zxiowa roa ] BUS ESPANA, S.L. MANUAL DE INSPECCION DE SEGURIDAD 8 crows roms iis exrann asZhongtong Bus Product Safety Inspection Manual 1. Purpose Safety is basic guarantee of vehicle operation. Vehicle manufacturer and user both have @ duty to keep bus working well, and the maintenance by user is very important. In order to make sure buses works well and create more value for user, we do the safety inspection manu. 2. Check item and standard () Engine compartment Generator wire, Sater wite, Power wire of AC system, Fuse holder of AC system, Chassis wire, Ground wire of generator, Copper braided ground wire, Turbocharger and lubrication cireuit, Air inlet pipe of intercooler, Exhaust tail pipe, Three-way Catalytic Converter, Air compressor Pipe, Silencer, Fuel pipe, Oil reservoir and pipe, Retarder wires, Preheating wire (2) Battery compartment Positive and negative terminals power wire, Tumbler switch, Fuse holder, Electromagnetic main power switch, Preheat relay, High power control box, Manual switch of retarder, Control box of retarder, Thread holes, relay 3) Others Heater, Pipes and wires near door pump, Wiper linkage, Central cable connector, Fuses and wires, Annihilator, Emergency hammer1 Engine compartment (J). Generator power wire-Engine compartment Check item and standard: Generator power wire should 100 mm away from heat sources (exhaust pipe, turbocharger, exhaust manifold, silencer, air compressor, air inlet of intercooler etc.); Generator power wire should 20 mm away from moving parts; Power wire should be separated with fuel pipe, ‘Treatment measures: Wires with slipshod standards should be redecorated. Ifthe space is too narrow to decorate power wires required, please protect the wire with heat barrier material. Ifthe space is not enough, please separate pipes with special ribbon. b. Check item and standard: ‘The connector of generator wire and generator should be connect well. All washers should be ‘tightened flat without being broken, ‘Treatment measures: Lock loose washer and nut, replace broken washer, clean rust on the connector.©, Cheek item and standard: Generator wire should be fastened well, when the wire crosses between engine and chassis. ‘And the wire should be 40-60mm longer than normaly, Treatment measures: Lock loose fasten point; Adjust pipe when the pipe isnot long enough 2), Starter wire-Engine compartment 4. Check item and standard: Starter power wire should 100 mm away from heat sources (exhaust pipe, turbocharger, exhaust manifold, silencer, air compressor, air inlet of intercooler et.); Starter power wire should 20 mm away from moving parts; Power wire should be separated with fuel pipe. ‘Treatment measures: Wires with slipshod standards should be redecorated, Ifthe space is too narrow to decorate power wires required, please protect the wire with heat barrier material, Ifthe space is not enough, please separate pipes with special ribbon,1b. Cheek item and standard: ‘The connector of starter wire and starter should be connect well. All washers should be tightened flat without being broken. ‘Treatment measures: Lock loose washer and nut, replace broken washer, clean rust on the connector. ¢. Check item and standard: Starter wire should be fastened well, when the wire crosses between engine and chassis. And the wire should be 40-60mm longer than normally. ‘Treatment measures: Lock loose fasten point; Adjust pipe when the pipe is not long enough.(3). Power wire of AC system-Engine compartment 4. Check item and standard: The distance between wire and AC compressor holder baseboard should be more than 20mm; the wire cross parts have different vibration frequency should be fastened well in all pars, ‘Treatment measures! Redecorate wires with slipshod standards, add fasten point when needed and lock nut in fasten point. 1b. Check item and standard: Alll connectors of wire and holders should connect well. All washers should be tightened flat without being broken, ‘Treatment measures: Lock loose washer and nut, replace broken washer, ele(4). Chassis wire harness-Engine compartment a. Check item and standard: “Wires near engine should be fastened in each 300-500mm by stainless steel couplings, and should be tied up by ribbon. Wire hamess, siainless steel couplings and chassis should be fastened together. The distance between chassis wires and moving parts should be more than 20mm, and heat source should be more than 100mm. ‘Treatment measures: Redecorate wires with slipshod standards, fix broken wire hamess. Ifthe space is too narrow to decorate power wires required, please protect the wire with heat barrier material. And please separate fuel pipe and wires with special ribbon. b, Check item and standard: Alll connectors of chassis wires should be fastened well, Wire should be protected with protection strip or protection rubber cot. ‘Treatment measures: Lock loose nut and connector. Add strip or rubber cot when needed.©). Generator ground wire-Engine compartment Cheek item and standard: All connectors of generator should connect well. The contact atea of wire and holder should aint removed and installed by intemal teeth serrated washer and extemal wash her and spring washer. ‘Treatment measures: Lock loose nut and connector. Remove rst and lock the nut with electrical contact protective grease, (6). Copper braided ground wire-Engine compartment Cheek item and standard: All connectors of generator should connect well. The nuts shall be tightened reliably, and the spring washers shall be flattened and no broken. ‘Treatment measures: Lock loose nut and connector. Add strip or rubber cot when needed,(1). Turbocharger and oil lubrication circuit-Engine compartment Check item and standard: [All pipe should in perfect condition, no loosen and no leak problem. Especially the oil lubrication pipe and turbocharger pipe and high presser pipe outlet of air compressor. ‘Treatment measures: Fix pipe or circuit with slipshod standards, lock or fasten loosen nut and make sure all pipes in perfect condition (8). Air inlet pipe of intercooler-Engine compartment Check item and standard: Distance between air inlet pipe and wire hamess should more than 100mm. If space is not cenaugh, please protect the pipe or wire harness with special material ‘Treatment measures: Fix pipe or wire hamess with slipshod standards, and protect the pipes with Heat barrier material(9). Exhaust pipe -Engine compartment Check item and standard: Distance between exhaust pipe and wire or air pipe or oil pipe should more than 100mm. And ‘make sure the exhaust pipe in perfect situation, no cracking or broken problem. ‘Treatment measures: Fix pipe or wire hamess with slipshod standards, and protect the pipes with Heat barrier material, Cheek item and standard: Three-Way Catalytic Converter should be fastened well and no broken, and there is no wire on the top of the converter. The distance between converter and wire or pipe should be more than 100mm. ‘Treatment measures: Fix pipe or wire hamess with slipshod standards, and protect the pipes with Heat barrier ‘material,(11). Air compressor pipe -Engine compartment (Check item and standard: ‘The distance between air compressor pipe and wire hamess should be more than 100mm. And distance between protected pipes should more than 5mm, ‘Treatment measures: ‘Adjust the distance with slipshod standards. And protect the pipes with Heat barrier material (12), Fuel pipe -Engine compartment Check item and standard: ‘The fuel pipe should be installed under wire hamess. Ifthe space is not enough, then fasten pipe and wite with special ribbon. When the fuel pipe on the top of the wire harness, please make sure the connector ofthe fuel pipe should not onthe top of the wire, ‘Treatment measures: When the distance is not enough , please separate and fasten the pipes with special ribbon ‘When the fuel pipe is broken, please clean the greasy dirt and make sure the distance between fuel pipe and heat source or moving parts enough.(13) Steering oil reservoir-Engine compartment Insepect contents and standards The steering oil reservoir and its below direction should keep away from the hamess, cnsuring that no oil drops on the hamess, when charging the steering oil . All pipe couplings should be tightened enough, without oil stain, avoiding the heat source and the movement ‘components, ‘Treatment measures: Ifan leakage is found in the couplings, repair and oil clean them in time.If any steering oil drops on the hamess when charging, clean work should be done in time (14),Retarder-Engine compartment a.Insepect contents and standards The power hamess and the bond strap should be tightened enough, no loosing, reliable, no relative movement , 20mm away from the movement components ,100mm away from the heat source. ‘Treatment measures: If the power hamess or the bond strap is found to be loosen, tighten it in times The power hhamess should be arranged reliablely, bensuring that wires have no relative motion with bus frame. If the wires are near to movement points or heat sources, please adjust to wire hamess and increase the protection measures.b.insepect contents and standards Retarder hamess arrangement, when the suspension is the air suspension,40-60min movement space of the hamess should be kept above and below the sir suspension limit position.when the suspension is the leaf suspension ,100-120mm movement space of the hames should be kept above and below the air suspension limit position. ‘Treatment measures: (15). Ignition line-Engine compartment Check item and standard Ignition line should be locked,no loose .no greasyaway from hot source, move source,no relative motion with edge ‘Treatment measures: If nut loose tighten it,far from hot source move source,no relative motion.clean the greasy intime, For example: (16).Chassis through-holes and edge-Engine compartment Check item and standard When Chassis pipes line pass the through-hole and edge,should be protected by adhesive tape or silicon seal or sealant ‘Treatment measures: TEthe port leakage ,fix itn time, clean greasy. Avoid steel oil spilled on wire harness.if spilled clean it in time For example: 2 Battery compartment (17). Positive and negative power wire -Battery compartment Check item and standard Al connecters fasten well, lock nuts and washer works well and dust cap be installed as required ‘Treatment measures:Lock loosen nuts and clean the joints regular, and make sure the dust cap be installed well (18).Manual switch-Battery Check item and standard ‘The connector is protected well and fastened well, and make sure the distance between manual switch and holder is more than 20mm, ‘Treatment measures: Adjust protection and distance with slipshod standards. (19).Fuse box-Battery compartment Check item and standard Check the A/C’s fuse loose or not, spring washer plate or not ‘Treatment measures: If fuse loose tighten , spring washer plate no burst(20).Power switeh-Battery compartment Cheek item and standard Wither the line of power switch is loose or not Wither the terminal touch the shell ‘Treatment measures: Ifthe line of power switch loose, tighten it, spring washer should be plate can't be brust ‘Adjust terminal in ease of terminal touch the shell For example: (21) Warm up relay-Battery compartment Check item and standard Check the powerline of warm up relay , wither the locking mut loose or not ‘Treatment measures:Ifthe nut loose, tighten the mut, spring washer should be plate can't be burst. For example: (22). High power control box-Battery compartment Check item and standard Check the fuse and al high current mut, if loose then fastening in time, ‘Treatment measures: Ifthe nut loose, fastening in time.. spring washer should be plate can’t be burst. All fuse should in places ean’t be off For example: (23). Retarder power switch-Battery compartment Check item and standard: ‘Check whether the power switch and the retarder fuse box nuts are loose ‘Treatment measures:{itis found that nuts are loose, tighten them in time. Tighten spring cushion unti it flatten, no ‘dynamite phenomenon, (24), Retarder controller-Battery compartment Check item and standard: ‘Check whether the retarder controller wire and grounding wire are loose, ‘Treatment measures: Ifitis found that nus are loose, tighten them in time. Tighten spring cushion until t atten, no dynamite phenomenon,(25). Thread holes-Battery compartment Check item and standard: ‘Check whether the thread holes apron protection in place and there is a wire hamess wear phenomenon. ‘Treatment measures: If found the apron protection doesn’t qualified, protect it timely, When there is a wire harness wear phenomenon, have to repair it timely. (26). Relay-Battery compartment Check item and standard: ‘Check whether relay in battery compartment is fixed reliable, the relay should be fixed on the board with locking serews. ‘Treatment measures: If the relay isn’t fixed firm or become flexible, pleas tight the relay timely.3 Others (27). Warm wind host- Warm wind compartment Check item and standard: Check warm wind host fuel pipes and wire, hamess distance from host shell more than 20mm, ‘Treatment measures: If found the fuel pipes and wire hamess too near from host shell, you should adjust the distance until itis more than 20mm (28). Door pump pipeline- Bus compartment ‘Check item and standard: Check whether the pipeline interfere with door pump linkage, the distance of pipeline and the linkage should be more than 20mm. ‘Treatment measures: If found the pipeline interfere with door pump linkage, please adjust it according to the requirement of process.(29). Wiper linkage- Dashboard inside Cheek item and standard: ‘When wiper linkage assembly operation, check whether pipeline is interference. The distance of pipeline and the wiper linkage should be more than 20mm. ‘Treatment measures: If found the pipeline and the wiper linkage are interference, please adjust it according to the requirement of process. 80). Central connection box- Electrical compartment Check item and standard: Check whether the central connection box muts is flexible, the central connection box ‘main wire should tight in place. Terminal should protect with glue set. ‘Treatment measures: If found protection does not reach the designated position, please protect it timely and adjust the distance of extremely joint and switch plate.31). Fuse and the electrie- Electrical compartment Check item and standard: Check whether the fuse's capability ofthe central connection conform to the design. Prohibit increasing the fuse capability. Prohibit changing the original wire hamess or installation of electrical equipment. ‘Treatment measures: Ifinsurance do not match should be replaced in time, If found there exist secretly install wire hhamess phenomenon, please remove it, arama (32), Fire extinguisher, Emergency hammer Check item and standard: Check whether the fire extinguisher pressure value is above the red range (the pressure ‘value isnot less than 1,2MP). Check whether the emergency hammer equipped. ‘Treatment measures: Tf'it is found that the fire extinguisher pressure values below the red line area, you should be