The engine cooling system controls the engine temperature and supplies water for the heating system. The cooling system is filled through the surge tank filler neck.

Coolant Surge Tank

There is no coolant recovery system. Check the coolant level through the sight glass.

TIRE CHANGE

Do not access suspension components from the wheel wells. Unintentional actuation could cause serious injury or death.

NEVER go under the coach while it is raised and supported on a jack only (Figure 87.).

Wheel and tire assemblies weight more than 200 lbs. (90 kg). Use caution when loosening the wheel nuts, and when lifting the wheel off the hub.

Figure 88.

1. Diesel (ULSD) Fuel Tank Filler Door

2. Diesel Exhaust Fuel (DEF) Tank Filler Door

Auxiliary Storage / Wheelchair Lift

Located at the rear curb-side of the coach,

immediately behind the trailing axle.

Baggage Compartments

Baggage compartments are located

between the front and rear axle.

To avoid pinching fingers, do not hold the edge of the door when closing it.

Baggage doors are locked by driver-controlled

switches on the switch panel.

DO NOT attempt to fit stud mount rims. DO NOT attempt to fit 8.25” rims. Only use tires that are sufficiently rated. Fit similar tires in similar condition on both sides of the axle. Only use correctly-profiled valve stems in hub-mounted 9” x 22.5” rims.

Front or Trailing Axle

1. Turn the front wheels straight ahead.

2. Run the flat tire up on the run-up block. Stop the coach and apply the parking brake.

3. Place the bottle jack under the axle beam so that the jack ram pad fits into the round recess at the bottom of the axle beam. Partially raise the wheel (Figure 89.).

67July 2015

Figure 89.

4. Before the tire is completely off the ground, loosen the wheel nuts.

5. Raise the wheel completely, remove the run-up block, and remove the wheel nuts and the wheel and tire assembly.

6. Mount the wheel on the hub pilot.

2. Place the bottle jack under the drive axle (Figure 91.) so that the jack ram pad fits the recess at the bottom of the jacking pad. The jack pad is on the rear face of the drive axle beam below the suspension support structure attachment. Partially raise the wheel.

Figure 91.

3. Before the tire is completely off the ground, loosen the wheel nuts.

7. Torque the wheel nuts to 450-500 ft.-lbs using the criss-cross sequence shown (Figure 90.).

Re-torque wheel nuts after 100 miles.

Figure 90.

Drive Axle

1. Run the inflated tire up onto the run-up block. Stop the coach and apply the parking brake.

The wheel and tire assemblies weigh more than 200 lbs. (90 Kg). Use caution when loosening the wheel nuts, and when lifting the wheel off the hub.

4. Raise the wheel completely, remove the run-up block, and remove the wheel nuts and the wheel and tire assemblies as required.

The drive axle wheel nuts are hub mounted: the wheel nuts hold both the outer and inner wheels. Take care when removing the nuts and tire assemblies.

5. Ensure that both wheels are properly seated on the hub pilot before tightening the nuts fully. Torque wheel nuts to 450-500 ft.-lbs using the criss-cross sequence shown in Figure 90.

Re-torque wheel nuts after 100 miles.

July 201568

FUELING

Two diesel (ULSD) fuel fillers are installed on the coach. One is located behind a filler door in the fuel tank compartment door on the curbside and the second location is on the roadside behind a filler door in the A/C condenser door (Figures 92 and 93).

Figure 92. Diesel (ULSD) Fuel Door

Diesel Fuel Specification

Engines must comply with EPA mandated low emission guidelines by using ULSD (ultra low sulfur diesel) fuel.

Failure to use ULSD fuel in 2015 EPA engines will result in component damage.

Biodiesel not to exceed B20.

Diesel Exhaust Fuel (DEF) Specification

DEF must meet ISO standard 22241-1.

AUXILIARY HEATER

The auxiliary heater is located in the left rear of the engine compartment. The auxiliary heater turns on automatically to augment the temperature of engine coolant for coach heating.

Figure 93. A/C Condenser Door

The fuel tank is equipped with a whistle that stops

when the tank is full. Close filler and latch it securely.

Do not fill the tank from both necks at once or have both fill caps open; the tank will over-fill and overflow.

DO NOT put anything but DEF in the DEF tank ( blue cap ).

One diesel exhaust fuel (DEF) filler door is next to

the curbside diesel (ULSD) filler door ().

To preheat the coolant or test the heater, turn the auxiliary heater ON with the AUX HEAT switch.

Auxiliary Heater Diagnostics

The operator can identify function and component diagnostics by checking the light bars or number display located on the front of the control module.

Figure 95.

Figure 94. DEF Tank Door

69July 2015

FLUID REPLACEMENT

Engine Lubricating Oil

The engine oil dipstick is accessible through the rear engine access door (Figure 100.). Always check the engine oil level with:

• the engine at normal operating temperature

• the coach on level ground

• the engine OFF.

NOTE: Leave the engine stopped for at least 5 minutes. Do not overfill.

Withdraw the dipstick and wipe it clean. Insert the dipstick fully, then withdraw it and read the oil level. If it is down to LOW mark, add sufficient oil to bring the level up to FULL mark.

Power Steering Fluid

The coach has a power steering fluid reservoir in the engine compartment (Figure 100.). The reservoir has a filler nozzle, sight glass and vent tube. The correct cold level is at the center of the sight glass. (Use the dipstick in the fill cap for hot level checks.) Check levels periodically and add if necessary.

Do not spill oil on the fan belts. The oil will cause the belt material to degrade rapidly and break.

Automatic Transmission Fluid - Allison

Refer to the heading “Transmission Operation” Allison Automatic Transmission - Transmission Fluid Level Checks, for the dipstick location and transmission fluid specifications.

Figure 96.

All fluids must be handled, stored and maintained according to the instructions on the “Waste Fluid Removal” decal. The decal is located in the rear engine compartment (Figure 97.).

Windshield Washer Reservoir

The windshield washer reservoir is in the front service compartment (Figure 96.).

Figure 97.

July 201570

LAVATORY TANK SERVICE PROCEDURES

Refer to local health regulations for proper disposal procedures and equipment. Lavatory waste must be disposed of according to the instructions on the “Lavatory Waste” decal. The decal is located on the inside of the curbside rear service door (Figure 98.).

Figure 99.

Charging the Lavatory Tank

Figure 98.

Draining the Lavatory Tank

1. Position the coach over a suitable sanitary sewage drain.

2. Open the dump valves (2.) and drain the tanks completely.

3. Connect a water hose to the rinse connection.

4. Close the upper dump valve and fill the upper tank.

5. Press the flush button for 30 sec on ds (if the coach has a flush toilet).

6. Open the dump valve and drain the tank.

7. Repeat Steps 1 to 5 until the discharged water appears clean.

1. Close both dump valves and fill the primary tank with water to one-third sight glass level.

Do not allow the lavatory chemicals to contact your skin.

2. Add approved chemical charge to the tank.

3. If the coach has a flush toilet, test.

71July 2015

Figure 100.

1. Coolant Fill, 15 psi Rad Cap

2. Remote Electrical Control Box

3. Back-up Alarm

4. Air Filter

5. Power Steering Reservoir

6. Lavatory Service Valves

7. Dual Denso Alternator, Top

8. Dual Denso Alternator, Bottom

9. A/C Belt

10. Alternator Belt

11. Fan Belt

12. Aux Heater

13. Engine Oil Fill Tube / Dipstick

14. Filter Minder

15. Gear Box Filler Tube

16. Radiator Door Handle location

17. Fuel Pro Fuel Filter

18. Transmission Oil Tube

July 201572

Figure 101.

1. Coolant Fill, 15 psi Rad Cap

2. Remote Electrical Control Box

3. Back-up Alarm

4. Air Filter

5. Power Steering Reservoir

6. Lavatory Service Valves

7. Dual Denso Alternator, Top

8. Dual Denso Alternator, Bottom

9. A/C Belt

10. Alternator Belt

11. Fan Belt

12. Aux Heater

13. Engine Oil Fill Tube (2 locations)

14. Filter Minder

15. Gear Box Filler Tube

16. Radiator Door Handle location

73July 2015

THIS PAGE INTENTIONALLY LEFT BLANK

July 201574

SPECIFICATIONS

VEHICLE HEIGHT (MAXIMUM NORMAL RIDE HEIGHT).................................................141.25 Inches (3587 mm)

(From Top Of Roof Hatches)

VEHICLE WIDTH (MAXIMUM) .............................................................................................102 Inches (2590 mm)

(Excludes Mirrors And Side Turn Lights)

GROSS VEHICLE WEIGHT RATING......................... ... .... ...................................................54,000 Lbs. (24,500 Kg)

CAPACITIES

DIESEL FUEL TYPE......................................................................................................ULSD (ultra low sulfur diesel)

DEF (DIESEL EXHAUST FUEL) TYPE....................................................................................ISO Standard 22241-1

ENGINE CRANKCASE.................................................................................. (SAE 15W-40) API Classification CJ-4

POWER STEERING SYSTEM.............................................................................................................7.5 Qts.(7.1 L)

(TES-389)

AUTOMATIC TRANSMISSION...............................................................................................................25 Qts.(23 L)

(TES-389)

COOLING SYSTEM............................................................................................................................25 Gals.(100 L)

(Glycol-based coolant)

AIR CONDITIONING....................... .......................................... ... ... ... ... .... ... ... ... ...............................23 Lbs.(10.4 Kg)

(R134 Refrigerant)

LAVATORY FRESH WATER TANK............................. ... ... ... .............................................. ... ... ... ... ..10 Gals.(37.8 L)

LAVATORY WASTE RETENTION TANK:

PRIMARY.......................................................................................................................................................16 Gals.

SECONDARY.................................................................................................................................................24 Gals.

PARCEL RACK (Right Side)..................................... .... ............................................. ... ... .... ... ........1184 Lbs (537 kg)

PARCEL RACK (Left Side)............................... ... ... .... ... ... ... ... .... ... ... ..............................................1332 Lbs (604 kg)

BATTERIES..........................................................................................................................8D, 1350 CCA Post type

TIRE SIZE (Basic).................................... ... .... ... ... ... .... ... ... ......................................315/80R22.5 on a 9.00 inch rim

TIRE SIZE (Minimum).......................................... ... .... ... ... ... ... .... ... ... ... ................................................. ... ... "J” Rated

75July 2015

Figure 102. J4500 MODEL BODY AND DOOR CLEARANCE DIAGRAM

July 201576

37’-5"

449.01

23’-2 5/8"

278.62

41’-10"

502.00

78.25

314.96

49.02

105.16

27.86

102.00

223.38

18’-7 3/8"

Figure 103. J4500 TURNING RADIUS

77July 2015

TIRE SPECIFICA TIONS

The tires listed below meet GHG regulations as LRR tires. It is the owner's responsibility for tire maintenance.

Replacement Tires

Always replace the tires with the same rating, size and the same or better rolling resistance coefficient (CRR). Contact the tire manufacturer for tires' CRR rating.

TIRE CHART

Make and Type Size

Goodyear G409 MBA

Michelin XZY-2 315/80R22.5 L All Axles

Michelin XZA2 315/80R22.5 L All Axles

Michelin XDN2 315/80R22.5 L Drive Axle Not approved

Firestone FS400 315/80R22.5 L All Axles

Bridgestone R249 315/80R22.5 J All Axles Firestone

HP 3000 Goodyear G124

(Grip Style) BF Goodrich 2T234 315/80R22.5 L All Axles

Matador DH1 315/80R22.5 J Drive Axle Not approved

Matador FH1 315/80R22.5 J Front/Tag Axle Continental

HSL ECO plus

B315/80R22.5 J All Axles

315/80R22.5 J All Axles

12R22.5 H Drive Axle Not approved

315/80R22.5 J All Axles

Load

Range

Axle

Front

Pressure

120 psi

(827 kPa)

120 psi

(827 kPa)

120 psi

(827 kPa)

120 psi

(827 kPa)

120 psi

(827 kPa)

120 psi

(827 kPa)

120 psi

(827 kPa)

120 psi

(827 kPa)

120 psi

(827 kPa)

Drive

Pressure

100 psi

(690 kPa)

100 psi

(690 kPa)

100 psi

(690 kPa)

100 psi

(690 kPa)

100 psi

(690 kPa)

100 psi

(690 kPa)

100 psi

(690 kPa)

100 psi

(690 kPa)

100 psi

(690 kPa)

100 psi

(690 kPa)

Not approved

100 psi

(690 kPa)

Tag Pressure

120 psi

(827 kPa)

120 psi

(827 kPa)

120 psi

(827 kPa)

Not approved

120 psi

(827 kPa)

120 psi

(827 kPa)

120 psi

(827 kPa)

Not approved

120 psi

(827 kPa)

Not approved

120 psi

(827 kPa)

120 psi

(827 kPa)

TIRE SIZE (Basic).................................... ... .... ... ... ... .... ... ... ......................................315/80R22.5 on a 9.00 inch rim

TIRE SIZE (Minimum).......................................... ... .... ... ... ... ... .... ... ... ... ................................................. ... ... "J” Rated

July 201578

DIAGNOSTIC CODES / ENGINE

DD13 DIAGNOSTIC CODES

SPN FMI CODE DESCRIPTION

51 2 Intake Throttle Position Deviation Error 51 3 Intake Air Throttle Circuit Failed High 51 4 Intake Air Throttle Circuit Failed Low 70 13 J1939 Park Brake Switch Signal from Source #1 is missing 70 19 J1939 Park Brake Switch Signal from Source #1 is erratic 84 0 Vehicle Speed Above Programmable Threshold1 While Driving 84 2 J1939 Wheel-Based Vehicle Speed Signal from Source#1 is erratic 84 2 VSS Anti Tamper Detection via Virtual Gear Ratio 84 3 Vehicle Speed Sensor Circuit Failed High 84 3 Vehicle Speed Sensor Circuit Failed High 84 4 Vehicle Speed Sensor Circuit Failed Low 84 4 Vehicle Speed Sensor Circuit Failed Low 84 6 VSS Anti-Tamper Detection via ABS Vehicle Speed Comparison 84 8 VSS Anti Tamper Detection via Fixed Frequency Device 84 9 J1939 Wheel-Based Vehicle Speed Signal from Source#2 is missing 84 10 J1939 Wheel-Based Vehicle Speed Signal fr om Source # 3 is errati c 84 11 Vehicle Speed Above Programmable Threshold2 While Driving 84 13 J1939 Wheel-Based Vehicle Speed Signal fr om Source # 1 is missing 84 13 J1939 Wheel-Based Vehicle Speed Signal fr om Source # 1 is missing 84 14 J1939 Wheel-Based Vehicle Speed Signal fr om Source # 3 is missing 84 19 J1939 Wheel-Based Vehicle Speed Signal fr om Source # 1 is errati c 84 19 J1939 Wheel-Based Vehicle Speed Signal fr om Source # 2 is errati c 84 20 Vehicle Speed Sensor Drifted High Error (VSS signal not plausible) 84 21 Vehicle Speed Sensor Erratic 84 21 Vehicle Speed Failure 91 0 Accelerator Pedal Circuit Failed High 91 3 Accelerator Pedal Signal Circuit Failed High 91 4 Accelerator Pedal Circuit Failed Low 91 13 J1939 EEC2 Message is missing 97 15 Water in Fuel 98 0 Oil Level High 98 1 Oil Level Very Low 98 18 Oil Level Low 100 1 Engine Oil Pressure Low 100 1 Oil Pressure Very Low 100 3 Engine Oil Pressure Circuit Failed High 100 4 Engine Oil Pressure Circuit Failed Low 100 17 Oil Pressure Plausibility 100 18 Oil Pressure Low 107 0 Air Filter Restriction High 108 3 Barometric Pressure Circuit Failed High 108 4 Barometric Pressure Circuit Failed Low 108 13 Ambient Air Pressure Signal Not Available via CAN 110 0 Coolant Temperature Very High 110 0 Coolant Temperature High 110 2 Coolant Outlet Temperature Not Plausible 110 3 Engine Coolant Outlet Temperature Circuit Failed High

79July 2015

DD13 DIAGNOSTIC CODES

SPN FMI CODE DESCRIPTION

110 4 Engine Coolant Outlet Temperature Circuit Failed Low 110 9 Coolant Temperature Signal Not Available via CAN 110 14 Coolant Temperature / Engine Oil Temperature Plausibility Fault 110 16 Coolant Temperature High 111 1 Coolant Level Very Low 111 3 Coolant Level Circuit Failed High 111 4 Coolant Level Circuit Failed Low 111 18 Coolant Level Low 111 19 Coolant Level Low (CAN) 120 13 J1939 Retarder Fluid Message is missing 157 7 No Description 157 16 Fuel Rail Pressure Low 157 18 Fuel Rail Pressure High 158 2 Ignition Switch Not Plausible 158 2 Kl15 ignition switch status of CPC2 and MCM do not match 158 7 Keys witch battery potential SA61 164 0 Quantity Control Valve (Low Side) Error 164 1 Quantity Control Valve (High Side) Error 164 3 Rail Pressure Sensor Circuit Failed High 164 4 Rail Pressure Sensor Circuit Failed Low 164 5 Rail Pressure Sensor Circuit Failed Open 164 20 Rail Pressure Sensor - Drift High 164 21 Rail Pressure Sensor - Drift Low 168 0 Battery Voltage High 168 0 Battery Voltage High 168 0 Battery Voltage High 168 1 Battery Voltage Low 168 1 Battery Voltage Very Low 168 1 Battery Voltage Low 168 7 Opt Idle Detected Charging System or Battery Failure 168 14 ECU power-down not completed (Main Battery Terminal Possibly Floating) 168 18 Battery Voltage Low 171 2 Ambient Temperature Sensor Data Erratic 171 9 J1587 Ambient Air Temp Sensor Data Message Stopped Arriving 171 13 Ambient Air Temperature Signal Not Available via CAN 171 14 J1587 Ambient Air Temp Sensor Data Not Received This Ignition Cycle 174 0 Fuel Temperature Too High 174 2 Fuel Temperature Sensor, General Temp. Plausibility 174 3 Fuel Temperature Circuit Failed High 174 4 Fuel Temperature Circuit Failed Low 175 0 Oil Temperature High Warning 175 3 Engine Oil Temperature Circuit Faile d High 175 4 Engine Oil Temperature Circuit Fa ile d Lo w 175 14 Engine Oil Temperature Sensor Plausibility Fault 175 15 Oil Temperature High Pre-Warning 188 31 Idle Speed Out of range 190 0 Engine Speed High 190 9 Engine Speed Signal Not Available via CAN 191 9 J1939 ETC1 Message is missing 191 13 J1939 Transmission Output Shaft Speed Signal is missing

July 201580

DD13 DIAGNOSTIC CODES

SPN FMI CODE DESCRIPTION

191 13 J1939 Transmission Output Shaft Speed Signal is missing 191 19 J1939 Transmission Output Shaft Speed Signal is erratic 191 19 J1939 Transmission Output Shaft Speed Signal is erratic 247 0 MCM Engine Hours Data higher than expected 247 1 MCM Engine Hours Data lower than expected 247 9 MCM Engine Hours Data not received or stopped arriving 247 10 MCM Engine Hours Data increasing at an implausible rate 247 14 MCM Reported Ash Mileage is Lower then the CPC Stored Value 411 0 EGR Differential Pressure Too High (Low Box) 411 1 EGR Differential Pressure Too Low (High Box) 411 2 EGR Delta Pressure Sensor Out Of Calibration 411 3 EGR Delta Pressure Sensor Circuit High 411 4 EGR Delta Pressure Sensor Circuit Low 411 13 EGR Delta Pressure Sensor Out Of Calibration 513 9 Actual Torque Signal Not Available via CAN 523 13 J1939 Transmission Current Gear Signal is missing 523 19 J1939 Transmission Current Gear Signal is erratic 523 19 J1939 Transmission Current Gear Signal is erratic 524 9 J1939 ETC2 Message is missing 527 9 J1939 CCVS Message is missing 558 2 Idle Validation Switch Inputs Reversed 558 3 Idle Validation Switch 1 Circuit Failed High 558 4 Idle Validation Switch 1 Circuit Failed Low 558 Idle Validation Switch 2 Circuit Failed Low 558 6 Idle Validation Switch 2 Circuit Failed High 596 13 J1939 Cruise Control Enable Switch Signal from Source #1 is missing 596 19 J1939 Cruise Control Enable Switch Signal from Source #1 is erratic 597 2 Service Brake Status Not Plausible 597 13 J1939 Service Brake Switch Signal from Source #1 is missing 597 19 J1939 Service Brake Switch Signal from Source #1 is erratic 599 4 Cruise Control SET and RESUME Circuits Failed Low 600 13 J1939 Cruise Control Coast Switch Signal from Source #1 is missing 600 19 J1939 Cruise Control Coast Switch Signal from Source #1 is erratic 602 13 J1939 Cruise Control Accelerate Switch Signal from Source #1 is missing 602 19 J1939 Cruise Control Accelerate Switch Signal from Source #1 is erratic 608 14 J1708 Data Link Failure 609 12 CPC2 Hardware Failure 625 2 Invalid Data on Engine CAN Link 625 2 Incorrect MCM System ID Received 625 4 ECAN Link Circuit Failure 625 8 MCM PT-CAN DM1 Message Not Received or has Stopped Arriving 625 8 MCM UDS DM1 Message Not Received or has Stopped Arriving 625 9 ACM PT-CAN DM1 Message Not Received or has Stopped Arriving 625 9 No Data Received from Engine CAN Link 625 14 ACM UDS DM1 Message Not Received or has Stopped Arriving 625 14 MCM System ID Not Received or Stopped Arriving 625 17 No ACM Communication - Pre Warning 625 18 No ACM Communication - Warning 628 2 EEPROM Checksum Failure 628 12 EEPROM Checksum Failure for the SCR Block

81July 2015

DD13 DIAGNOSTIC CODES

SPN FMI CODE DESCRIPTION

628 14 XFLASH Static Fault Code Memory Page Read Write Failure 628 17 1000ms ECU OS Task Timed out Prior to Completion 629 2 CPC Hardware/Software Mismatch 629 12 DDEC Data X flash Write Error. Replace CPC2. 630 13 SCR Number Out of Range 636 1 Crankshaft Position Sensor Signal Voltage Too Low 636 2 No Match of Camshaft and Crankshaft Signals 636 3 Crankshaft Position Sensor Open Circuit 636 8 Crankshaft Position Sensor Time Out 636 10 Crankshaft Position Sensor Signal Erratic 636 11 Crankshaft Position Sensor Failure 639 9 J1939 PROP11 message is missing 639 13 HDMS Fan is configured and the J1939 message was not received. 639 14 J1939 Data Link Failure 639 14 J1939 Data Link Failure 647 3 Fan Stage 1 Circuit Failed High 647 4 Fan Stage 1 Circuit Failed Low 647 5 Fan Stage 1 Circuit Failed Open 651 3 Injector Cylinder #1 Needle Control Valve Abnormal Operation (MAX) 651 4 Injector Cylinder #1 Needle Control Valve Abnormal Operation (MIN) 651 6 Injector Cylinder #1 Needle Control Valve, Valve Shorted Circuit 652 3 Injector Cylinder #2 Needle Control Valve Abnormal Operation (MAX) 652 4 Injector Cylinder #2 Needle Control Valve Abnormal Operation (MIN) 652 6 Injector Cylinder #2 Needle Control Valve, Valve Shorted Circuit 653 3 Injector Cylinder #3 Needle Control Valve Abnormal Operation (MAX) 653 4 Injector Cylinder #3 Needle Control Valve Abnormal Operation (MIN) 653 6 Injector Cylinder #3 Needle Control Valve, Valve Shorted Circuit 654 3 Injector Cylinder #4 Needle Control Valve Abnormal Operation (MAX) 654 4 Injector Cylinder #4 Needle Control Valve Abnormal Operation (MIN) 654 6 Injector Cylinder #4 Needle Control Valve, Valve Shorted Circuit 655 3 Injector Cylinder #5 Needle Control Valve Abnormal Operation (MAX) 655 4 Injector Cylinder #5 Needle Control Valve Abnormal Operation (MIN) 655 6 Injector Cylinder #5 Needle Control Valve, Valve Shorted Circuit 656 3 Injector Cylinder #6 Needle Control Valve Abnormal Operation (MAX) 656 4 Injector Cylinder #6 Needle Control Valve Abnormal Operation (MIN) 656 6 Injector Cylinder #6 Needle Control Valve, Valve Shorted Circuit 677 2 Starter Switch Inconsistent 677 3 Engine Starter Relay Shorted to High Source 677 4 Engine Starter Relay Circuit Failed Low 677 5 Engine Starter Relay Open Circuit 677 7 Engine Starter Relay - Starter Does Not Engage 679 7 Pressure Limiting Valve, Failed to Close 701 3 Digital Output 4 09 Circuit Failed High 701 4 Digital Output 4 09 Circuit Failed Low 702 3 Digital Output 3 17 Circuit Failed High 702 4 Digital Output 3 17 Circuit Failed Low 703 3 Digital Output 3 09 Circuit Failed High 703 4 Digital Output 3 09 Circuit Failed Low 704 3 Digital Output 4 07 Circuit Failed High 704 4 Digital Output 4 07 Circuit Failed Low

July 201582

DD13 DIAGNOSTIC CODES

SPN FMI CODE DESCRIPTION

705 3 Digital Output 1 13 Circuit Failed High 705 3 Digital Output 1 13 Circuit Failed High 705 4 Digital Output 1 13 Circuit Failed Low 705 4 Digital Output 1 13 Circuit Failed Low 706 3 Digital Output 3 10 Circuit Failed High 706 4 Digital Output 3 10 Circuit Failed Low 707 3 Digital Output 2 10 Circuit Failed High (CEL / AWL Lamp) 707 4 Digital Output 2 10 Circuit Failed Low (CEL / AWL Lamp) 708 3 Digital Output 3 12 Circuit Failed High 708 4 Digital Output 3 12 Circuit Failed Low 709 3 Digital Output 3 16 Circuit Failed High 709 4 Digital Output 3 16 Circuit Failed Low 710 3 Digital Output 4 06 Circuit Failed High 710 3 Digital Output 4 06 Circuit Failed High 710 4 Digital Output 4 06 Circuit Failed Low 710 4 Digital Output 4 06 Circuit Failed Low 711 3 Digital Output 1 05 Circuit Failed High 711 4 Digital Output 1 05 Circuit Failed Low 712 3 Digital Output 1 04 Circuit Failed High 712 4 Digital Output 1 04 Circuit Failed Low 713 3 Digital Output 3 07 Circuit Failed High 713 4 Digital Output 3 07 Circuit Failed Low 713 5 Digital Output 3 07 Open Circuit 713 7 TOP2 Shift Failure 714 3 Digital Output 3 08 Circuit Failed High 714 4 Digital Output 3 08 Circuit Failed Low 714 5 Digital Output 3 08 Open Circuit 715 3 Digital Output 4 10 Circuit Failed High 723 8 Camshaft Position Sensor Time Out 723 10 Camshaft Position Sensor Signal Erratic 723 11 Camshaft Position Sensor Failure 904 9 J1939 EBC2 Message from ABS is missing 904 13 J1939 Front Axle Speed Signal is missing 904 19 J1939 Front Axle Speed Signal is erratic 972 2 Throttle inhibit switch signal not plausible due to excess vehicle speed 973 2 Evo bus 5stage retarder level position not plausible 973 9 J1939 EBC1 Message is missing 973 13 Evobus 5stage retarder level calibration not plausible 973 13 J1939 Engine Retarder Selection Signal Missing 973 19 J1939 Engine Retarder Selection Signal Erratic 974 2 Remote Accelerator Pedal Supply Voltage Out of Range 974 3 Remote Accelerator Pedal Circuit Failed High 974 4 Remote Accelerator Pedal Circuit Failed Low 979 9 J1939 PTO Message Not Received This Ignition Cycle 986 9 J1939 CM1 Message is missing 1037 0 DPF HC Absorption Very High 1037 15 DPF HC Absorption Warning 1037 16 DPF HC Absorption High 1071 3 Fan Stage 2 Circuit Failed High 1071 4 Fan Stage 2 Circuit Failed Low

83July 2015

DD13 DIAGNOSTIC CODES

SPN FMI CODE DESCRIPTION

1071 5 Fan Stage 2 Circuit Failed Open 1072 3 Jake Brake Stage 1 Circuit Failed High 1072 4 Jake Brake Stage 1 Circuit Failed Low 1072 5 Jake Brake Stage 1 Circuit Failed Open 1073 3 Jake Brake Stage 2 Circuit Failed High 1073 4 Jake Brake Stage 2 Circuit Failed Low 1073 5 Jake Brake Stage 2 Circuit Failed Open 1077 5 Quantity Control Valve Error, Current Too Low 1077 6 Quantity Control Valve, Current Too High 1077 14 Leakage in High Pressure Fuel System Too High (Leak Down Test) 1077 31 Rail Pressure Governor Error, Open Loop Error 1231 9 ACM Message Not Received or has Stopped Arriving 1267 3 Digital Output 4 10 Circuit Failed Open 1267 4 Digital Output 4 10 Circuit Failed Low 1590 9 Adaptive Cruise Control Device Reporting Error 1590 19 Adaptive Cruise Control Message Not Received 1624 9 J1939 TCO1 Message is missing 1624 13 J1939 Tachograph Vehicle Speed Signal is missing 1624 19 J1939 Tachograph Vehicle Speed Signal is erratic 1636 0 Charge Air Cooler Low Efficiency 1636 2 Engine Air Temperature - Plausibility Fault Out of Range (Low Box) 1636 3 Intake Manifold Temperature Circuit Failed High 1636 4 Intake Manifold Temper at ur e Circ uit Faile d Lo w 1639 2 Fan Speed Fault 1659 18 Thermostat Error Detected 1663 7 Optimized Idle Safety Loop Faulted 1716 9 J1939 ERC1 Message is missing 1761 1 DEF Tank Level 0 - Empty (Speed Limited) 1761 3 DEF Tank Level Sensor Circuit Failed High 1761 4 DEF Tank Level Sensor Circuit Failed Low 1761 17 DEF Tank Level 2 - Very Low 1761 18 DEF Tank Level 1 - Empty 1761 31 DEF Tank Level 3 - Low 1814 9 VDC1 Message was not received or has stopped arriving. 1845 9 J1939 TCFG2 Message is missing 2630 2 Engine Air Temperature - Plausibility Fault Out of Range (High Box) 2630 3 Charge Air Cooler Outlet Temperature Circuit Failed High 2630 4 Charge Air Cooler Outlet Temperature Circuit Failed Low 2630 16 Charge Air Cooler Performance Monitor 2631 1 Low Air Flow 2659 0 EGR Flow Target Error Diagnostic - High Flow 2659 18 EGR Flow Target Error Diagnostic - Low Flow 2791 7 EGR Valve Actuator, Failsafe Mode, Motor On 2791 9 EGR Valve Actuator, Failsafe Mode, Motor Off 2791 10 EGR Actuator Slow Response 2791 14 EGR Valve Actuator, No Failsafe Mode, Motor Off 2791 16 EGR Valve Actuator, Temperature Fault 2797 3 Injector Needle Control Valv e Cylin de r 1, 2,3 Shorted to Battery 2797 4 Injector Needle Control Valve Cylinder 1, 2, 3 Shorted to Ground 2798 3 Injector Needle Control Valv e Cylin der 4,5,6, Shorted to Battery

July 201584

DD13 DIAGNOSTIC CODES

SPN FMI CODE DESCRIPTION

2798 4 Injector Needle Control Valve Cylinder 4, 5, 6 Shorted to Ground 2900 9 J1939 ETC7 Message is missing 3031 2 DEF Tank Temperature - Drift 3031 3 DEF Tank Temperature Sensor Circuit Failed High 3031 4 DEF Tank Temperature Sensor Circuit Failed Low 3056 2 SCR Inlet Nox Sensor - Error 3057 2 SCR Outlet Nox Sensor - Error 3216 2 SCR Inlet Nox Sensor - Drift 3216 3 SCR Inlet Nox Sensor Circuit Failed High 3216 4 SCR Inlet Nox Sensor Circuit Failed Low 3216 13 SCR Inlet Nox Sensor Signal Not Available 3216 21 SCR Inlet Nox Sensor - Drift (Low Box) 3226 2 SCR Outlet Nox Sensor - Drift 3226 3 SCR Outlet Nox Sensor Circuit Failed High 3226 4 SCR Outlet Nox Sensor Circuit Failed Low 3226 13 SCR Outlet Nox Sensor Signal Not Available 3226 21 Nox Outlet Sensor Drift High 3236 9 Exhaust Mass Signal Not Available via CAN 3242 3 DOC Inlet Temperature Circuit Failed High 3242 4 DOC Inlet Temperature Circuit Failed Low 3242 8 DOC Inlet Temperature - Signal Spike 3242 20 DOC Temperature Drift - Inlet High or Outlet Low 3246 0 DPF Outlet Temperature - Very High 3246 3 DPF Oulet Temperature Circuit Failed High 3246 4 DPF Oulet Temperature Circ uit Failed Lo w 3246 8 DPF Outlet Temperature - Signal Spike 3246 15 DPF Outlet Temperature - High 3246 20 DPF Outlet/SCR Inlet Temperature - Abnormal 3246 21 DPF Outlet Temperature Sensor - Not Plausible 3250 0 DOC Outlet Temperature - Very High 3250 3 DOC Outlet Temperature Circuit Failed High 3250 4 DOC Outlet Temperature Circuit Failed Low 3250 8 DOC Outlet Temperature - Signal Spike 3250 14 Abnormal DOC Temperature Rise 2 3250 15 DOC Outlet Temperature - High 3250 20 DOC Temperature Drift - Inlet Low or Outlet High 3250 31 Abnormal DOC Temperature Rise 3251 0 DPF Pressure - Out of Range Very High 3251 2 DOC Inlet Pressure Sensor - Not Plausible 3251 16 DPF Pressure - Out of Range High 3361 0 DEF Pressure Duty Cycle High 3361 1 DEF Pressure Duty Cycle Low 3361 3 DEF Dosing Valve Circuit Failed High 3361 4 DEF Dosing Valve Circuit Failed Low 3361 5 DEF Dosing Valve Circuit Failed Open 3361 7 DEF Unit - Unable to clear Restriction 3363 0 DEF Tank Temperature - High 3363 1 DEF Tank Temperature - Low 3363 3 DEF Coolant Valve Circuit Failed High 3363 4 DEF Coolant Valve Circuit Failed Low

85July 2015

DD13 DIAGNOSTIC CODES

SPN FMI CODE DESCRIPTION

3363 5 DEF Coolant Valve Circuit Failed Open 3364 1 Improper DEF Quality Final Warning 3364 2 Improper DEF Quality 3364 17 Improper DEF Quality Warning 3464 3 H Bridge 1 Circuit Shorted to Battery 3464 4 H Bridge 1 Circuit Shorted to Ground 3464 5 H Bridge 1 Circuit Open Load 3464 31 Intake Air Throttle Control Electrical Fault 3471 3 HC Doser Circuit Failed High 3471 4 HC Doser Circuit Failed Low 3471 5 HC Doser Circuit Failed Open 3480 0 Fuel Compensation Pressure High 3480 1 Doser Fuel Supply Pressure Abnormal 3480 2 Doser Fuel Line Pressure Low 3480 3 Fuel Compensation Pressure Sensor Circuit Failed High 3480 4 Fuel Compensation Pressure Sensor Circuit Failed Low 3480 14 Doser FLP Sensors Failed Self Test 3480 31 Fuel Cut Off Valve Pressure Not Plausible 3482 3 Fuel Cut Off Valve Circuit Failed High 3482 4 Fuel Cut Off Valve Circuit Failed Low 3482 5 Cut Off Valve Circuit Failed Open 3509 3 ACM Sensor Supply 1 Short to Battery 3509 3 5V Sensor Supply Bank 1 Circuit Failed High 3509 4 ACM Sensor Supply 1 Short to Ground 3509 4 5V Sensor Supply Bank 1 Circuit Failed Low 3510 3 5V Sensor Supply Bank 2 Circuit Failed High 3510 3 ACM Sensor Supply 2 Short to Battery 3510 3 Accelerator Pedal Supply Voltage Circuit Failed High 3510 4 Accelerator Pedal Supply Voltage Circuit Failed Low 3510 4 ACM Sensor Supply 2 Short to Ground 3510 4 5V Sensor Supply Bank 2 Circuit Failed Low 3510 7 Accelerator Pedal Supply Voltage Circuit Failed High 3512 3 3V Sensor Supply Bank 2 Circuit Failed High 3512 4 3V Sensor Supply Bank 2 Circuit Failed Low 3556 0 Regen Temperature - Ou t of Ra ng e Hig h 3556 1 Regen Temperatur e - Ou t of Ra ng e Lo w 3556 18 DOC Outlet Temp Low, (Low Temp Regen) 3563 3 Intake Manifold Pressure Circuit Failed High 3511 3 3V Sensor Supply Bank 1 Circuit Failed High 3511 4 3V Sensor Supply Bank 1 Circuit Failed Low 3563 4 Intake Manifold Pressure Circuit Failed Low 3563 18 Inlet Manifold Pressure Failed Low 3563 20 Ambient and Inlet Manifold Pressure Difference (Low Box) 3597 3 High Side Digital Output 1 Circuit Failed High 3597 3 Proportional Valve Bank 1 Circuit Failed High 3597 4 Proportional Valve Bank 1 Circuit Failed Low 3597 4 High Side Digital Output 1 Circuit Failed Low 3598 3 Proportional Valve Bank 2 Circuit Failed High 3598 4 Proportional Valve Bank 2 Circuit Failed Low 3599 3 High Side Digital Output 3 Circuit Failed High

July 201586

DD13 DIAGNOSTIC CODES

SPN FMI CODE DESCRIPTION

3599 3 MCM Internal Injector Power Supply Failed High 3599 4 High Side Digital Output 3 Circuit Failed Low 3599 4 MCM Internal Injector Power Supply Failed Low 3606 9 J1939 ESS Message is missing 3609 3 DOC Inlet Pressure Circuit Failed High 3609 4 DOC Inlet Pressure Circuit Failed Low 3610 2 DPF Outlet Pressure Sensor - Not Plausible 3610 3 DPF Outlet Pressure Circuit Failed High 3610 4 DPF Outlet Pressure Circuit Failed Low 3659 3 Injector Cylinder #1 Amplifier Control Valve Abnormal Operation (MAX) 3659 4 Injector Cylinder #1 Amplifier Control Valve Abnormal Operation (MIN) 3659 6 Injector Cylinder #1 Amplifier Control Valve, Valve Shorted Circuit 3660 3 Injector Cylinder #2 Amplifier Control Valve Abnormal Operation (MAX) 3660 4 Injector Cylinder #2 Amplifier Control Valve Abnormal Operation (MIN) 3660 6 Injector Cylinder #2 Amplifier Control Valve, Valve Shorted Circuit 3661 3 Injector Cylinder #3 Amplifier Control Valve Abnormal Operation (MAX) 3661 4 Injector Cylinder #3 Amplifier Control Valve Abnormal Operation (MIN) 3661 6 Injector Cylinder #3 Amplifier Control Valve, Valve Shorted Circuit 3662 3 Injector Cylinder #4 Amplifier Control Valve Abnormal Operation (MAX) 3662 4 Injector Cylinder #4 Amplifier Control Valve Abnormal Operation (MIN) 3662 6 Injector Cylinder #4 Amplifier Control Valve, Valve Shorted Circuit 3663 3 Injector Cylinder #5 Amplifier Control Valve Abnormal Operation (MAX) 3663 4 Injector Cylinder #5 Amplifier Control Valve Abnormal Operation (MIN) 3663 6 Injector Cylinder #5 Amplifier Control Valve, Valve Shorted Circuit 3664 3 Injector Cylinder #6 Amplifier Control Valve Abnormal Operation (MAX) 3664 4 Injector Cylinder #6 Amplifier Control Valve Abnormal Operation (MIN) 3664 6 Injector Cylinder #6 Amplifier Control Valve, Valve Shorted Circuit 3695 9 DPF Regen Inhibit MUX Switch Message Stopped Arriving 3695 13 DPF Regen Inhibit MUX Switch Message Contains SNV Indicator 3695 14 DPF Regen Inhibit MUX Switch Message Not Received this Ignition Cycle 3695 19 DPF Regen Inhibit MUX Switch Message Contains Data Error Indicator 3696 9 DPF Regen Force MUX Switch Message Stopped Arriving 3696 13 DPF Regen Force MUX Switch Message Contains SNV Indicator 3696 14 DPF Regen Force MUX Switch Message Not Received this ignition Cycle 3696 19 DPF Regen Force MUX Switch Message Contains Data Error Indicator 3711 31 Parked Regen Failed - DOC Temp In Low Preventing Dosing 3713 31 Parked Regen Failed - DOC Temp Out, Not Reaching Target Temp 3716 31 High Idle Regen - Low Temperature 3719 0 Soot Level Very High 3719 15 DPF Zone 3 Condition 3719 16 Soot Level High 3719 31 DPF Zone 2 Condition 3720 15 DPF Ash Clean Request 3936 18 DPF Pressure - Out of Range Low 4041 0 20ms ECU OS Task Locked in an Endless Loop 4041 9 20ms ECU OS Task Timed out Prior to Completion 4041 16 1000ms ECU OS Task Locked in an Endless Loop 4077 0 Doser Fuel Line Pressure High 4077 3 Doser Fuel Line Pressure Sensor Circuit Failed High 4077 4 Doser Fuel Line Pressure Sensor Circuit Failed Low

87July 2015

DD13 DIAGNOSTIC CODES

SPN FMI CODE DESCRIPTION

4077 14 Doser Fuel Line Pressure Failed Self Test 4193 2 Coolant Inlet Temperature Not Plausible 4193 3 Engine Coolant Inlet Temperature Circuit Failed High 4193 4 Engine Coolant Inlet Temperature Circuit Failed Low 4193 10 Coolant Temperature Sensors not Plausible 4257 3 Injector Amplifier Control Valve Cylinder 1, 2, 3 Shorted to Battery 4257 4 Injector Amplifier Control Valve Cylinder 1, 2, 3 Shorted to Ground 4258 3 Injector Amplifier Control Valve Cylinder 4, 5, 6 Shorted to Battery 4258 4 Injector Amplifier Control Valve Cylinder 4, 5, 6 Shorted to Ground 4334 2 DEF Pressure Sensor - Drift 4334 3 DEF Pressure Sensor Circuit Failed High 4334 4 DEF Pressure Sensor Circuit Failed Low 4334 7 DEF Pressure Low 4334 17 DEF Purge Pressure High 4335 1 DEF Air Pressure Not Detected (from vehicle supply) 4335 2 DEF Air Pressure Sensor - Drift 4335 3 DEF Air Pressure Sensor Circuit Failed High 4335 4 DEF Air Pressure Sensor Circuit Failed Low 4335 7 DEF Air Pressure Low 4335 14 DEF - Information Only 4335 31 DEF - Information Only 4336 3 DEF Air Valve Circuit Failed High 4336 4 DEF Air Valve Circuit Failed Low 4336 5 DEF Air Valve Circuit Failed Open 4337 2 DEF Dosing Unit Temperature - Drift 4337 3 DEF Temperature Sensor Circuit Failed High 4337 4 DEF Temperature Sensor Circuit Failed Low 4353 3 Diffuser Heater Circuit Failed High 4353 4 Diffuser Heater Circuit Failed Low 4353 5 Diffuser Heater Open Circuit 4354 3 SCR Line Heater #1 Circuit Failed High 4354 4 SCR Line Heater #1 Circuit Failed Low 4354 5 SCR Line Heater #1 Open Circuit 4355 3 SCR Line Heater #2 Circuit Failed High 4355 4 SCR Line Heater #2 Circuit Failed Low 4355 5 SCR Line Heater #2 Circuit Failed Open 4356 3 SCR Line Heater #3 Circuit Failed High 4356 4 SCR Line Heater #3 Circuit Failed Low 4356 5 SCR Line Heater #3 Circuit Failed Open 4357 3 SCR Line Heater #4 Circuit Failed High 4357 4 SCR Line Heater #4 Circuit Failed Low 4357 5 SCR Line Heater #4 Circuit Failed Open 4358 3 DEF General Heater Circuit Failed High 4358 4 DEF General Heater Circuit Failed Low 4358 5 DEF General Heater Circuit Failed Open 4360 3 SCR Inlet Temperature Sensor Circuit Failed High 4360 4 SCR Inlet Temperature Sensor Circuit Failed Low 4360 8 SCR Inlet Temperature - Signal Spike 4360 20 SCR Inlet Temperature Sensor Drift High in Range 4363 0 SCR Outlet Temperature High

July 201588

DD13 DIAGNOSTIC CODES

SPN FMI CODE DESCRIPTION

4363 3 SCR Outlet Temperature Sensor Circuit Failed High 4363 4 SCR Outlet Temperature Sensor Circuit Failed Low 4363 8 SCR Outlet Temperature - Signal Spike 4363 20 SCR Outlet Temperature Sensor Drift High in Range 4364 1 SCR NOX Conversion Efficiency Very Low 4364 18 SCR NOX Conversion Efficiency Low 4375 3 DEF Pump Circuit Failed High 4375 4 DEF Pump Circuit Failed Low 4375 5 DEF Pump Circuit Failed Open 4375 6 DEF Pump Supply Current High 4752 0 EGR Cooler Low Efficiency 4752 31 EGR Cooler Performance Monitor 5016 3 Coolant Valve Supply Voltage Failed High 5016 4 Coolant Valve Supply Voltage Failed Low 5017 3 High Side Digital Output 5 Circuit Failed High 5017 4 High Side Digital Output 5 Circuit Failed Low 5246 0 Regulatory Fault Ignored - Final Action (Speed Limit) 5246 15 Regulatory Fault Ignored - De-rate On 5246 16 Regulatory Fault Ignored - Final Action Pending 5298 14 SCR Abnormal Temperature Rise 5357 16 Fuel Quantity High Detected 5357 18 Fuel Quantity Low Detected 5397 31 DPF Regen Too Often 520231 13 Fuel Mass Signal Not Available via CAN 520232 9 NOx Mass Signal Not Available via CAN 520249 4 SCR Inlet Temperature High

89July 2015