User Manuals: GILLIG LOW FLOOR Transit Bus Manufacturer

User Manuals: GILLIG LOW FLOOR Transit Bus Manufacturer

Manuals and User Guides for GILLIG LOW FLOOR Transit Bus Manufacturer. We have 1 GILLIG LOW FLOOR Transit Bus Manufacturer manual available for free PDF download: Service Manual

GILLIG LOW FLOOR Service Manual

GILLIG LOW FLOOR Service Manual (506 pages)

Brand: GILLIG | Category: Buses | Size: 16.74 MB

Table of Contents

Table of Contents
3
Specifications
11
Weights and Measurements
11
Torque Values-Bolts and Nuts
12
Axle & Suspension Torque Values
14
Wheel Nut Torque Values
15
Fluid Specifications
16
Chapter - General Information
19
Important Safety Information
19
Introduction
19
Bus Operation
22
Jacking and Towing
29
Supporting the Coach on Jack Stands
30
Towing Instructions
31
Driveshaft Removal
34
Axle Shaft Removal
35
Welding Precautions
36
Warranty Information
37
Chapter 2- Preventive Maintenance

41
- Adjusting Maintenance Intervals
  41
- Daily Maintenance
  42
- Lubrication Points
  43
- Maintenance Schedule
  45
Chapter 3- Engine

59
- Engine Oil
  59
- Checking the Oil Level
  60
- Probalyzer Sampling System
  61
- Changing the Oil
  61
- Engine Oil Filter
  62
- Oil Pressure Gauges and Senders
  64
- Throttle
  64
- Spinner II Oil Filter
  65
- Fuel System
  70
- Fuel Specifications
  75
- Fuel Tank
  76
- Engine Cooling
  79
- Radiator
  86
- Surge Tank
  89
- Air Intake System
  90
- Exhaust System
  93
- Engine Removal & Installation
  98
- Drive Belts
  104
- Engine Diagnostics
  109
Chapter 4- Transmission/Driveline/Rear Axle

111
- Transmission
  111
- Operation
  112
- Transmission Fluid
  114
- Checking Transmission Fluid Level
  116
- Davco Transmission Fluid Level Gauge
  119
- Fluid and Filter Change Intervals
  123
- Fluid and Filter Change
  124
- Exterior Inspection and Cleaning
  125
- Transmission Fluid Cooler
  125
- Transmission Replacement
  126
- Driveline
  130
- Drive Axle
  134
Chapter 5- Suspension

139
- General Information
  139
- Air Springs
  140
- Shock Absorbers
  143
- Ride Height Adjustment
  146
- Front Suspension
  149
- Rear Suspension
  151
- Rear Axle Alignment
  156
- Suspension Troubleshooting
  157
- Front Axle
  159
- Axle Overhaul
  162
- Steering Linkage
  163
- Front End Alignment
  168
- Front Axle Troubleshooting
  172
- Steering Column
  174
Chapter 6- Air System

183
- Air System Operation
  183
- Suspension Air System Operation
  186
- Kneeling System Operation
  188
- Door Control Operation
  190
- Air Compressor
  193
- Maintenance
  195
- Compressor Removal and Installation
  197
- Performance Testing
  199
- Troubleshooting
  200
- Air Governor (Bendix D-2)
  203
- Preventive Maintenance
  203
- Air Reservoirs
  208
- Valves and Pressure Switches
  209
- Safety Valve
  209
- Check Valves
  211
- Air Lines
  213
- Brake System Operation
  215
- Brake Valves
  215
- Brake Valve (Bendix E-10R)
  215
- Preventive Maintenance
  218
- Retarder Brake Valve Adjustment Procedure
  224
- Relay Valve (Bendix R-12Dc)
  226
- Brake Relay Valve (Bendix R-14)
  233
- Quick Release Valve (Bendix Qr-1)
  238
- Spring Brake Valve (Bendix Sr-1)
  240
- Parking Brake Control Valve (Bendix Pp-1)
  245
- Brake Interlock Solenoid Valve
  246
- Air Dryer (Bendix AD-9)
  247
- Regular Scheduled Maintenance
  247
- Rebuilding the Air Dryer
  249
- Air Dryer Troubleshooting
  254
- Air System Condenser/Separator
  257
Chapter 7- Brakes & Wheels

261
- Hazardous Material Warning
  261
- Brake System
  263
- Maintenance
  264
- System Tests
  266
- Parking Brake
  267
- Brake Chambers
  267
- Rear Brake Chamber Maintenance
  268
- Spring Brake Manual Release
  269
- Removal and Installation of Rear Brake Chambers
  270
- Verifying Brake Adjustment
  272
- Automatic Slack Adjusters
  272
- Automatic Brake Adjuster Checking Procedures
  277
- Troubleshooting Brakes
  279
- Anti-Lock Braking System Operation
  281
- Front and Rear Wheel Hub Assemblies
  283
- Wheels and Tires
  288
- Mounting and Demounting Safety Precautions
  288
- Vehicle Operation Safety Precautions
  289
- Wheel Maintenance
  289
- Wheel Nut Torque
  292
- Wheel Installation
  293
- Tire Maintenance
  295
- Wheel and Tire Balancing
  300
Chapter 8- Hydraulic System

303
- System Operation
  304
- Fan Motor Circuit Valves
  306
- Spool Valve
  306
- Pwm Fan Control System
  308
- Hydraulic Fan Motor
  309
- Troubleshooting the Fan Motor Circuit
  310
- Fan Motor Removal
  312
- Fan Motor Inspection and Repair
  313
- Hydraulic Pump
  315
- Hydraulic Fluid
  315
- Hydraulic Pump Removal
  316
- Hydraulic Pump Overhaul
  317
- Hydraulic System Reservoir
  320
- Hydraulic System Cooler
  320
- Pressure Gauges and Testing
  320
- Bleeding/Filling Power Steering Hydraulic System
  324
- Steering System
  326
- Diagnosis of Problems
  331
- Hydraulic / Steering System Troubleshooting
  332
Chapter 9- Electrical System

339
- Battery
  339
- Battery Maintenance
  339
- Battery Disconnect Switch
  341
- Disconnecting/Removing the Batteries
  342
- Replacing Batteries
  343
- Battery Inspection
  344
- Electrolyte Maintenance
  346
- Battery Testing
  347
- Charging the Battery
  350
- Battery Capacity Ratings
  352
- Common Causes of Battery Failure
  352
- Jump Starting with a Booster Battery
  353
- Battery Equalizer
  356
- Equalizer Troubleshooting
  358
- Equalizer Replacement
  359
- Em70D Electrical System Monitor
  361
- Charging System
  363
- Alternator
  363
- On-Vehicle Charging System Checks
  366
- Alternator Repair
  369
- Alternator Cable/Fuse Installation Procedure
  371
- Starting System
  373
- Multiplexing System
  382
- Multiplex System Connections
  388
- Troubleshooting
  389
- Module Led's
  391
- Diagnosis
  392
- Welding Precautions
  394
- Electrical Panels
  395
- SAE J939 Interface
  398
- Rear Run Box
  400
- Electric Horns
  401
- Fire Detection System
  403
- Fire Suppression System
  405
- Interior Lighting
  406
- Exterior Lighting Equipment
  411
- Marker, Clearance, and Identification Lights
  415
- Speedometer
  416
- Wheelchair Ramp
  417
- Electrical Connectors
  419
- Wiring Harnesses, Junctions, and Connectors
  426
- Chapter 0- Heating / Air Conditioning
  429
- Passenger Heating and Air Conditioning
  429
- System Control
  432
- Driver's Heater and Defroster System
  433
- Booster Pump
  433
- Auxiliary Coolant Heater (Optional)
  441
- Chapter - Body and Interior
  443
- Underbody
  443
- Corrosion Protection
  443
- Exterior
  445
- Side Framing and Skins
  445
- Cobolt/Gusset Connections
  445
- Cobolt/Gusset Repair
  447
- Windshield Wipers
  455
- Access Doors
  458
- Body Repair and Painting
  459
- Interior
  463
- Passenger Doors
  465
- Front Doors
  468
- Rear Doors
  472
- Door Repair
  478
- Windows
  479
- Windshield
  479
- Driver's Side Window
  481
- Window Removal
  482
- Emergency Egress Windows
  483
- Driver's Seat
  485
- Passenger Seating
  496
- Index
  499

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