NAVISTAR IC BUS SERVICE MANUAL

What does this catalog contain?

NAVISTAR IC BUS SERVICE MANUAL contains high quality images, diagrams, instructions to help you to operate, maintenance, diagnostic, and repair your machine. This document is printable, without restrictions, contains searchable text and bookmarks for easy navigation.

NAVISTAR IC BUS SERVICE MANUAL includes:

• Numbered table of contents easy to use so that you can find the information you need fast.
• Detailed sub-steps expand on repair procedure information.
• Numbered instructions guide you through every repair procedure step by step.
• Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
• Notes, cautions and warnings throughout each chapter pinpoint critical information.
• Bold figure number help you quickly match illustrations with instructions.
• Detailed illustrations, drawings and photos guide you through every procedure.
• Enlarged inset helps you identify and examine parts in detail.

What will you get when you get this service catalog?

• After payment has been received, a few minutes later.
• Lifetime PDF and Access To Download (By Request).
• Compatible With Windows, Mac, IOS, Android and Other Systems.
• Searchable Text and Built-in Index For Instant Information Search Bookmarks.
• Printable – Pages Or Entire Manual.
• Zoomable – Detailed Exploded Diagrams, Picture.

TABLE OF CONTENT OF THE NAVISTAR IC BUS SERVICE MANUAL

1. OPERATION……………………………………………………………………………………………….1
1.1. VEHICLE CERTIFICATION PLATE……………………………………………………………..1
1.2. DRIVER’S CONSOLE…………………………………………………………………………..3
1.3. WARNING DEVICES……………………………………………………………………………3
Audible………………………………………………………………………………………3
Visual Warning Lights………………………………………………………………………4
Eight Lamp Warning System………………………………………………………………4
1.4. AIR CIRCULATION……………………………………………………………………………..5
Heater/Defroster Controls………………………………………………………………….5
Fresh Air Vent………………………………………………………………………………5
Fans…………………………………………………………………………………………6
1.5. WINDSHIELD WIPER/WASHER SYSTEM……………………………………………………..6
Windshield Wipers………………………………………………………………………….6
Windshield Washer…………………………………………………………………………7
Windshield Washer Container……………………………………………………………..7
1.6. FIRST AID KIT/FIRE EXTINGUISHER/TRIANGULAR REFLECTORS.. . .. .. .. . .. .. . .. .. .. . .. .. . .. .7
1.7. DOOR CONTROLS……………………………………………………………………………..8
Manual Door Control……………………………………………………………………….8
Air Actuated Door Control…………………………………………………………………8
Air Door Dump Valve……………………………………………………………………….9
1.8. VANDAL LOCK SYSTEM……………………………………………………………………….9
1.9. STOP ARM ADJUSTMENT VALVE (AIR ACTUATION)……………………………………….10
1.10. BODY ELECTRICAL ACCESS PANEL………………………………………………………10
1.11. SEAT ADJUSTMENT…………………………………………………………………………11
Forward/Aft………………………………………………………………………………..11
Reclining…………………………………………………………………………………..11
Height………………………………………………………………………………………11
1.12. PRECAUTIONS………………………………………………………………………………12
1.13. REPORTING SAFETY DEFECTS……………………………………………………………14
1.14. COMPONENT INSPECTION INTERVALS……………………………………………………14
1.15. LUBRICATION RECOMMENDATIONS FOR LOCKS AND HINGES…………………………15
2. BUS BODY CONSTRUCTION……………………………………………………………………………16
2.1. HOW THE BUS BODY IS DESIGNED AND CONSTRUCTED. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . ..16
2.2. PROCEDURE FOR REMOVAL AND REPLACEMENT OF RIVETS…………………………..16
2.3. BODY PANEL REMOVAL PROCEDURE……………………………………………………..18
2.4. BODY PANEL INSTALLATION PROCEDURE………………………………………………..20
2.5. FRONT CAP REPLACEMENT…………………………………………………………………21
2.6. SIDE PANEL REPLACEMENT………………………………………………………………..23
2.7. TOUCH UP PROCEDURE FOR NATIONAL SCHOOL BUS YELLOW URETHANE
(KAY0015/CT0066)…………………………………………………………………………….26
Surface Cleaning and Preparation……………………………………………………….26
Metal Preparation and Prime……………………………………………………………..26
Topcoat…………………………………………………………………………………….26
2.8. BODY TIE DOWN BOLTS……………………………………………………………………..27
Description………………………………………………………………………………..27
Maintenance……………………………………………………………………………….27

3. DOORS AND ACCESSORIES……………………………………………………………………………30
3.1. AIR DOOR ADJUSTMENTS…………………………………………………………………..30
3.2. DOOR SPEED…………………………………………………………………………………30
3.3. PRESSURE REGULATOR…………………………………………………………………….32
3.4. DOOR CONTROL SWITCH……………………………………………………………………32
3.5. SIDE EXIT DOORS…………………………………………………………………………….33
3.6. ROOF HATCH…………………………………………………………………………………35
3.7. MAINTENANCE……………………………………………………………………………….35
3.8. OUTWARD OPENING AND FORWARD FOLDING DOOR CONTROL LUBRICATION/
MAINTENANCE………………………………………………………………………………..36
Inspection………………………………………………………………………………….36
Adjustment………………………………………………………………………………..38
Lubrication and Maintenance…………………………………………………………….44
Troubleshooting…………………………………………………………………………..45
4. LETTERING/DECALS……………………………………………………………………………………46
4.1. SURFACE PREPARATION…………………………………………………………………….46
Plastic and Glass………………………………………………………………………….46
Painted Metals and Base Metals………………………………………………………….46
Interior Painted Surfaces…………………………………………………………………46
Temperature Requirements……………………………………………………………….46
Application Instructions………………………………………………………………….46
5. WINDOWS……………………………………………………………………………………………….48
5.1. DESCRIPTION…………………………………………………………………………………48
5.2. REMOVAL PROCEDURE FOR STATIONARY GLASS………………………………………..48
5.3. INSTALLATION………………………………………………………………………………..49
5.4. SIDE WINDOW — GLASS REPLACEMENT PROCEDURE ………………………………….50
6. FLOOR COVERING………………………………………………………………………………………55
6.1. MAINTENANCE……………………………………………………………………………….55
6.2. INSPECTION…………………………………………………………………………………..55
6.3. REPAIR………………………………………………………………………………………..55
7. HEATERS AND ACCESSORIES…………………………………………………………………………56
7.1. GENERAL INFORMATION…………………………………………………………………….56
7.2. MAINTENANCE……………………………………………………………………………….56
7.3. HEATER COILS……………………………………………………………………………….56
7.4. HOSES…………………………………………………………………………………………56
7.5. MOTORS/SWITCHES/BLOWERS AND FANS………………………………………………..56
7.6. ANTIFREEZE………………………………………………………………………………….57
7.7. TROUBLESHOOTING…………………………………………………………………………57
No Heat from the Engine………………………………………………………………….57
No Air Flow From Heater Vents or Ducts…….. ………… ………… …………. ………..59
Access Main Front Heater/Defroster Blower Motors and Resistors Assembly . . . . . . . . . .59
7.8. BLOWER ACCESS……………………………………………………………………………61
Auxiliary/Midship Heater Motor Access………………………………………………….61
7.9. TROUBLESHOOTING ………………………………………………………………………..62
8. SEATS……………………………………………………………………………………………………68
8.1. MAINTENANCE……………………………………………………………………………….68

Upholstery Care and Cleaning Recommendations………………………………………68
Recommended Cleaning Instructions……………………………………………………68
8.2. REPLACING SEAT UPHOLSTERY……………………………………………………………69
SEAT CUSHION……………………………………………………………………………73
SEAT BACK UPHOLSTERY AND FOAM REMOVAL……………………………………..73
DRIVER’S SEAT……………………………………………………………………………73
SEAT BELTS……………………………………………………………………………….73
9. MIRRORS………………………………………………………………………………………………..73
9.1. INSIDE REAR VIEW MIRROR…………………………………………………………………73
Description………………………………………………………………………………..73
Maintenance……………………………………………………………………………….74
Glass Replacement……………………………………………………………………….74
9.2. OUTSIDE REAR VIEW MIRRORS…………………………………………………………….75
Description………………………………………………………………………………..75
Adjustments……………………………………………………………………………….76
9.3. TORQUE CHART………………………………………………………………………………81
10. BODY ACCESSORIES AND MISCELLANEOUS………………………………………………………82
10.1. WINDSHIELD WIPER SYSTEM………………………………………………………………82

Moreover

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle.
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