EB eS eSeane ZHONG TONG BUS ESPANA, S.L. MANUAL DE OPERACIONES Y MANTENIMIENTOIntroduction Thank you very much for choosing Zhongtong Bus. Let your vehicle to obtain the best benefits, is our common goal. But mostly depends on your familiarity with the vehicle and the careful and comprehensive maintenance. Through this manual, you can familiarize with the vehicle operating procedures and maintenance information, so that you can operate and maintain the vehicle to create greater operational efficiency of the vehicle. Due to the continuous improvement and improvement of our products, some of your vehicle equipment or technical status information may not be mentioned in this manual. In case of the above problems, please contact your local dealer. The dealer will give you help or tell you our contact information. Zhongtong Bus Holdings Co., Ltd. is responsible for the preparation, interpretation and technical consultation of this manual. Please refer to "Parts Inquiry and Procurement Process” and "Vehicle Warranty Agreement" for quality warranty and spare parts purchase of our products, or contact our after-sale service department. The after - sales service Contact information: Tel: +86 6358322930, E - mail: service@zhongtong.com.Chapter | Vehicle Information Chapter II Good driving habits Chapter II|_ Compulsory maintenance of new bus Chapter IV Vehicle regular maintenance agreement Chapter V_ Daily maintenance Chapter VI Maintenance Operating Instructions Chapter Vil Common Fault Causes and Troubleshooting COCCOCOOCOEE COLO COO OE OOEE EE OO EEOC OOO OEE OOO EEL OOOE OOOO OE OC OCOEEE CEEChapter! Vehicle Information 1. Vehicle Nameplate Following important information is remarked on the Vehicle nameplate : product trademarks . VIN code, vehicle type. engine model, rated power, total weight. seats number, series number etc. The nameplate is usually located in front of the first passenger door step(picture 1) or after the baffle(picture 2) Some of the vehicle nameplate in front of the passenger door (Picture 3) Please give us the VIN nameplate photo when you buy spare parts or Feedback vehicle failures. E_Zhong Tong Bus Picture 3 2. VIN (Vehicle Information Nameplate) VIN is printed on the frame girder on the inside of the right front wheel and the chassis nameplate is also in this position.Chapter II Good driving habits 1, Precautions before starting the engine 1) Daily inspection of the work must be carried out before starting the engine. The checking contents please refer to inspection of the “daily inspection and maintenance of vehicles’. 2) Turn on the mechanical power switch in the battery compartment; Adjust the seat position, back angle, head height; Adjust the inside and outside mirrors; Turn off unnecessary electrical equipment. 3) For natural gas vehicles. Open the gas cylinder shut-off valve and the supply valve on the control panel (Note: cylinder stop valve and air supply valve should be turned on slowly to prevent the over-flow protect valve close and impact system components, etc.); Check all connectors for leakage phenomenon; Turn on the main power switch, check the digital meter is normal. 4) Fasten your seat belt 2, Start the engine 1) Make sure that the hand brake control vaive is in the braking state. The accelerator pedal in idle position, do not step on the accelerator. The accelerator pedal in idle position, do not step on the accelerator 2) Make sure that the manual transmission shift lever or the automatic transmission operation button is in the neutral position. Close the vehicle's total power switch connected to the circuit. Tum the key switch to "ON" position; wait for 5-10 seconds, until all the electrical equipment ECU self-test is completed and check the alarm light is normal light. 3) Manual transmission vehicle, the clutch pedal to the end, and the key to the START position, start the engine. Automatic transmission vehicle depresses the brake pedal and turns the key to the START position to start the engine. 4) Relieve the key immediately after starting the engine. Each start engine time cannot be more than 10 seconds, if not a successful start, to wait 1 to 2 minutes, and then start again. If the engine is not started three times in succession, the fuel supply system and the electrical system should be checked and restarted after the fault has been rectified 5) In order to prevents the turbocharger to lubricate the bad ablation because of the floating bearing. The engine speed could not be immediately improved or bus could not be immediately moved, the engine should be maintained in idling operation 3 ~ 5 minutes, make sure the oil pressure to 0.2MPA then add the load. 6) Idle operation of the engine is not allowed to exceed 10 minutes. There is insufficient combustion at idle, unburned fuel will form coke, and dilute the oil washed, so long idle operation (10 minutes), will cause poor enginelubrication, causing early wear and tear. If the engine must be idle for a long time, it must be at idle speed (1000 rpm or higher). 7) If there is no oil pressure display within 15 seconds, the oil alarm light is not extinguished, you need to immediately stop and check the lubrication system. 8) When the coolant temperature is lower than 71 °C, do not let the engine running for a long time at low speed. 9) Check the exhaust of the engine for adequate heating operation, check the exhaust color is normal or not, if any exception, refer to the manual vehicle fault diagnosis part of the treatment. 3. The vehicle start moving 1) Check the brake pressure before starting the vehicle, when the air pressure alarm light should not start moving 2) Start the engine, let the engine temperature gradually rose to 60 degrees or more and then start: Moving .the method : slowly depress the accelerator pedal, observe the engine speed table, the table needle indicates 1000 to 1800 rpm. If Engine Speed is too low, maybe cause warm-up too slow; speed is too high, likely to cause the engine to meet overload. Moving after engine temperature above 60 degrees, can extend the engine life of 2 to 3 years. 3) Because the weight of the bus is large, and the weight of the vehicle is not very big change when the full load, in order to extend the life of transmission parts, the vehicle should be start with first gear, and then slowly accelerate. Do not start with 2nd or higher gear 4) Must avoid a large accelerate, rapid acceleration start, The large throttle start maybe cause clutch damage or uneven tire wear 5) Cold season or cold areas, the vehicle should run some distance with first gear and the second gear. The distance should be reduced 4, Vehicle running 1) When the vehicle running please observing whether there is abnormal sound, smell and Observing whether the indicator indicates normal operation especially the oll pressure gauge, water temperature gauge and barometer 2) Once the engine turn off, the brake air supply will stop working; the same time, power steering hydraulic pump will stop working, and the steering will turn heavy. In order to ensure safety, should avoid driving with Refueling - tum off — neutral running. 3) When using the clutch, the separation should be rapid and complete; clutch Incompletely separation is a major reason of damage. Semi-linkage should be avoided, because the semi-linkage directly affect the clutch operation and service life, when finish the clutch operation, foot could not put on the clutch pedal 4) Grasp the timing of the shift can extend the life of transmission system. Do not forcibly shift gears when the vehicle speed and engine speed are notreached . 5) In order to save fuel, choosing the right gear drive, low-grade and high-speed will be fuel costs, high-grade low-speed will be fuel-efficient 6) When driving, will always ensure what the engine speed pointer in a green area, do not let the engine speed into the red zone, do not let the engine speed in the green zone below 7) Water temperature which is outside of the normal range will reduce engine life. If the water temperature is too high, stop the car and cool it by idling. 8) Prohibited neutral gear . the brake distance will be extend if emergence brake because There is no engine braking effect when neutral coasting . This is very dangerous . 9) In the vehicle completely stopped, pause, and then ‘step in the end of the clutch pedal in reverse gear. otherwise the drive system will be damaged soon . It is strictly forbidden to use the handbrake to stop bus in the running!. 5, Brake 1) Whatever the good braking effect or advanced brake facilities , The safety brake driving premise is the enough distance of brake and brake time . 2) Try to avoid the use of emergency brake parking, emergency braking will accelerate the tire and brake friction plate wear 3) Normally the zhongtong bus are fixed ABS system . It can prevent brake lock ,improve brake Directional stability . the braking way can avoid frequent point braking . 4) Vehicles with ABS devices will also drift . ABS function is anti-skid brake lock , Because the bus often use high-pressure air as the brake object .the frequency of Brake lock is low. Seeing the brake lock after a regular intermittent impression is normal . 5) When the vehicle is equipped with retarder or engine exhaust brake, try to use the foot brake and retarder or engine exhaust brake and other auxiliary braking system 6. Turn off the engine 1) Before turning off the engine, make sure that the switch of the high-power electrical equipment such as air conditioner, heater, water dispenser and headlight switch is in the off state. 2) Finish of the driving, no special circumstances could not immediately tum off, should gradually reduce the load. Especially the engine load is high or engine speed is high, the engine temperature is generally high, we recommend that running the engine with idle 3 to 5 minutes, so that the piston, cylinder, bearings and turbocharger components can be fully cooled 3) After the vehicle are turned off , should waiting at least 1 minute and then turn off the vehicle power switch . it can ensure that the electricalequipment self-test or engine exhaust system complete work. If stopping for along time, you need to tun off the battery compartment manual switch 7, Driving across water 1) Do not allow electrical equipment to be soaked in water . A short circuit in the electrical wiring may cause a fire 2) If driving wading, we must pay attention to the vehicle air cleaner, unless the water go into cylinder water and damage the engine 3) Try to bypass, must pass through and other vehicles to maintain the necessary distance, and observe, slow driving. Due to slippery road surface, but also by water, waves and other factors, manipulation is very difficult, we must be careful to control the speed 8, Slope and mountain road 1) Testing the brake function before steep slope or the long slope 2) Frequent use of the brake for a long time, will cause the brake shoe heat decay, reducing the braking force Downhill, the effective use of exhaust braking, retarder lamp auxiliary brake and the main brake match, so that the speed of the vehicle to maintain a safe and controllable range 3) With retarder vehicles, manual switch can be placed in the second gear position, assisting the main brake 4) When the downhill or low gear shift, the engine speed can not exceed the maximum allowable speed. Engine over-speed operation, can cause some parts mechanical failure in the mechanical state. 5 ) Do not turn off the engine when downhill 9, Driving on ice or snow 1) When the vehicle is equipped with anti-skid chain, the vehicle's ABS system may be invalid, using brake will be careful 2) Avoid high speed, rapid acceleration, emergency braking and sharp turns 3) Using low-gear brake, relying on the engine drag to achieve deceleration effect; careful use of foot brake 4) With retarder vehicles, using control handle, change shift cannot be too fast 5) Driving should be keeping enough distance with the front vehicle.Chapter III Compulsory maintenance of new bus Good initial run-in helps the bus reduce fuel consumption, and develop the vehicle performance, extend bus service life, improve the vehicle reliability and economy, while reducing environmental pollution. In the company's proposed run-in period of 3000-5000 km or 2 months, whichever comes first. Please refer to the following table for maintenance work items and technical requirements after the completion of the maintenance. Maintenance projects and technical requirements ite component a maintenance projects. technical requirements | ; ‘According to the engine operating 1 | Engine running maintenance instructions and warranty manual. Inspect and tighten the 2a lana ? The required torque to tighten. engine feet 3._| Check the fuel system No leakage. No air leakage, and hose Check the engine air intake | °°." 998999: 2 4 ane installation is reliable, no loose or m. Engine and e interfere. ancitary |, | Check the engine exhaust | No leakage, exhaust bellows in a systems system. natural, vertical state, and stretch. No water leakage, the cooling 6 | Check the cooling system. liquid level to meet the requirements. Replace the oil in accordance with 7 | Check the fan angle actuator, | "°P1208 ihe oll in acoo the provisions of the oil. Check and adjust the bett 8 : Meet the relevant requirements. tension. Should be se letely, 9 | Check the clutch operation oer ipgre ree comcler smooth joints anes Check and adjust the clutch | 3~5mm Pedal free stroke 20 ~ 10 | pedal free travel, free whee!_| 30mm, clutch cylinder free stroke 3 |_| tip ~ 5mm 11. | Check the clutch hydraulic ol | No leakage, liquid level in the coece cpipeline and joint seal | required range Replace the transmission oil 85W / 90 API GL-4 level (Automatic transmission in | | 12 | and clean the transmission ae a | | accordance with its provisions |__| breather a | __| require oil) Check and adjust the speed Transmissio | 13 4 change mechanism nani T —— | | Check and tighten the Tight, no loosening | transmissio | 14 | | | transmission support rod nsystem ae gg | Check and tighten the drive | 90~100N-m | |_~ | shaft connection nut _ a Lubricate the shaft | 2 # high-quality general-purpose lubrication points | car lithium grease | 85W90 API GL-54i(Meritor rear 47 | Replace rear axle differential | axte and ZF rear axle in gear oil accordance with the provisions Li of the required oil) | | Check and tighten the bolts _| Tight, no loosening | | 18 | and nuts of all components of the front axle Inspect and tighten rear axle | Tight, no loosenin: Front and | er e hee . 19 | housing, differential case, | rear axle __| rear axle bolt and nut : | 2 # high-quality automotive | general-purpose lithium-based | || Perform four-wheel 7 | grease, according to the | 20 | maintenance and tighten . . required torque (Meritor axle, ZF wheel nuts 5 a axle in accordance with its | _| provisions) 21 | Check the tire pressure___| as requested gp | Check and adjust the brake | Free travel: 5 ~ 10mm brake pedal free travel rake +— ee Inspect and tighten the According to the specified torque | | syster \ | 23 | fastening nuts of the front and rear brake shoes24 Check the vehicle brake Adjust the drum gap and the gap between the hand brake disc and the drum as required Brake maximum performance, the pedal stroke should not exceed the full trip of 3/4 25 Check the brake pipe and joint seal No leakage 0~ 1.5mm gametes tires; 1.5 ~ 26 | Adjust the toe vseine 3mm with bias tires a7 | Replace the power steering | Replace the steering cl wth the oil and filter specified oil Steering oe The maximum amount of free 7 28 | Check the steering system | rotation of the steering wheel in the middle position + 10 degrees 9g | Check and tighten the joints | Steering without interference, no of the steering linkage loose ball head, cotter intact Check the fastening bolts Regular tightening by standard 30 | and nuts attached to the | torque chassis gq | Lubricate the entire vehicle | 2 # high-quaity general-purpose lubrication points car lithium grease hock roe ithout oil spill, 32 | Check the shook absorber | Sock absorbers without oil spi card, bolt fastening Other ‘Check and tighten the U-bolt | According to the specified torque : 33 | nut before and after leaf chassis sprin om ~ Check the retarder cl nd e 34 | Check the retarder ee Sr clearance at ee install the fixing bolts ster Check all fasteners for air | All stoners are not loose, replace 35 : the self-locking nut or lock washer suspension : if necessary. Check the air bag height and | According to the provisions of 36 | clean the pressure protection | adjustment, cleaning valve cartridge37 All parts and welds All parts and welds are free of cracks. 38 Lighting and signal devices are normal Terminals in good condition, the Electrical Check the battery pole wiring | 39 : wiring harness and connector is appliances and fixation well fixed Insulation intact, no dawdle, 40 | Check harness ; interference Manual gearbox vehicles do not turn off neutral gear sliding; automatic transmission vehicles 41 | Correct operation F are not neutral driving; not to make the engine idle operation for a long time Technical ; In accordance with the provisions Training “le ma of regular vehicle maintenance, replacement of oil and diesel fuel 42 | Proper maintenance core and filing butter Check the braking routine, the importance of direction Engine maintenance knowledgeChapter IV Vehicle regular maintenance agreement 1, Maintenance instructions The durability, safety, economy and reliability of the vehicle depend on the careful use in the operation and regular maintenance to the designated Zhongtong bus special maintenance station. The driver's driving habits and his love of the vehicle's have a direct impact technical condition and life of the vehicle. The vehicle should be maintained for the period specified in this manual. However, if the vehicle is operating under adverse conditions, it should be appropriate to shorten the maintenance cycle. A Warning: @ if you are not familiar with maintenance procedures, do not check and adjust © Ifthe vehicle fuel is natural gas, do not smoke in the maintenance process, so that the fire source is near the gas or battery liquid and other flammable materials to cause the fre. @ Please note that hair, hands, clothing, tools and other objects are inaccessible to rotating fans and belts and other components. @ Donot service the hot parts of the engine before the engine cools down to avoid injury. People do not lie in the car when use jack jacking vehicles, Ensure that the repair area is well ventilated. Keep the child away from the fluid. Make sure that no debris such as tools or rags are left inside the cover before cover closed. © If the vehicle fuel is natural gas, please check and replace the natural gas. high-pressure stee! braided hose in order to ensure the safety of your vehicle when running 6 months,. If the hose breaks or damages, it will cause a great accident.® Note: © Before welding the vehicle, disconnect all cables of the computer contro! box. © Before servicing electrical equipment, turn off the ignition switch and remove the negative battery cable. Do not use the tool or other metal parts to make short-circuit of the cable to avoid the battery damage. @ Please use quality and reliable maintenance tools to prevent damage and injury. © Never flush the engine surface with water. © Nowater rinse batteries, electronic control module, wiring harness and various plug connectors @ Do not disassemble the plugs of the electronic control module .No touch the metal pins of the plug. © Cut the power supply before disconnect all plugs of the electronic contro! module, unplug the plugs carefully, do not pull the wire harness hard and clean regularly. 2, Periodic maintenance instructions for vehicles In order to maintain a good technical condition of the vehicle, to reduce vehicle failure, to ensure traffic safety, to extend the service life of vehicles, please do the vehicle maintenance in accordance with Zhongtong vehicle maintenance operations 4) Maintenance classification Regular maintenance is divided into: daily maintenance, Level one maintenance, Level two maintenance 2) Daily maintenance Customers and drivers should check and do some jobs before the trip and after the trip: 1. Clean the appearance of the vehicle and keep the vehicle clean and tidy; 2. Check and supplement tire pressure ,all parts of the lubricating oil (grease), fuel, coolant, brake fluid, air conditioning refrigerant and other working media:3.Inspect and calibrate the brake, steering, transmission, suspension, lighting, signal and other safety parts and engine operating status. For details, refer to Chapter 5, "Routine Maintenance" 3) Primary maintenance Vehicles traveling 3000-5000 km to conduct a primary maintenance; If maintenance cycle can not be determined by mileage, vehicle do the Level one maintenance inspection within one month. In addition to daily maintenance operations (clean, lubricate, fastening operations). Check the braking, handling and other safety components. See Appendix A for the contents of the primary and the secondary periodic maintenance work. 4) Secondary periodic maintenance work Vehicles traveling 8000 ~ 12000 km to carry out a secondary maintenance; If maintenance cycle cannot be determined by mileage, vehicle do the Level one maintenance inspection within three months. In addition to the primary maintenance (Check and adjust the steering knuckle, steering arm, brake shoes, suspension, etc.). Dismantling tires, tire change, check and adjust the engine working conditions and exhaust pollution control devices. See Appendix B for the contents of the primary and the secondary periodic maintenance work.Chapter V_ Daily maintenance Dally routine maintenance before driving every day, before driving, driving, after driving inspection and maintenance, is the basis of regular maintenance. Mainly focusing on the observation, clean, the center content is clean, supply and safety inspection. ‘To make the bus best use condition, ZHONGTONG BUS special tips 1, Before Driving 1) Before starting the bus should check indicator in the instrument is working normally, if is unusual should be processed before the car. 2) Check the engine oil, clutch oil, power steering oil and coolant fluid level 3) Check the belt tightness and adjust in time. 4) Check the tires (including the spare tire) tire pressure is normal, the tire appearance is in good condition, tire fixed nut loose. 5) Check the lock the door and storehouse check. 6) Check the steering gear, chassis driving mechanism, operating mechanism and suspension each bolt and nut fastening, and whether there is loose, issuing a phenomenon. Check the steering wheel free stroke, look to whether abnormalities, including the steering wheel free trip to less than 10° 7) Check the chassis all pipeline of oil, gas, urea, lines with and without damage, without bending, presence of wear, interference with other parts. 8) Check sealed and aging of examination admission line and regularly clean air filter element. 9) Check the clutch total free stroke of push rod pump. 10) Before driving the idle state, check whether the runtime engine sound. 11) Check the brake system and the suspension is normal, whether line seal tightly. 12) Cheok whether engine compartment harness have wear phenomenon. 13) The bus with hand switch of retarder, check whether already back to zero; Requirements in a timely manner after using back to zero. 14)Check all external lamps and lanterns (headlights, brake lights, fog lamps, reverse lights, turning lights, contour lights, alarm indicator, etc.), and internal lamps and lanterns (inside light, instrument lights, rocker switch light, reading lamp and ladder step lights, etc.). 15)Clean the battery, check the liquid level and voltage; Check the cable and connectors 16) Check the windshield washer, wiper, horn, defrosting system, cold environment on the windshield washer is used in antifreeze type detergent. 17) Check that all the door lock, be sure to switch is flexible, reliable locking. 18) Check the gas alarm device (natural gas) engine. 19) Check whether the car safety hammer is complete, the skylight is flexible,the vehicle fire extinguisher pressure is normal. 20) The leakage of natural gas lamp drive should focus on inspection before, if there are any exception, have been processed before launch vehicles. 21) To bus emission standards the Europe IV above, check the post-processing exhaust pipe and the exhaust treatment fluid (DEF or urea) level. Tl, During Driving 1) In order to ensure the safety of driving do not operate in the DVD or watch screen 2) In order to ensure the normal of electronic control engine is made, when the engine oil pressure is too low, the water level is too low, the water temperature is too high, air filter blocking alarm lamp or the engine failure indicator, should stop check, troubleshooting; 3) When driving check whether there is abnormal steering wheel oscillation, or tun a great resistance phenomenon; Such as found in a driving wheel is abnormal oscillation, or run a great resistance phenomenon, should immediately stop check, troubleshooting before driving. 4) To equipped with automatic system, engine compartment in an emergency, please use the instrument on the stage of “fire alarm switch start". Til, After Driving 1. Check whether the heat system is emptying completely after parking; Fuel precipitator, gas reservoir, oil-water separator drain automatic door system 2. Check and supplement fuel, engine oil and coolant. When add, replace the clutch oil, forbidden to clutch fluid splash drip on the instrument. 3. Check whether the oil, water and air leakage 4. Check whether the brake drum fever is normal. 5. Check whether the high and low voltage power line is loose. 6. The engine idle time shall not exceed 5 minutes in a row, after driving for a tong time when parking, engine idle for 3 to 5 minutes to stall, for vehicle exhaust level euro V above, need to wait at least 2 minutes then switch off the vehicle power supply work. Uphill should shift in advance, can't drag. 7. For residual gas cylinders focus on natural gas bus, instrument desk when you check the volume will be gas meter and gas cylinder or gas panel scale than view, ensure accurate residual gas cylinders IV, Regularly Check The Project 1. If the bus air conditioning system or warm air system for a long time without use, suggest once every 30 days to start, and run at least an hour 2. If a bus for a long time shut down, it is recommended that the weekly check the battery power, and use external charger charge to the rated voltage.Chapter VI Maintenance Operating Instructions © note: © if the vehicle is running in a relatively harsh conditions should be appropriate to shorten the maintenance cycle. The so-called "harsh conditions" includes the following types: In dusty areas or saline-alkaline areas; On rough roads, flooded roads or steep slopes; Frequent emergency braking: More than 50% of the time at 32 U or higher temperatures in traffic Jams in the urban areas or in the wild high-speed road; © Overloading driving; © Dirty fuel. 1. Engine 1), Inspection, addition and replacement of engine lubricating oil ® CAUTION: Never operate the engine when the oil level is below the “L" low oil mark or above the “H” (high oil level) mark. This causes the engine performance degradation or damage the engine. Note: More critical is to turn off the engine before opening the engine compartment. @® Check the oil level ‘The bus should parked in the horizontal plane, keep the engine placed horizontally to ensure that the measured value is accurate. The correct reading can only be measured when the engine is stopped. Wait at least 15 minutes after the engine stopped, and then check the oil level. At the same time oil flow back to the oil pan. Remove the oil scale, wipe with a cloth, then put the scale back and piug in the end, wait a few seconds, and then remove the oil marked again observed: oil level in the upper and lower marking (as shown).lower marking \ If the oil level is below the lower mark, open the oil cap and add the oil Ifthe "H" (high) mark is exceeded, the excess oil must be removed from the engine oil pan oil drain plug. @ Note: oil can not exceed the scale fine. if oil over the mark, the engine fuel consumption will increase. @ Replace the oil il replacement cycle depends on the use of ol, new engine or overhaul engine, and after the Run-in periods should change new oil. oll condition should be always checked, if the oil color turbidity, even if less than a regular replacement mileage, The oil should also be replaced. ® Special attention! © When replacing the oil, replace the oil filter cartridge at the same time. © Waste oil must stored in a fixed place when replacing oil or oi! filter, So as not to pollute the environment. @ Release the oil Oil should be immediately released after the vehicle driving (ie, engine hot) to ensurethat the dirty oil and dirt can be maximum discharged, Place the vehicle or chassis on a flat ground and leave it for 5 minutes; place the oiling tub undemeath the engine drain bolts; use a wrench to loosen the oil bolts by hand and place the engine oil sump into the oil below until the oil no longer flows out from the engine. Clean the oil drain plug to ensure the bolt is clean. Tighten the oll drain plug according to the specified torque after releasing the oil. The drain bolt should be tighten well and sealed well, oil leakage shall not occur, 4 Warning: © The engine oil temperature may be too high, when loose the oil plug, the oil temperature is enough to bum your fingers. Therefore, wait until the drain plug is sufficiently cooled so that it can be touched by hand. @ Add oil Unscrew the filler cap on the engine top face, wipe clean the fill hole, and slowly fill the oil through the filler hole until the oil is between the upper and lower scale marks of the oil scale. After filling, start the engine and idle for 3 minutes, then shut down, 5 minutes and then check the oil level. Tighten the oil cap after the oil level is correct. 4 Warning. © Keep oil ina safe place and avoid ingestion by children or animals. © When changing the oil, try to avoid oil contact with the skin, When you accidentally touch, then use soap and water thoroughly cleaned. And wash the oil clothes or cloth. © Waste oil and oil fiters should be recovered or properly disposed of il specifications check Appendix oil section © Oilfilter replacement Change the oil fiter when change the oil. Operation as follows: Loosen the engine oil fiter counterclockwise by a special oil filter wrench and then remove it Using a clean cloth, wipe the mounting surface of the filter holder or the sealing gasket. If the gasket is damaged, repiac a new one. Take a new oil fer, add the clean engine oil to the new oil fiter cartridge, Slightly belowthe surface of the filter, to ensure that the oil has enough time to pass through the filter element; And use clean engine oll cover the rubber gasket on its mounting surface, Install the new oil fter on the engine body by hand and rotate it clockwise until the gasket is in full contact with the mounting surface. “Use a special wrench to rotate a certain distance (or a specified torque) from the contact Point as specified. ‘Start the engine, and idjing running. Check the filter seal and the oil pan oil drain plug whether there is seepage, pills, Problem must be promptly ruled out. ‘Tum off the engine. Wait about 5 minutes for oil to flow from the upper engine part. Check the oil level again. Dnote: “The engine oil pressure must be displayed on the meter within 15 seconds after engine start-up. If the oil pressure is not displayed in 15 seconds, immediately stop the engine to avoid any damage. Make sure the oil level in the oil pan is correct. “Tighten the oil filter properly and bring the gasket into full contact with the mounting surface. -To prevent the oll filter from leaking, make sure that the ail filter is tightened; but do not over tighten it as this may cause damage. “if you can not replace it yourself, please go to the authorized service center for replacement. 2) Engine coolant inspection, addition, and replacement @ Check the level of the coolant daily Check that the water level of the coolant wheather between the full and low scal Ifit is too low, open the expansion tank cover to add coolant. Start the engine idle running 5 minutes, so that the cooling system of air excluded, if the water level down, please add up,Coolant addition port ‘When the engine is in the hot state, it should be opened slowly in two steps. The first step: remove the high pressure, but the lid cannot be win down to prevent burns. The second step: After discharged the pressure, then take down the lid. Avoid add a large amount of coolant to hot engine, to prevent any engine parts damage., If there is no coolant under extreme conditions, allow the warm coolant to be added slowly, and add coolant from the fill port to the overflow. Starting the engine, Continue to fill the coolant with the engine running (1000 rpm) until the bottom of the expansion tank filled and theliquid level are stable. Finally, close the lid. & warming: © The water tank lid is not allowed to unscrew when the engine is stil hot. Or hot air and cootant will be sprayed by high pressure. This can easily lead to burns. Must wait for the engine become cool before operation. © Engine antifreeze contains harmful substances, so avoid contact with the skin! © Donot add cold coolant to the hot engine. Otherwise it will damage the engine castings. @ Replace the coolant Coolant should be replaced every two years, the engine runs to 40000km, should wash the engine, replace the new coolant. Replace all coolant systems, open the radiator and other piping switch, through the radiator drain valve emptying the cooling system. When the coolant is added, foosen the vent holes of the liquid heater, radiator, etc., ‘and wait unti the air is not tightened. rN Waring: Coolant is recommended to use the company’s long-term antifreeze rust coolant,Do not use tap water or wells, river hard water.lf you do not use the recommended antifreeze will cause the engine and its cooling system components and other early corrosion problems. The vehicle damage caused by the use of a defective coolant is not covered in the warranty.Long-acting organic coolants must be used for engines with wet cylinder liners, and Fleetguard Fleetcoo! long-lasting organic coolants are recommended. Do not uses seal additives to solve cooling system leakage problems. This can lead to blockage of the cooling system and poor flow of coolant, which causes the engine to overheat. And this may damage the pump seals. Do not use soluble oil in the cooling system. The use of soluble oil will resutt in corrosion of brass and copper, damage to the heat exchange surface, damage to seals and hoses. For coolant specifications, please refer to the attached table 3) After-treatment System inspection Check the appearance of urea tank is normal, check the urea pipeline is normal (Euro IV emission standards and above models) Diesel exhaust treatment liquid (aqueous urea solution) liquid level must be checked daily. It is recommended to visually check the liquid level to avoid the failure of the liquid level sensor. Timely add the liquid when the level is low. ®, Note @) Diesel Exhaust Fluid (DEF) containing urea. Do not allow these substances into the eyes. Immediately flush eyes with plenty of water for at least 15 minutes. Do not swallow. In case of inhalation of diesel exhaust treatment fluid, consult a doctor immediately. @Do not attempt to mix agricultural grades of urea with water to make a diesel exhaust treatment fluid (DEF). Agricultural grades of urea do not meet the required specifications, which may damage the reprocessing system Add urea specifications according to the engine manufacturers to 4) After-treatment Exhaust pipe inspection The exhaust tall pipe must be in the correct orientation, or it must be corrected.5) Oil-water separator release ©For spin-on oil-water separators, turn off the engine and manually open the drain valve. Tum the valve counterclockwise about 3 turns until the valve drops and begins to drain, Drain the water in the separator until you see clean fuel. When closing the valve, lift the valve and rotate it clockwise until itis tightened by hand. Dnote Do not overtighten the valve when closing the valve. Over-tightening can damage the threads. @ For oll-water separators fitted with automatic drain valves, do not need to do the ‘manual drainage. 6) Belt and pulley inspection @visual inspection Multi-wedge belt: Check whether the belt cross-surface cracks. Transverse (belt width direction) cracks are acceptable. Longitudinal (belt length) cracks and transverse cracks are unacceptable. if the belt is worn or a small piece of material is missing, replace the belt. Toothed belt: If the belt is cracked, wom or incomplete, then replace. Small cracks are acceptable. If the beit surface is bright, indicating belt slippage, need to adjust the belt. Pulley: Check the pulley is cracking, pulley whether there is oil, etc., replace the crack pulley, remove oil and other impurities. @ Inspection and Adjustment of Flatness and Belt Deflection of Pulley 1, Inspection and Adjustment of Parallelism of Pulley: 41.1 Straight and active pulley flat fit (as shown in Figure 1), Adjust the difference between the axial and straight distance between the upper and lower ends of the other pulley plane. The difference should be (| $1-82_ | ) <2;4.2 Straight and active pulley flat fit (as shown in Figure 2), Adjust the difference between the left and right ends of the other pulley plane axial and straight rod spacing The difference should be (| P1-P2. |) <1: 2. The gap (| T1-T2 |) between the two belt pulley and the reference wheel: Straight and active pulley flat fit, respectively measure the belt and the two pulleys cut from the benchmark distance T1, 12.2.1, L500, (Lis the center distance of two measuring pulleys, below is the same) Straight and active pulley fiat fit, adjust the two pulley plane axial clearance difference | THT2 1) <2: 2.2, 50012 __ 12 All ___ [555 19 All 10-41 | 2, All the torque compensation clamp tightening torque 8 + 0.5N.m, free torque 0.45N.m, the minimum failure torque 11.7N.m; The torque compensation clamp style is shown below,8) Air tank drain fusing the automatic drain valve, check that the vaive is working properly. If using a manual drain valve, drain the drain valve. 9) Check the shock absorber ~ ‘Visual inspect the shock absorbers without oil spills or damage, the shock absorber i works properly. e The easy way to determine the shock absorber: after properly working the shock absorber should be heat. . ® Note : the damper may be hot = 2, Wheel ~ Tires are the second most expensive part of a vehicle's fuel consumption. Proper a use, careful maintenance is the important factor and way to extend tire life and ensure . the bus safety.1) Tire pressure and tire condition Check the pressure of each tire with the tire pressure gauge, if necessary inflate the tire to reach the required pressure. Specific tire pressure control standards please see attachment tire pressure contro! instructions. Check the tire side there is no out, the tread has no cracks and uneven wear. Such damage can cause the tire to be punctured or burst. If such damage Is found, replace the tire immediately without delay. Check whether there is a foreign body on each tire surface, if found to be removed even if the foreign body, or easy to puncture the tire and deformation of the rim. Note: Even a small nail, the tire will be punctured and even lead to burst 2) Check tire wear Check tire tread depth. If the depth is less than 1.6mm (3.2mm on the highway) the tire needs to be replaced. The depth of the tread should be checked by a 1.6mm mark on the tread, which is evenly distributed on the tire as a sign of tire wear, and when they reach the surface of the tire, the tread pattern Depth is equal to or less than 1.6mm, the tire should be replaced. Rim ring should be installed appropriated. Tighten the tire nut, first press the diagonal direction to tighten it, So that the spherical surface of the nut and the rim of the boit hole on the spherical surface can fit well. After nut and bolt rod centering, then tighten them according to the order of tightening torque. Otherwise the bolt would be easily loose or broken (especially the rear) when bus running D tire use precautions: When assembling the tire, the rim size must meet the technical requirements, no deformation and serious imbalance, and should eliminate the surface of the oil and rust; inside and outside the tire assembly should be sprinkled with talc before powder to protect the rubber,© In the same bridge is not allowed to install different specifications or tires f pattern of different tires, the vehicle j should not be mixed; prohibited front wheel with retread tires. © For every 10,000 km or less, regular transposition of the tire. This will have a significant impact on tire life. ©. Tires should not be overloaded, when =e the rear tire between the tires and tread pattern with stones, should be immediately removed; often check the tire pressure, not the use of ela] low-pressure tire driving. © The toe should be adjusted to within the specified range to avoid premature wear of the tire and to ensure handling stability. © In order to prevent excessive wear and tear of the tire, should try to avoid sharp braking and violent start. © When the vehicle is stopped for a long time, the wheels should be erected and the sun should be avoided... Replace the tire after the vehicle four-wheel positioning, to ensure that the vehicle in a normal state. 3. Steering system 1) Steering hydraulic oil inspection Check the oil level when the engine stops, check the hydraulic oil level, to ensure that the liquid level is not less than 1/2 cup, not more than 2/3 of the oil cup. The liquid level must exceed the filter element. 2) The addition of steering hydraulic oilStart the engine (power steering cover does not cover the engine can not start) Starting the engine, make the engine in idle working condition; turn the steering wheel Until the hydraulic oll level is no longer falling, no bubbles, as well as the entire steering system without "buzzing" sound; Then tum off the engine; add the oil to the liquid level to not less than 1/2 and not more than 2/3 of the oil cup, the oil lid tighten. 3) Power steering oil replacement Put the oll tank under the steering gearbox, Loosen the power steering oil lid, Loosen the oil return fitting direction, the power steering oll outfiow; Start the engine, keep the engine in idle working state; At the same time, turn the steering wheel until the oll no outlet; Shut off the engine, tighten the joints; Refill the power steering oil in accordance with the instructions for adding the hydraulic fluid. Power steering oil specifications check appendix. 4. Clutch system 4.1 Clutch pedal installation height, free travel and total travel requirements: 4.1.1 Adjust the height of the clutch switch to adjust the pedal height, ensure that the distance between pedal center and ground is(135#10)mm_, while ensuring that the pedal of the empty travel is (1045) mm (Press the clutch pedal to the end, to ensure the minimum point of the pedal from the floor is not less than mm, In this case, the lower limit screw must be in effective contact with the clutch pedal arm), Note: When the clutch pedal is in the bottom, adjust the lower limit screw to just touch the pedal arm. Turn the limit screw to 2-3mm in the direction of the pedal to ‘ensure the clutch pedal is in effective contact with the lower limit. 4.1.2 Adjustment method (see Figure 1): ‘adjust the height of the clutch switch so that the clutch pedal center is at a height from the floor (135410) mm. @Loosen the nut on the master cylinder, adjust the length of the top screw, So that the lower end of the plunger and the head of the master cylinder piston hole can contact, at the bottom, Now there is no more clearance between the piston and piston ring whenyou press the pedal; @Mark the putter hexahedron at facing the adjuster side, With reference to the markings, put the putter rotation spin 0.5-1 circle, the gap between the lower end of the push rod and the bottom of the upper hole of the piston is made to be 1 # 0.5mm, At this point the free travel of the clutch pedal to achieve the required requirements of 10mm + 5mm. Note: For the clutch master cylinder is not adjustable structure, can be adjusted by adjusting the pedal screw on the limit to achieve master cylinder free stroke adjustment: Adjust the limit bolts on the pedal so that the lower end of the ball head and the head of the master cylinder piston bottom hole just in contact, Mark the putter hexahedron at facing the adjuster side, Reference is made to the marking, Rotate the putter 1-1.5 turns, So that the lower end of the plunger and the bottom of the piston hole to create a clearance (clearance 1+0.5mm), At this point the free travel of the clutch pedal can meet the specified requirements 10mmt5mm. This free travel, is Cl0+5) 435410) mm Figure 1 Pedal height and free stroke adjustment diagram @Atter the above steps are adjusted, must lock the putter nut and putter fixed sets. 4.2 Coaxial adjustment of clutch master cylinder: (See Figure 2) @ The maximum deviation angle of the clutch master cylinder is not to be greaterthan 3 degrees (In the push rod center distance less than 100mm, the distance from the total pump center less than 5mm), Otherwise it will easily lead to partial wear of the piston, affecting the use of results and service life. @ Detection method: fit a straight ruler with the master cylinder shell, Measure the distance of the push rod from the straight ruler in the direction of the center of the push rod, The distance in the push center should less than 100mm, The distance difference between two measure points less than 5mm. Master cylinder Figure 2 clutch master cylinder rod concentricity adjustment diagram 4.3 Cylinder travel adjustment, inspection: © Cylinder free travel (rocker arm) control at 3-6mm, This travel is controlled when the clutch cylinder is installed: After installation, lock the nut at the point of blue paint to do anti-loose mark. ® Cylinder effective travel not less than 20mm, That the total stroke of the putter is not less than 23mm. 4.4 Clutch oil(brake oil) manual filling method 4.4.1 Prepare before filing @Disconnect the air supply from the clutch cylinder or drain the air in the auxiliary reservoir. @Connect the bleed screw discharge port of the clutch cylinder to the clean container through the transparent tube. @Loosen the cylinder bleed screw. 4.4.2 Clutch oil (brake fluid DOT4) filing and exhaust 4.4.2.4 Clutch oil(brake oil) manual filling methodManual filing clutch oil, the following two methods can be used: Method 1: Use the simple refueling device made by spray water bottles to achieve pressure discharge, exhaust: 1D. Open the clutch cover to remove the filter, fill in the oil pot about 1/3 of the oll volume of the clutch oil, Insert the fuel filler of the olling device directly into the oil outlet of the clutch oiler, and to ensure that the two connect well. 2), Start the refueling device, and step on the clutch pedal, requiring every 2-5 seconds to depress a clutch pedal, the pedal should be steped on the process to ensure that clutch pedal to the end and back in place. Method two: Using gas source pressure to achieve the clutch system of oil discharge, exhaust: 1) Open the clutch cover to remove the filter, refueling to the level of the oiler is not less than 2/3 of the volume of the oiler, tighten the oil cap. 2) Pressurized on a vent hole in the oil cap by compressed air. The air pressure is not less than 0.5Mpa. 3) When the liquid level in the clutch oiler reaches 1/3 of the volume of the oiler, the pressurization is stopped, and repeats the operations in 1), 2) above. 4.4.2.2 Notes @Using the above two methods of clutch oil filing, to ensure that the clutch oil pump cylinder bleed screw at the oil discharge of not less than 1000mi, And there is no bubble in the discharged clutch oil in the transparent hose. When the discharged clutch oil is free of air bubbles, tighten the cylinder bleed screw. Collect the clutch olf discharged in the clean container Until the bubble completely eliminated before re-use., @To step the pedal in 2-5 seconds once (to avoid the clutch cylinder plunger does not retum to lead the clutch putt pushed). Continuously depresses the clutch pedal, step on the process to ensure that the clutch step to the end, back in piace, When the pedal has obvious resistance, keep the clutch pedal of the afterburner state, Unscrew the cylinder bleed screw, discharge the clutch oil containing the air, and tighten the bleed screw immediately, release the clutch pedal. Repeat these work until the clutchpedal is stif @aAtter the clutch pedal is stiff, Follow the method in @ and then repeat the operation 5-6 times, in order to pipe the air row more thoroughly. Finally, tighten the bleed screw to complete the exhaust system clutch. @Check the oil level Make sure the fluid level is between 1/2 and 2/3 of the oller volume and install the strainer and oil cap in place. 4. The method how to check the clutch system air is exhausted ‘The vehicle is parked on the trench, the engine is shut off, and clean compressed air in the clutch auxiliary tank. Measure the free stroke of the clutch cylinder in the trench and record the value S1. Use the normal pedal force (30-40 kgf) to step on the clutch pedal and measure the stroke from the step clutch pedal feel resistance to clutch pedal hardening, and record the value $2 (see below). If $2 s S1* B, means that the clutch system has been exhausted air; If S22 S1 * B, means the clutch system has air, the exhaust operation is required. Note: 8 is the total system leverage, commonly used models of § values are as follows: Models ‘Total Cylinder Travel CoefficientB ‘Sunshine Bus (domestic pump) 51 ‘Sunshine Bus (WABCO) 66 Fashion Bus / Middle passenger | 4.7 bus(domestic pump) Fashion Bus (WABCO) 64 Engine front-mount LCK6120A (WABCO) | 6.1 Engine front-mount bus /school bus | 5.1 (domestic pump)Pedal stroke measurement diagram 4, Brake system 1. Drum brakes 1) Brake gap adjustment Brake gap is divided into two kinds; one for automatic gap adjustment arm, automatic gap adjustment arm according to the actual situation can automatically adjust the brake shoe and the gap between the brake hubs; The other is for manual clearance adjustment: Jack up the wheel and make it off the ground, Use a suitable wrench in the head of the worm shaft and press the locking sleeve inward (If the locking sleeve pressure does not go down, the hammer can gently tap the wrench, and then press the locking sieeve), Toggle the worm shaft and toggle the wheel at the same time, Until the wheel and the worm shaft can not move, Then tum back 1/2-3/ 4 turn, Make sure the wheels are free to rotate.2) Automatic clearance adjustment arm maintenance © lubricating Regularly lubricate the brake gap automatic adjustment arm with a lithium-based grease (fil grease from the nipple) in usually work. (Maximum lubrication of the gap should not exceed 10,000 km). Long-term lubrication of the adjustment arm, arm that no lubrication nipple, do not need regular lubrication. @ Check the reverse adjustment torque Every 20,000 km check once the reverse adjustment torque; attach the torque wrench to the hex nut on the end of the adjustment arm. Tum the wrench counter-clockwise, check whether the hexagon nut (clutch) rotates when the torque is bigger than 18N.m. If yes, must replace the adjustment arm 3) Brake shoes replacement In the maintenance, for the scorched, polished and oil friction of the film must be replaced immediately, Replace the new drum when the brake has any excessive wear; ®D note: The above replacement must ensure that the friction plate (or brake drum) on the same bridge at the same time replacement.The brake should be fully adjusted after replacing the brake shoes. Rotate the arm shaft with a wrench to bring the brake shoe surface into contact with the brake surface, and then rotate it in the reverse direction until the four or five beeps slide down (at this time, the gap is 0.5-0.7mm). The friction plate wear limit is 8.5mm. 2, Pneumatic disc brakes (Code for maintenance of pneumatic disc brakes —\ Check the friction plate jickness. Because it is a new bus, so in this one Inspection can be without demolition, using visual observation can know the current situation; do not need to use other means of detection. Friction plate alarm line detection. Mainly check whether the alarms function is complete, from the dashboard can be directly ‘observed, if the alarm light is always light, means a fault occurs, need to conduct a detailed inspection. Check the connection parts weather solid or lessen, this type of fault can be determined by visual inspection and tapping. I, Brake clearance detection By using the plug gauge can detect the size of the gap can also be a light step on the brake means to see its return to the situation to determine whether the gap within the allowable range. Ey Brake disc detection Mainly to see the working condition of the brake disc surface, with or without scratches and cracks, whether the contact surface to achieve the best running effect, and whether affect the braking effect 2. Check brake cylinder and brake hose. Light step on the brake, Check for leaks, visual brake hose with or without bending phenomenon, air way is smooth or not. (Key Points for Maintenance of Disc Brake @ Friction pads: The friction material is not allowed to wear to a thickness less than 2 mm from theback of the friction pad (Fig. 1), Do not exceed 40Nm, either when adjusting the brake forward or reverse. Do not use pneumatic tools to adjust the brakes. Itis not permissible to use friction pads other than those recommended by the vehicle manufacturer. Do not use compressed air to purge the brake / brake disc area. If the human body inhales dust, ranging from irritating, while it will be hazardous to health. Do not attempt to use compressed air to accelerate drying. Do not pull or over-squeeze the liner wear indicator cable, replace the friction pads. Use a vacuum brush to remove the dry brake dust. Or wipe the area with a damp loth, Replace all friction pads on the complete axle. Visually inspect the remaining service life of the liner for 12,000 miles (20,000 km) or every 4 weeks. The brake is equipped with a visual wear indicator (Figure 2). @ Clamp body Do not use any grease other than those recommended by the vehicle manufacturer. Grease is not allowed to install the piston jacket. The hands should be kept clean and greased. ‘Attempting to remove the worn oval bushing from the housing from the regulator side and chamfering on the other side of the bushing to prevent slipping out of the housing. To replace the piston jacket and guide pin jacket, when found to be damaged Ifthe sheath is damaged, be sure to clean and inspect the relevant components.To check whether the clamp can slide on the guide post (Figure 4), ifthe clamp can not slide freely or the gap is too large, then the need to check the brake guide column liner wear conditions, to mark, remove the clamp body Oval village sets before (Figure 6). To use the correct service tool, when replacing the guide post bush (Figure 7). Be sure to remove it from the side of the tappet (Fig. 8). @service Visual inspection of the remaining life ofthe friction linings shall be made at intervals of 12,000 miles (20,000 km) or 3 months. Lining of the lining wear to 2.0mm (Figure 1), should replace the brake friction pad. Visually check the general condition of the brake system, including whether the sheath is damaged or corroded. If there is any doubt as to the suital of the friction pad, perform further repairs and replace / reset.Check every 12 months or every time the liner is replaced Inspect the guide sleeve and the piston sheath to ensure that they are free of any damage and that they are securely fastened. If there is damage, replace it according to the axle maintenance manual. Check that the clamp assembly can be easily slid onto the brake bracket on the guide post 4).1f the clamp does not slide easily, follow the procedure described in the Service Manual for "Inspection and / or Replacement’ Replace linings When the liner thickness is worn to the remaining 2.0 mm (Figure 1), the brake pads should be replaced and, in any case, replaced with all friction pads on the complete axle. Remove the friction pad retainer and remove the wear warning indicator for the liner. It may be necessary first to reverse the brake to remove the worn brake friction pad Remove the regulator lever shield. Place the appropriate 10 mm socket wrench on the adjusting rod and turn the wrench counterclockwise against the brake chamber (Figure 3). 5. Air suspension 1) Routine inspection 1. Observe the vehicle body whether tilt or not on every day before driving. The air spring (or piping) of one side is leaky if this side is lower. Another way to judge whether the air spring is leaky is as follows: record the heights of some points which are easy to measure after driving back. Measure these heights again on the next day before driving. Then compare the results in order to find out whether the body is descending. 2 Coming to where the air springs are installed when the vehicle parked in the midway or drove back, and then listen carefully. If we can hear the sound of leaking obviously, we should drive the vehicle onto the pit for a further check. Then deal with the problem after confirming the specific leaky location If the check result is abnormal, you must find out the causes and remove the hitch, and maintain it when necessary. 2) Periodical Safety Inspection While checking, the vehicles should be parked on the clean flat, it had better be parked on a repairing ditch, stopped, braked and fixed( this instruction is suitable to all following described inspections and maintenance), Safety Inspection Items:1) Make sure all the fasteners are not loose, no soil, rust or metallic wom substances resulted from loosing around the bolts and nuts . 2) When the feed pressure is over 6.0 bar, the air springs feed normally, the stability degree of the two-side air bags of the same axle are consistent, check there are no worn, mutilation and improperly heave on the air spring and make sure the clearance space around it is over 25mm. 3) Shock absorber works normally without leakage and damage; the simple way to judge whether the shock absorber works normally is: when the shock absorber is hot after driving, then it works normally. Note: the shock absorber may scald your hands. 4) There are no crackle in all the parts and welding. 6. Electric 4, Check and clean of storage batteries Open the battery compartment door and check whether corrosion or Crack phenomenon occurs in the pole of battery and whether the acid is in appropriate height and whether the power line is loosened and whether the battery is fixed tightly etc. The pole that is corroded shall be sanded until the metallic luster shown; distilled water shall be added to supplement the acid; the battery wire shall be connected tightly with the storage battery to ensure the normal start of vehicle and normal charging of electric generator. Replace broken terminals, connectors, or cables If necessary, apply grease to the terminals to prevent corrosion. ® Note: Maintenance-free batteries are sealed and do not require additional distilled water. 2). Inspection of lamps and lanterns of vehicles Open all lamplight circuits and check whether the bulbs in the circuits can work properly. Replace the damaged bulbs based on the correct type and power parameters, © NOTE: When replacing the lamp in your vehicle, you must check the Jamp in advance to see if the voltage and current are the same as before. It is recommended not to directly contact the lamp, it is best to use the necessary gloves and other tools. 3). Inspection of vehicle fuseVehicle fuse is also called fuse protector o fuse wire and serves as circuit protector. ‘When the current is higher than the specified value, the fuse wire shall be fused by its own heat, which shall shut down the circuit to prevent the wire from connecting the circuit and avoid bumout of electric equipment. Thus control the fault to its minimum effect. For the inspection of the front electric controlled box and electric equipment, when the fuse of a certain circuit is broken, immediate inspection shall be made in this circuit and electric equipment. When the fault is removed completed, replace the fuse by the one with the ‘same capacity. The fused safety lever can not be re-used, because it can not have protective effect. ® Caution: Do not use copper wire or other electrical conductors to replace the fuse! 4). Inspection of vehicle relay With regard to electric equipment (generally greater than 8A) with high operating frequency or high power shall be controlled by relay. First of all, check whether relays on Vehicle are all in readiness, and whether there is condition of unfulfilment of insertion, and it shall be removed to normal in accordance with requirements. If relay fails to operate normally, multicenter and other instruments shall be used for measurement. Test whether there is phenomenon of open circuit and short circuit in relay coil; and whether there is phenomenon of erosion and adhesion on normally open contact and normally closed contact of relay, 5). Inspection of control switch of instrument desk Inspect rocker switch on instrument desk and combination switch on steering wheel one by one, and detect whether there is phenomenon of clamping stagnation and damage, if any, necessary maintenance and replacement shall be conducted. 6). Instrument reading and inspection of all warning lights Open power switch and ignition key gear of complete vehicle, and observe whether the reading of six small instruments including motor grease, water temperature, grease mass, air pressure (1, 2), voltage is normal. Check whether warning lights of low engineoil, low air pressure and charging is lit; and check whether work indicator lights of power supply, parking, passenger door and so on are normal. After normal start of engine, all alarm tights shall be turned off, and all indicators in small instruments shall be in green area of scale. If there is warning light appears in alarm phenomenon, fault name of alarm can be detected in accordance with Function Table of Instruments Indicator Lights. Fault elimination can be conducted for related electric equipment until waming light goes out and circuit recovers normal. 7). Inspection of wires around all connectors, generators and starter Connector usually refers to connecting plug and socket, which is used for interconnection between wire and wire or wire hamess and relay or electric equipment. Inspect all connectors exposed to the external to check whether there are conditions of looseness and corrosion. Especially for connection of high-power wires around generator and starter, safety, reliability and complete isolation with heat source and moving ‘components shall be guaranteed. 8). Wiper and scrubber Inspect whether the surrounding of wiper motor is clean, and maintain it dry around the ‘motor. Check whether the doctor blade is aged. It is suggested that wiper blade shall be replaced every year. Check whether the range of blade is suitable, and length of connecting arm shall be promptly adjusted to ensure that the range of blade is within proper scope. Promptly add cleansing fluid into Kettle of scrubber, and promptly check whether wash motor operates normally. Wiper and scrubber are not allowed to use without water. 7. Vehicle body and accessory @ Vehicle body shall be usually kept clean, and dirt shall be promptly cleared after driving every day. It is not allowed to scrape it by tools after drying lest grease paint will be scratched, thus, skin framework will rust. © Sealing rubber strips of doors and windows shall be kept perfectly, and it shall be promptly replaced when there is damage.© tis prohibited to use hot water, salt water, kerosene and other grease fluid which is bad for grease paint to clean paint part of vehicle body. © Constantly check connection between vehicle body and frame, and reapir shall be conducted if any abnormal condition is found. © Constantly check fasteners of internal components and promptly fasten them, © Constantly check conditions of passenger door, and prompt adjustment shall be conducted in case of looseness. © Constantly check lighting conditions of bus, and replacement shall be promptly conducted in case of damage. 1). Kettle for containing detergent of windshield Check kettle of detergent, and detergent shall be filled up with in necessity. Ordinary detergent shall be added in summer. Ant freezing detergent shall be added in winter. 2) External cleaning Cleaning shall be conducted when vehicle body is dirty. Vehicle body shall not be cleaned by salt or damp things in winter to avoid corrosion. During the painting of vehicle body, try to avoid the falling of bird’s excrement on vehicle body! Excrement of birds will pollute and erode grease paint, and it cannot be wiped stainless You can clean your vehicle in accordance with the following description: © Carefully use water pipe to wash smudginess in lower part of vehicle (part of wheel covers of wheels, muddiness around doors and so on.) © Use water pipe to wash vehicle body from top to bottom and avoid that water directly comes into lock hole.© Use cleaning cloth to scrub vehicle body. Warm water or cold water except hot water shall be used. © Use dry cleaning cloth to scrub vehicle body dry. 3) Polishing and waxing If you find that paint loses its original luster, and ordinary cleaning cannot recover its original luster, you shall conduct polishing and waxing for vehicle. Under normal conditions, surface of vehicle shall be conducted polishing treatment in one year. Vehicle shall be cleaned before polishing or waxing. Please select detergent, vehicle wax and other material produced by standard manufacturer. It is not only convenient in using but also can protect paint from oxidation, dirts and darkening and make surface of vehicle body firm, smooth and glossy. Notes: Damage in paint will lead to corrosion and damage of metal part. Therefore, if any paint damage is found, repairing measures shall be taken as soon as possible. Regularly check paint, and it is wise to check whether there is damage in each cleaning. 8. Vehicle interior cleaning Interior decorations and seats generally are washed with soap and water, and as for the dusts hard to clean like grease and shoe-polish, the special cleaning agent is needed and used according to the instructions of manufacture of cleaning agent. Notes: the vehicle interior shall be inspected regularly to ensure the decorative materials and the vehicle pet in side in drying condition, and do not wash it with water. Remember to never use petroleum-based products when you clean the door covering the surface of plastic or fiber products! c Coogee ‘6, Passenger door debugging 6.1. The passenger door swinging outside: First turn on the power and gas, check the door pump system without leakage phenomenon 1, Anti-clamp adjustment: (Debugging air pressure: As the door pump pipeline pressure on the size of the door pump has the greater impact, The provisions of the door pump debugging pressure range 0.6Mpa-0.8Mpa; Door pump debugging tube connector end with a barometer, Displays the door pump commissioning air pressure value. (Door pump working pressure 0.4Mpa ~ 0.8Mpa )> (2)Mechanical anti - folder debugging @When the passenger door is open, the gap between the anti-clamping large nut and the pump cover should has 2 to 5 adjustment gap, as shown in Figure (1) below. Anti-clamping nut along the edge of the adjustment. locking screw flocking block @Fine adjustment anti-folder large nut position: Pneumatically close the passenger door, Fine adjustment of the pump body at the top of the big clamp nut around the top and bottom position; When the air pressure in the 0.6 ~0.65Mpa, the left and right position of mechanical anti-clasp switch contact ball, To the groove width centerline as the base line 1~2, As shown in Figure (2); ball up and down position to prevent the clamp nut up and down the height of the cross-section of the middle line as the benchmark upward 1 to 2, As shown in Figure (3); anti-clamping effective and then tighten the big lock nut clamping screws. ce ‘ ‘Nut gap center line i \\ Mut gap depth centerline Stepping Lights covet ball | Anti-clip electric shock bal Anti-clip nut 4S) KY upper | ~2 @When the air pressure value reaches 0.8Mpa, the mechanical anti-clogging switch contacts the ball up and down and about the ideal position should be anti-folder large nut groove center, as shown in picture (4). Stepping Sa) oti slip lights switch ball switch ball COCEE OOO ELEC EOE OEOCOEEEE ‘ fi Cocee ¢ COCCE EE c © coe eco’ Core@Anti-clamp debugging: In any case,the anti-clog switch contact ball can not contact with the anti-clamping large nut, Hand push passenger door or encounter other external force in door closing process, The rotation of the door pump mechanism will be transformed into an upward movement, Anti-clamp switch contact ball will be in contact with large anti-folder nut, solenoid valve work, The passenger door opens automatically. Anti-clamping large nut position adjustment is not correct; The anti-clog switch contact ball will also contact the clamp large nut, the passenger door automatically open. Rotary column top of the top axis of the top wire, adjustable anti-clamping force of the size; down the big top wire rotation, anti-clamping force increases, otherwise reduced; anti-clamping force should be 100 + 40N. @Step light: open the door, the step staircase ball above the anti-clamp nut and does not touch the nut, step lights on; Closed state, the step staircase ball contact the nut, step lights off. @)Electronic anti-folder debugging: Pneumatically close the passenger door, Anti-clamping nut under the electronic anti-clamping pin -3 to 5, And make the middle position of the nut groove corresponding to the electronic anti-seizure sensing stud (left and right direction), and then tighten the big nut locking screw after the clamping is effective, as shown in picture (5).