C.
ENGINE COMPARTMENT
1.
Steering
Inspection Procedures:
Repair (or note) if:
Out of Service if:
a.
Play
Check for play in the steering system, at the
steering wheel, using the following
procedures:
1)
?
Visual check -
from inside bus with
engine running, rotate steering wheel
lightly from side to side until the
turning motion can be observed at
tires and note free play (lash) at
steering wheel outer diameter.
This
procedure must be performed with
the vehicle on the ground.
2)
?
To check power assist operation run
engine at fast idle, turn steering
wheel a full right and left turn, and
feel for binding, jamming, or belt
slippage.
b.
Column
Check steering column inside bus for up and
down play (parallel to shaft), side to side play
(perpendicular to shaft), and for proper
mounting.
85
Steering wheel plastic is cracked (repair).
(Continued on Page 87)
Free play (lash) exceeds amounts specified
in Chart 8, page 86.
Plastic is cracked or missing so that metal
steering wheel reinforcement is exposed.
Steering wheel is loose on column.
Steering wheel is non-O.E.M. design.
Power assist is inadequate, or there is
binding, jamming, or belt slippage.
Side to side play in steering column exceeds
1/4 inch or up and down play exceeds 1 inch.
Column assembly mounting (including floor
mounting plate) or fasteners are loose.
Supp.
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CHART 8
STEERING WHEEL PLAY (LASH) MEASUREMENTS
Steering Wheel Size
15 inches - 1 3/4” (4.4 cm)
16 inches - 2” (5.1 cm)
18 inches - 2 1/4” (5.7 cm)
20 inches - 2 1/2” (6.4 cm)
22 inches - 2 3/4” (7.0 cm)
Wheel Size:
16 inches or less - 1/4” (6.5 mm)
17 to 18 inches - 3/8” (9.5 mm)
Over 18 inches - 1/2” (13 mm)
86
€
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ENGINE COMPARTMENT
1.
Steering
Inspection Procedures:
Repair (or note) if:
Out of Service if:
c.-h.
?
Steering Gear Box and other
external components will be
checked using the following
procedure:
1)
?
Vehicle should be on ground (not
suspended).
2)
?
With engine running have assistant
move steering wheel back and forth
repeatedly to load steering
components.
3)
?
Visually observe the following
external steering and related
suspension and frame components
for looseness while assistant works
steering (also see specific
procedures under each component):
(Continued on Next Page)
87
Tilt/telescopic assembly (if equipped) will not
stay locked in position.
Steering column U-joint inside the bus (if
equipped) is loose, damaged, or noisy after
lubrication.
Firewall rubber boot at floor (if equipped) is
torn, or ripped, or missing.
Column U-joint (if equipped; see Figure 1,
page 89) is loose, damaged, or noisy after
lubrication.
Flexible coupling, if equipped (rag joint,
Figure 2, page 89) has loose or missing
fasteners, damaged flexible disc, or
elongated holes.
Any column U-bolt, pinch bolt, other column
fasteners, or input shaft coupling is loose,
damaged, or missing.
Supp.
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C.
ENGINE COMPARTMENT
1.
Steering
Inspection Procedures:
Repair (or note) if:
Out of Service if:
a)
Column shaft and hardware.
b)
?
Column U-joints or flexible
coupling (as equipped).
c)
Coupling at gear box.
d)
Gear box.
e)
Pitman arm.
f)
Drag link.
g)
Steering knuckle or arms.
h)
Tie rod ends.
i)
Idler arm (as equipped)
j)
Vehicle frame crossmembers and
frame cross-members and frame
braces (including associate rivets
and fasteners for looseness and
condition).
4)
?
Have assistant carefully operate
steering to full left and right turn and
check for power assist pop-off and
steering stops.
5)
?
As follow-up to the above steering
check, also perform a visual and
hands-on check of each of the listed
components.
See the following
details on pages 91 through 93.
88
Pot joint (shell coupling) rubber is damaged
or torn (repair).
Pot joint if equipped (shell coupling; See
Figure 3, page 89) is loose.
Pot joint (shell coupling) rubber is missing.
Steering gear box is loose on frame, or
fasteners, or lock tabs are loose or missing.
Frame braces or crossmembers are
cracked.
Rivets or other fasteners at frame braces or
crossmembers are loose or missing.
Any axle or suspension component is loose
beyond specifications prescribed elsewhere
in this manual.
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89
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C.
ENGINE COMPARTMENT
1.
Steering
Inspection Procedures:
Repair (or note) if:
Out of Service if:
c.
Steering Gear Box Mounting
Check mounting, condition, and tightness of
steering gear box, and check frame, frame
braces, and associated rivets or fasteners
for looseness and condition.
d.
Pitman Arm
Check the Pitman arm for looseness or
misalignment at sector shaft splines and
looseness at all joints.
Check looseness of
pinch bolt and fasteners and condition of
Pitman arm.
91
Pitman arm grease fitting (if originally
equipped) is loose or missing (repair).
Steering gear box is loose.
There is any binding in steering gear box.
Frame, frame braces, and associated rivets
or fasteners are loose, damaged, or missing.
Any play is observed between Pitman arm
and sector shaft.
Pinch bolt at sector shaft is loose or missing.
Pitman arm to sector shaft-timing marks is
misaligned.
Pitman arm ball-joint (if equipped) has more
than 1/16 inch play (axial, i.e., in and out
play between the ball stud and socket). (See
Figure 4, page 94).
Pitman arm ball-joint (if equipped) has loose
or missing nut, or cotter pin is missing.
Pitman arm is cracked or damaged.
Supp.
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C.
ENGINE COMPARTMENT
1.
Steering
Inspection Procedures:
Repair (or note) if:
Out of Service if:
e.
Drag Link
Check the drag link ends, shaft, and
fasteners for looseness and condition (on
vehicles with I-beam suspension).
f.
Steering Arm
1)
?
Check upper steering arm (Ackerman
arm) and left and right side lower
steering arms for securement and
condition.
2)
?
Check condition and securement of
steering stops and lock nuts.
92
Any drag link end grease fitting (as
equipped) is loose, missing, or will not take
grease (repair).
Drag link end boot is damaged or missing
(repair).
Drag link needs lubrication (repair).
Drag link dust boot (as originally equipped) is
cut, damaged, or missing (repair).
(Continued on Next Page)
Drag link ball stud is loose in pitman arm or
upper steering arm.
Any nut is loose or missing, or cotter pin is
missing.
Drag link shaft is damaged or bent.
Drag link end (nonadjustable type) has more
than 1/16-inch axial play (See Figure 4, page
94).
Horizontal socket type (adjustable) drag link
end has more than 1/16-inch axial or lateral
play.
Any steering arm has been bent, is cracked,
or is damaged.
Any steering arm attachment point is loose,
or any fasteners or cotter pins are missing.
Either steering stop or lock is loose,
damaged, or missing.
Supp.
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C.
ENGINE COMPARTMENT
1.
Steering
Inspection Procedures:
Repair (or note) if:
Out of Service if:
g.
Tie Rod and Ends
Check tie rod ends, tie rod, dust boots, and
clamps or fasteners (as equipped) for
looseness, damage, and condition.
h.
Idler Arm
Check idler arm assembly (as equipped) for
looseness, damage, and condition.
93
Tie rod end dust boot is cut, damaged, or
missing (repair).
Tie rod end needs lubrication (repair).
Any tie rod end grease fitting is loose,
missing, or will not take grease (repair).
Idler arm needs lubrication (repair).
Idler arm grease fitting is loose, missing, or
will not take grease (repair).
Tie rod clamps, fasteners, or cotter pin is
stripped, missing, or loose.
Any clamp (as equipped) is improperly
positioned.
Any tie rod or end is cracked or damaged.
Any tie rod end has more than 1/16 inch
axial play (See Figure 4, page 94).
Tie rod end ball stud is loose in steering arm
or idler arm.
Any idler arm fasteners are loose or missing.
Idler arm is cracked, or damaged, or cotter
pin is missing.
Idler arm up and down play is greater than
1/4 inch total (1/8 inch either direction). (See
Figure 5, page 94.)
Supp.
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FIGURE 4 - Checking the Rod and Drag
FIGURE 5 - Checking Idler Movement, Typical
Link End Movement
A
Movement in the axial direction
must be less than 1/16 inch.
B
Tie rod/drag link free to rotate
within steering arm socket.
1
Tie rod/drag link end
2
Steering arm
94
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C.
ENGINE COMPARTMENT
2.
Batteries
Inspection Procedures:
Repair (or note) if:
Out of Service if:
a.
Holddown
Check for tightness, condition, and type of
battery holddown.
b.
Battery Terminals
Check terminals for cleanliness, tightness,
and condition.
c.
Battery Cables
Check cable assemblies for routing,
securement, condition, and size.
(Continued on Next Page)
96
Holddown assembly or tray is loose,
corroded, or damaged causing insecure
mounting of battery.
Holddown is a flexible strap or other non-
rigid design.
Any terminal is loose, damaged, corroded, or
has missing hardware.
Any positive terminal has missing insulation.
Cable or insulation is cracked or damaged,
or cable is corroded.
Cable is misrouted, unsecured, or grommet
is missing to allow it to abrade on any metal
or sharp edge.
Cable is routed against the exhaust or any
other extremely hot surface.
Cable is smaller than original equipment
size.
Supp.
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C.
ENGINE COMPARTMENT
2.
Batteries
Inspection Procedures:
Repair (or note) if:
Out of Service if:
d.
Cleanliness
€
Check cleanliness of battery or batteries.
€
e.
Tray
Check battery tray for operation, condition,
and securement.
f.
Electrolyte Level
Check electrolyte in battery or batteries for
proper level (if applicable).
97
Battery top or sides are corroded, greasy,
dirty or wet with electrolyte (repair).
Battery slide tray is corroded, dirty, or hard to
slide in and out (repair).
Electrolyte is low (repair).
(Continued on Page 99)
Cable appears to be too small in diameter or
of excessive length (See Chart 9, page 98).
Flat braided engine ground cable is frayed,
corroded, or ends are not secure.
Battery is cracked or damaged.
Battery slide tray securement device or tray
stop is missing or nonfunctional.
Battery tray does not slide in and out.
Battery slide tray or box is damaged or
deteriorated reducing security of battery or
batteries.
Battery box door does not open or will not
stay latched.
Electrolyte is too low exposing plates.
Supp.
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CHART 9
€
CHARGING SYSTEMS CABLE SIZE CHART
€
SYSTEM
VOLTAGE
RATED
OUTPUT
IN
AMPERES
RECOMMENDED MINIMUM CHARGING CABLE GAUGE SIZE
UP TO
4 FT.
4 TO
7 FT.
7 TO
10 FT.
10 TO
13 FT.
13 TO
16 FT.
16 TO
19 FT.
19 TO
22 FT.
22 TO
28 FT.
12
VOLT
0 - 20
14
12
12
10
10
8
8
8
20 - 35
12
10
8
8
6
6
6
4
35
- 50
10
8
8
6
6
4
4
4
50
- 65
8
8
6
4
4
4
4
2
65
- 85
6
6
4
4
2
2
2
0
85
- 105
6
6
4
2
2
2
2
0
105 - 125
4
4
4
2
2
0
0
0
125 - 150
2
2
2
2
0
0
0
00
MAXIMUM DIFFERENCE BETWEEN BATTERY VOLTAGE AND ALTERNATOR VOLTAGE IS 0.5 VOLT FOR 12 VOLT
SYSTEMS AT FULL RATED OUTPUT.
MAXIMUM VOLTAGE DROP IN THE SENSE (#2-TERMINAL-LEAD) MUST NOT EXCEED 0.2 VOLT FOR 12 VOLT 3-WIRE
SYSTEMS.
CABLE GAUGE SIZE CALCULATION TAKES INTO ACCOUNT TERMINAL CONNECTION RESISTANCE.
WHEN AN INSULATED (NO FRAME GROUND) CHARGING SYSTEM IS INSTALLED, LENGTH OF RETURN CIRCUIT MUST
BE INCLUDED TO OBTAIN TOTAL CIRCUIT LENGTH TO DETERMINE PROPER WIRE SIZE.
98
€
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ENGINE COMPARTMENT
2.
Batteries
Inspection Procedures:
Repair (or note) if:
Out of Service if:
g.
Load Test (Optional)
Perform battery load test on battery or
batteries to check condition.
Check battery
or batteries for proper type and load rating.
99
Battery cable length or battery mounting
restricts access to battery or batteries for
servicing (repair).
CHART 10
BATTERY TEST
Remove surface-charge:
Discharge at 300 amps for 15 seconds.
Check for blue haze or smoke.
TEST
Measure electrolyte temperature. Discharge at
1/2 the CCA rating of the battery for 15
seconds.
Battery voltage must not drop below the listed
values during the 15 second test.
Degrees in F
Min.Voltage
70 or over
9.6
60
9.5
50
9.4
40
9.3
30
9.1
20
8.9
10
8.7
0
8.5
Battery or batteries is of insufficient CCA
rating.
Battery fails load test (See Chart 10, this
page).
Supp.
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C.
ENGINE COMPARTMENT
3.
Fluid Levels and Conditions
Inspection Procedures:
Repair (or note) if:
Out of Service if:
a.
Brake Fluid
Check brake fluid and brake power-assist
hydraulic fluid (if equipped) for level and
condition.
b.
Power Steering Fluid
Check power steering fluid level and
condition.
c.
Oil
Check level and condition of oil.
Engine oil is below “Add” mark (repair).
100
Level of brake fluid in either side of master
cylinder reservoir is lower than 1/4 inch from
top or below “Add” mark (if equipped).
Brake fluid or power-assist fluid shows
evidence of excessive water, oil, or dirt
contamination.
Brake power-assist hydraulic fluid is below
cold “Add” mark.
Power steering fluid is below cold “Add”
mark.
Power steering fluid shows evidence of
excessive water, oil, or dirt contamination.
No oil is observed on dipstick.
There is evidence of fuel or water
contamination in the oil.
Dipstick is missing.
Supp.
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C.
ENGINE COMPARTMENT
3.
Fluid Levels and Conditions
Inspection Procedures:
Repair (or note) if:
Out of Service if:
d.
Transmission Fluid
Check level and condition of transmission
fluid.
e.
Windshield Washer Fluid
Check windshield washer fluid level.
101
Transmission fluid is below “Add” mark
(repair).
Transmission fluid shows evidence of
excessive water or dirt contamination
(repair).
Transmission fluid shows need of servicing
(discoloration and/or burnt smell) (repair).
Reservoir is low (note).
Windshield washer
windshield (note).
does not spray
(Continued on Next Page)
Transmission fluid is not present on dipstick.
Transmission fluid above full mark
(overfilled).
Dipstick missing.
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ENGINE COMPARTMENT
3.
Fluid Levels and Conditions
Inspection Procedures:
Repair (or note) if:
Out of Service if:
f.
Coolant
Check coolant (antifreeze) level, condition,
and freeze protection.
102
Coolant level in radiator or reservoir is low
(repair).
Coolant shows evidence of excessive oil, dirt
contamination, or rust and corrosion (repair).
Coolant freeze/boil protection is inadequate
(acceptable freeze protection - 20
�
F or lower
(See Chart 11, page 103; repair).
Coolant
(repair).
Coolant
(repair).
pH level is too high
additive package
or too low
deteriorated
Coolant cannot be seen in reservoir or in
radiator tank with cap removed.
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CHART 11
€
103
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ENGINE COMPARTMENT
4.
Belts and All Hoses
Inspection Procedures:
Repair (or note) if:
Out of Service if:
€
a.
Belt(s)
1)
Tightness
Visually and physically check all drive
belts for proper tension. If available,
use a tension gauge (See Figure 9,
page 106).
If a gauge is not
available, use a ruler to measure the
deflection of the belt(s) up and down
at the widest point between the drive
and driven pulley(s) (See Figure 10,
page 106).
2)
Condition
Visually inspect belt(s) for glazing, oil
contamination, dry rotting, cuts, and
separation of plies.
Check belts for
twisting or distortion.
3)
Routing
Visually inspect belt(s) for rubbing or
contact with objects other than
pulleys and for routing around correct
pulleys.
104
Any belt exceeds tension reading
recommended by manufacturer, if a tension
gauge is used (See Figure 9, page 106;
repair).
Using ruler method, any belt is less than 1/2
inch deflection (too tight) when firm pressure
is applied (See Figure 10, page 106; repair).
Any belt is glazed (note).
(Continued on Next Page)
Any belt tensioner does not pivot or move
freely and apply spring pressure on belt.
Tension on any belt is too loose (based on
specifications of type tension gauge used).
Tension of any belt (using ruler method) is
too loose when firm pressure is applied
(greater than 3/4 inch deflection).
Any belt is oil saturated, dry-rotted, or cut or
plies of belt(s) are separated.
Any belt is twisted or distorted.
Any belt is making contact with objects other
than pulley(s).
Any belt is routed around incorrect pulley(s).
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ENGINE COMPARTMENT
4.
Belts and All Hoses
Inspection Procedures:
Repair (or note) if:
Out of Service if:
€
4)
Belt Alignment
Visually inspect belts for proper
alignment.
105
Any belt is not inline (note).
Belt misalignment is excessive and could
result in failure.
(Continued on Page 107)
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CHECKING BELT TENSION AFTER TIGHTENING
€
FIGURE 9 - Checking Belt Tension
FIGURE 10 - Measuring Belt Tension
Gauge Method
Rule Method
106
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ENGINE COMPARTMENT
4.
Belts and All Hoses
Inspection Procedures:
Repair (or note) if:
Out of Service if:
€
b.
Hose(s)
1)
Clamp(s) and Connections
Visually and physically check that
hose connections or clamp(s) are
tight.
NOTE: References to hoses
include all types of hoses located
in the engine compartment,
including power steering, coolant,
air compressor intake, vacuum,
brake hydraulic assist, engine oil,
and transmission hoses.
2)
Condition
Visually inspect all hoses for cuts,
abrasions and wear, oil saturation,
dry rotting, or “ballooning.”
3)
Routing
Visually inspect routing and
securement of all hoses.
107
Any hose connection or clamp(s) is loose or
is too tight digging into hose (repair).
Any hose is misrouted or unsecured so that
heat damage, abrasion, or cuts could cause
long-term failure (repair).
Any hose connection or clamp(s) is stripped
or damaged.
Any hose is cut, abraded, worn, oil
saturated, dry-rotted, or “ballooned” to the
point that failure is imminent.
Any hose is misrouted or unsecured so that
heat damage, abrasion, or cuts could cause
imminent failure.
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ENGINE COMPARTMENT
5.
Accessory Mounting and Condition
Inspection Procedures:
Repair (or note) if:
Out of Service if:
€
a
.
Air Cleaner
Check air cleaner assembly (housing, lid,
piping, gasket(s), seal, clamp(s)) for
securement, condition, and record filter
restriction. Check for presence of wing nut
and seal (if equipped).
b.
Power Steering Pump
Check securement and condition of power
steering pump.
c.
Air Compressor and Filter
Check securement and condition of air
compressor and filter assembly.
108
Any portion of air cleaner assembly or
mounting is loose or damaged, including
piping, nuts, bolts or clamps (repair).
There are any worn or damaged seals or
gaskets (repair).
There are any air or vacuum leaks or
missing components (repair).
Air compressor air filter (if equipped) is dirty
(repair).
Diesel air filter restriction exceeds
manufacturer’s specifications.
Any portion of the power steering pump,
mounting bracketry or fastener is cracked,
loose, or missing.
Any portion of the air compressor,
compressor air filter (if equipped), filter and
compressor mounting bracketry, filter cover,
or fastener is cracked, loose, or missing.
Hose from engine air cleaner to
compressor is damaged, torn, or missing.
air
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ENGINE COMPARTMENT
5.
Accessory Mounting and Condition
Inspection Procedures:
Repair (or note) if:
Out of Service if:
€
d.
Water Pump
Check condition of water pump and pulley.
e.
Fan
Check fan blade and fan clutch assembly for
securement and condition.
f.
Alternator
Check securement and condition of
alternator assembly.
109
There is evidence of coolant seepage from
water pump, seal, gasket surface, or weep
hole (repair).
Water pump fasteners are loose, damaged,
or missing (repair).
Alternator is noisy (repair).
Water pump is noisy, bearing is damaged, or
coolant is dripping out.
Fan has any cracked, bent, or broken
blades.
Any portion of fan mounting is loose.
Fan clutch is seized or loose.
Any portion of the alternator, mounting
bracketry, or fastener is cracked, loose, or
missing.
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ENGINE COMPARTMENT
6.
Wiring
Inspection Procedures:
Repair (or note) if:
Out of Service if:
€
Routing and Condition
Check routing, securement, and condition of
all wiring and any electrical cable in the
engine compartment.
110
There is any loose, damaged, or corroded
wiring connector or terminal end (repair).
Any repair has been made using improper
gauge wiring (repair; see Chart 12, page
111).
There is any unsecured or poorly routed
wiring that could cause potential short or fire
due to abrasion or heat damage.
There is any burnt wiring or wiring (other
than ground wires) missing insulation.
Supp.
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1
2
3
4
5
6
7
8
9
10
CHART 12
€
PROPER WIRING GAUGE USAGE
€
MAXIMUM LENGTH OF CONDUCTOR IN FEET FROM POWER SOURCE TO LOAD
€
SAE Wire Size
20
18
16
14
12
10
Circuit Current
in
AMPS
ft
ft
ft
ft
ft
ft
15
20
20
36.4
18.2
12.2
9.1
7.3
6.1
5.2
52.3
26.1
17.4
13.1
10.4
8.7
7.4
6.5
5.8
5.2
78.0
39.0
26.0
19.5
15.6
13.0
11.1
9.8
8.6
7.8
5.2
63.0
42.0
31.5
25.2
21.0
18.0
15.8
14.0
12.6
8.4
6.3
99.0
66.0
49.5
39.6
33.0
28.2
24.8
22.0
19.8
13.2
9.9
6.6
78.8
63.0
52.5
45.0
39.4
35.0
31.5
21.0
15.8
10.5
111
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ENGINE COMPARTMENT
7.
Fuel System and Lines
Inspection Procedures:
Repair (or note) if:
Out of Service if:
€
Fuel System and Lines
Visually check the condition, operation, and
securement of all fuel system components,
including fuel lines and routing in the engine
compartment.
112
There is evidence of dirt, algae, or water in
the fuel water separator (if equipped (repair).
There is any unsecured, or poorly routed, or
loose fuel line or hose that could cause
potential fire due to abrasion or heat
damage.
Any fuel system connection is stripped,
loose, cracked, or leaking.
Any fuel system component is damaged or
not mounted securely.
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ENGINE COMPARTMENT
8.
Radiator
Inspection Procedures:
Repair (or note) if:
Out of Service if:
€
a.
Radiator Mounting
Check radiator assembly and mounting for
securement and condition.
b.
Cap
Check condition of radiator cap.
WARNING: ALWAYS USE PROPER
PROCEDURES WHEN REMOVING
RADIATOR CAP.
c.
Reservoir
Check coolant reservoir (including any
deaeration or overflow tank) and sight glass
(if equipped) for mounting and condition.
d.
Fan Shroud
Check fan shroud for mounting and
condition.
113
Any portion of radiator or mounting system is
cracked, damaged, or has loose or missing
fasteners (repair).
Radiator cap is hard to open or close
(repair).
Radiator cap leaks down slowly at p.s.i.
(pounds per square inch) rating (repair).
Radiator cap is of the wrong pressure rating
(repair).
There is any visible damage to the pressure
seat or vacuum relief seat of the cap (repair).
Any portion of coolant reservoir or mounting
system is cracked or damaged, is leaking, or
has loose or missing fasteners (repair).
Any portion of fan shroud or shroud
mounting is cracked, damaged, or has loose,
or missing fasteners (repair).
Radiator cap is missing.
Radiator cap fails pressure test.
Fan shroud is missing.
Supp.
00-1
