Maintenance Guide for Foton AUV Bus

FOTON INTERNATIONAL TRADE CO., LTD, BEIJING

Nov 2020
 Contents

Part 1 Overview
Part 2 Running-in maintenance for new vehicle
Part 3 Periodic Maintenance Schedule at All Stages
Part 4 Lubrication oil request
Part 5 Lubricating oil and replacement cycle for the imported product
Part 6 Maintenance items at All Stages
Part 7 Maintenance request for body
Part 8 Other Cautions
 Part 1: Overview
With the increase of running mileage, the technical performance of the vehicle will be gradually reduced, so that the dynamic
property, the economic efficiency and the reliability are reduced. If the rule of technical performance change can be mastered,
some preventive measures can be taken in a timely manner, so the performance, i.e. the power and economic efficiency could be
improved, the maintenance cost reduced and the service life prolonged.
The change of technical performance is related to the structure and usage conditions of the vehicle (road, climate, running
condition, using intensity, driving operation level, maintenance condition, etc.). To determine the maintenance period of the
vehicle, sufficient and credible data are required. In addition to the regular statistical accumulation, a group of vehicles can be
used as the observation object, and some operation tests can be made consciously, so as to obtain the actual usage data of the
vehicle and to formulate the actual maintenance period. The data of the concept of maintenance at all stages, operational content
and maintenance cycle in this Manual are based on the actual data in use in China and has been proved to be effective, especially
for those assembly components and lubrication oil manufactured produced in China. We recommend to overseas users these
practices that have been proven effective in China; however we also encourage overseas users to make appropriate adjustments
based on local conditions.
Vehicle maintenance classification:
In this Guide, the maintenance of vehicle is classified as: running-in maintenance, routine maintenance, 5,000 km maintenance,
15,000 (or 20,000 km maintenance), 60000 km maintenance and 80,000 km maintenance. The purpose, content and cycle of each
class maintenance are different.
Running-in maintenance: The running-in maintenance is only applicable to the newly-used and overhauled vehicle. For the new
vehicle and overhauled vehicle, there are iron filings and impurities unavoidably remain on the components surface and their
matching may not yet in the best state. During the initial operation, a large amount of iron filings are generated, and these iron
filings and impurities will affect the service life of components. The main purpose of running-in maintenance is to remove the
iron filings and impurities by replacing lubricating oil. Meanwhile, during initial running of vehicle, the technical state of the
fitting surface of components changes largely, and the connection between the parts maybe loose, so inspection and fastening of
the fastener are also necessary. Therefore, it is strongly recommended to carry out running-in maintenance of the new vehicle and
overhauled vehicle. It is very effective to prolong the service life of components and reduce the rate of malfunction. The mileage
of running-in maintenance cannot be less than 2500 km or more than 5,000 km.
Note: No need to carry out the running-in maintenance of ZF products for they were finished before delivery.
Routine maintenance: It shall be finished by the end user before or after bus running, and the maintenance contents include as
following: Check if the fuel, lubricating oil and anti-freezing coolant are sufficient, and add them if not enough; Check if the
operating mechanism has looseness, oil leakage or air leakage. And check if the tyre pressure, the lights and the appearance are in
good condition etc.
Every 5,000 km (or 1 month) Maintenance: The main task focuses on tightening and lubricating, as well as some necessary
adjustment items during the maintenance inspection.
Every 15,000km (or 2 months) Maintenance: After the running-in maintenance of new vehicle, this class maintenance shall be
carried out for every 15,000km of running. This maintenance is only applicable to vehicles equipped with Euro 2 engines. In
addition to completing the 5000km maintenance requirements, the following maintenance items will be added: replacement of
engine oil, oil filter element and diesel filter element.
Every 20,000km (or 3 months) Maintenance: After the running-in maintenance of new vehicle, this class maintenance shall be
carried out for every 20,000km of running. After 20,000km running, the performance of the vehicle has some changes, and some
components related to operation safety might have hidden danger, so this class maintenance includes more items. In addition to
those items included in 5,000km maintenance, the following main maintenance items are added: Replace engine oil, oil filter and
fuel filter (applicable to plug-in type extended mileage electric bus). Replace air filter and lubrication oil of electrical air
compressor, Inspect and adjust brake system, steering system, and replace grease of hub bearing etc. Through the inspection and
adjustment, the most performance of the braking and steering system is recovered.
Every 60,000km (or 8 months) Maintenance: In addition to those items included in 5,000km and 20,000km maintenance, the
following main maintenance items are added: replace transmission oil, replace rear axle final drive oil.
Every 80,000km (or 12 months) Maintenance: In addition to those items included in 5,000km and 20,000km maintenance, the
following main maintenance items are added: Replace air drier filter of brake and A/C system, and check if the frame, vehicle
body and other basic components have corrosion, crack or fracture in order to eliminate hidden dangers of the vehicle.
 Part 2: Running-in maintenance for new vehicle
In order to keep the better performance, high efficiency and a long life of the electric vehicle, the vehicle is not allowed to operate
at the maximum output power during the running-in period. Be careful of driving the vehicle and pay attention to any abnormal
conditions of the vehicle. The mileage of running-in period for new vehicle shall be between 2500km and 5,000 km, and the
speed should not exceed 70 km/ h during this period.
Preparation before the vehicle operation
1. Check whether the coolant is enough and there is leakage in the cooling system.
2. Check whether engine oil, clutch oil, steering oil is enough and there is leakage for related parts.
3. Check whether the air pressure and the brake of the vehicle are normal.
4. Check whether the steering system is working normally and there is looseness or jamming.
5. Check whether the electric equipment, lights and gauges are working normally.
6. Check whether the tyre pressure is normal;
7. Check whether the internal and external rear-view mirrors are well.
Notice during running-in period:
1. Correct driving and request to start at 1st gear, smoothly engage the clutch and shift gear, don't impact; It is strictly prohibited
to turn off the engine and run with neutral gear and avoid emergency braking.
2. Speed limit: first gear shall not exceed 10km/h; Second gear not exceeding 20km/h; Third gear not exceeding 30km/h; Fourth
gear not exceeding 50km/h; Fifth gear not exceeding 70km/h; Overspeed is not allowed during this period.
3. Special attention should be paid to the oil pressure and the temperature of the engine coolant within the normal range.
Running-in maintenance items：
System Contents of running-in maintenance Main technical parameters
1. Engine oil Refer to part 4.
2. Replace the oil filter element. Refer to the engine operating instructions.
3. Replace the fuel filter element (only for Euro 2 engine) Refer to the engine operating instructions.
4. Drain water of oil separator element.
5. Drain water of high/low gas filter element(only for CNG engine)
6. Clean air filter element. Use compressed air to blow it from inside to outside, air pressure not more
than 0.4Mpa.
7. Check whether coolant is enough.
Engine
8. Check and adjust tightness of the transmission belt. Pressure under the force of 98N, the deflection is about 10-12 mm.
9. Check and adjust the idle speed of the engine. Refer to the engine operating instructions.
10.Check the sealing of each pipeline and the joint.
11.Check and tighten all connecting bolts.
12.Check and tighten all clamps of air inlet and exhaust pipes and the
connecting parts.
13. Check fuel tank and fuel supply pipes.
14. Check and clean radiator and water expansion tank.
15. Check and tighten engine suspension.
1. Check clutch oil pipe and connector and no leakage.
2. Check whether clutch oil is enough.
Clutch 3. Check and adjust free travel of clutch pedal. Free travel: 30 ~ 40 mm
4. Check and adjust free travel of clutch slave cylinder.
5. Add grease for clutch release bearing.
1. Replace transmission oil. Oil request see part 4.
Transmi 2. Check gear shift mechanism connecting parts.
ssion 3. Check whether there is leakage of transmission.
4. Check and wash the vent hole.
System Contents of running-in maintenance Main technical parameters
1. Check free travel of steering wheel. The maximum free rotation of the steering wheel is at about 10 degrees in
the middle position
Steering 2. Check whether steering oil is enough. It is recommended to use ATF DEXRON III.
system
3. Check steering pipes and sealing of connector.
4. Add grease for drag link ball joint, driveshaft and rocker arm. 2 # Lithium-based lubricating grease
1. Check the operation of the driving and parking braking Lining clearance: 0.60 - 0.80 mm; when fully braking, the pedal stroke
should not exceed full stroke 1/ 2.
Brake
2. Check whether the brake air pressure of the whole vehicle reaches More than 1.0 Mpa.
system
the specified value;
3. Check the sealing condition of the brake pipe and the joint. No leakage.
1. Lubricate extension sleeve of the universal joint pin of the Propeller 2 # Lithium-based lubricating grease
Propelle shaft cross shaft
r shaft 2. Check and tighten the connecting bolts and nuts of Propeller shaft. Refer to vehicle parameter control list.
3. Check clearance of middle bearing and bracket.
1. Lubricate the steering kingpin and adjuster arm and the camshaft. 2 # Lithium-based lubricating grease
2. Check and adjust the front toe in of the front wheel; 0～+2mm for spring suspension; 0～+1mm for air suspension;
3. Check and tighten the bolts and nuts of all components of front axle Refer to vehicle parameter control list.
Front 4. Replace the rear axle gear oil and clean the vent. Use API CL-5 SAE 80W-90 or 85W-90 gear oil.
and rear 5. Check and tighten the bolt of rear axle housing and final drive Refer to vehicle parameter control list.
axle 6. Check and tighten the bolt of half axle. Refer to vehicle parameter control list.
7. Check and tighten wheel nuts. Refer to vehicle parameter control list.
1. Check and tighten all fastening bolts and nuts of body and chassis. No looseness. Refer to vehicle parameter control list.
2. Lubricate all lubrication points of vehicle. 2 # Lithium-based lubricating grease
3. Check shock absorber. When the vehicle has just stopped after driving, it is normal for the
Chassis absorber to have certain temperature, and pay attention to the
high-temperature scald.
4. Check the U-bolts and nuts of spring suspension. Refer to vehicle parameter control list.
5. Check and tighten the bolts of the air suspension. Refer to vehicle parameter control list.
 System Contents of running-in maintenance Main technical parameters
Electric 1. Check whether all lights and instrument cluster are normal.
al 2. Check whether the connection joint of 24V battery is firm and free of If the binding post is oxidized, wash it with warm water of about 60 °C,
system corrosion; and the anti-oxidation of a few drops of oil is allowed.
3. Check low voltage wiring harness. Fixed without suspension, wire harness and plug surface without obvious
wear. The plug-in is firmly connected and there is no ablative contact.
AC 1. Check and adjust AC belt.
system 2. Clean the filter screen of air conditioner return air outlet.

Part 3: Periodic Maintenance Schedule at All Stages

1. Meaning of English letter in the following table: R~ Replacement; I ~ Inspection & adjust; C~ Clean; T~ Tighten; D~ drain water; G~
Grease;
2. The end customer should finish running-in maintenance of new vehicle at 2,500 to 5,000 Km (or 3 months).

Maintenance cycle
*1000km/interval
Maintenance 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
mileage Run
items
Month/interval -in
3 4 5 6 7 8 9 12
month
1. Engine system
Engine oil R R R R R R
Diesel Engine Oil filter R R R R R R
(Euro 2 emission Fuel filter element R R R R R R
standard) Oil-water separator
D D D D D D R D D D D D R D D D
element
 Maintenance cycle
*1000km/interval
Maintenance 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
mileage Run
items
Month/interval -in
3 4 5 6 7 8 9 12
month
Engine oil R R R R R
Diesel Engine Oil filter R R R R R
(Euro 3 emission Fuel filter element I R R R R
standard) Oil-water separator
D D D D D D D R D D D D D D D R
element
Engine oil R R R R R
Oil filter R R R R R
Fuel filter element I R R R R
Diesel Engine Oil-water separator
(Euro 4 emission D D D D D D D R D D D D D D D R
element
standard and Metering injection
above)
pump inlet filter R R
screen
Compressed air filter R R
Engine oil R R R R R R
Oil filter R R R R R R
HP gas filter element D D D D D R D D D D D R D D D D
LP gas filter
D D D D D R D D D D D R D D D D
element(CNG)
LP gas filter element
CNG Engine D D D D D D D D D R D D D D D D
(LNG)
Replace sparking plug R
Replace high voltage
R
ignition wire
Clean mixer C
Clean the electronic
C
throttle
 Maintenance cycle
*1000km/interval
Maintenance 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
mileage Run
items
Month/interval -in
3 4 5 6 7 8 9 12
month
Element of the air filter C C C R C C C R C C C R C C C R
Coolant(replace every 2 years) I I I I I I I I I I I I I I I I
Check and adjust tightness of the
I I I I I I I I I I I I I I I I
transmission belt
Check all pipes and sealing of connectors I I I I I I I I I I I I I I I I
Check and tighten all coupling bolts I&T I&T I&T I&T I&T
Tighten all coupling parts and clamps I I I I I
Check fuel tank and fuel pipes I I I I I I I I I I I I I I I I
Adjust the valve clearance I
Radiator and expansion water tank I&C I&C I&C I&C I&C I&C I&C I&C I&C I&C I&C I&C I&C I&C I&C I&C
Check fuel pump I&C I&C I&C I&C I&C
Check water pump I I I I I
Check inlet and exhaust manifold, muffler,
I I I
exhaust pipe
Check supercharger I&C I&C I&C I&C I&C
Check intercooler C C C C C C C C C C C C C C C C
Check engine suspension I&T I&T I&T I&T I&T
2. clutch system
Check clutch oil pipe and connector and
I I I I I I I I I I I I I I I I
no leakage.
Check whether clutch oil is enough. I I I I I I I I R
Check and adjust free travel of clutch
I I I I I I I I I I I I I I I I
slave cylinder.
Add grease for clutch release bearing. G G G G G G G G G G G G G G G G
3. Transmission
Replace transmission oil. R R
Check whether there is leakage. I I I I I I I I I I I I I I I I
 Maintenance cycle
*1000km/interval
Maintenance 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
mileage Run
items
Month/interval -in
3 4 5 6 7 8 9 12
month
Check gear shift mechanism connecting
I I I I I I I I I I I I I I I I
parts.
Check and wash the vent hole. C C C C C
4. Propeller shaft
Add grease to each lubrication point of the
I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G
Propeller shaft
Check cross joint and bearing I I I I I
Tighten propeller shaft bolt. I I I I I
5. Brake system
Check service brake and parking brake I I I I I I I I I I I I I I I I
Check sealing of brake pipeline and joint I I I I I
Check air dryer (replace once year) I I I I R
Drain water of brake reservoir I I I I I I I I I I I I I I I I
Check aire reservoir and safety valve I I I I I
Check brake exhaust system I I I I I
Check retarder work condition I I I I I
6. Axle and tyre
Check tyre and wheel rim (texture depth,
I I I I I I I I
steel rim state)
Check and tighten the rear axle housing
and differential housing, back cover I I I I I
half-shaft bolt and nut of rear axle housing
Check and tighten half axle bolt and nut I I I I I I I I I I I I I I I I
Check and tighten nut of final drive flange I I I I
Lubricate the steering kingpin and brake
I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G
adjustment arm and the camshaft bush
Check and tighten wheel bolt and nut I I I I I I I I I I I I I I I I
 Maintenance cycle
*1000km/interval
Maintenance 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
mileage Run
items
Month/interval -in
3 4 5 6 7 8 9 12
month
Tyre rotation I I I I
Four-wheel maintenance (cleaning
I&G I&G I&G I&G
bearing, replacing lubricating grease)
Change gear oil (for Free maintenance
I I I R I
axle)
Check wear of brake drum and friction
I I I I
lining and adjust clearance of lining
Check and tighten brake bottom plate I I I I
Clean final drive vent hole C C C C
Replace rear axle oil R I I R I
Check and adjust front toe in I I I I I
Lubricate steering tie rod ball joint I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G
7. Suspension system
Check the tightening of leaf spring, hoist
I I I I
eye, bracket
Check air suspension wheel base I I I I
Check air suspension (height, skin etc.) I I I I I
Check wear of stabilizer bar and hoist bar
I I I I I
bush
Check suspension fastening parts I I I I I
Check leaf spring bush and lubricate it I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G
Check shock absorber I I I I I
8. Steering system
Check whether steering oil is enough
I I I I I I I I I I I I I I I R
(replace once year)
 Maintenance cycle
*1000km/interval
Maintenance 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
mileage Run
items
Month/interval -in
3 4 5 6 7 8 9 12
month
Replace steering oil filter element R
Check sealing of oil pipeline I I I I I
Check free travel of steering wheel I I I I I
Tighten all steering parts and bolts I I I I I
Check and lubricate steering drive shaft
ball joint, drag link ball joint. Replace if I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G I&G
damaged.
Check dust boot of steering column I I I I I
9. Electric system
Check whether all lights and instrument
I I I I I
cluster are normal.
Check whether the connection joint of
I I I I I
24V battery is firm
Check low voltage wiring harness and
I I I I I
plugs.
10. Body frame
Check whether there is rust and crack for
I I I I I
body frame.
Check air spring and support bar of
I I I I I
compartment door.
Check sealing strip of door and
I I I I I
compartment door.
Check and tighten seats. I I I I I
11. CNG supply system
Check the fittings and seals for gas
I I I I I I I I I I I I I I I I
cylinders, aeration panels and gas lines
 Maintenance cycle
*1000km/interval
Maintenance 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
mileage Run
items
Month/interval -in
3 4 5 6 7 8 9 12
month
Drain water in the gas system pipeline D D D D D D D D D D D D D D D D
Check whether the gas leak alarm device
I I I I I I I I I
is working normally
Clean and inspect engine gas system parts I I I I I I I I I
Clean and check the ignition distributor
I I I I I I I I R
and high voltage cable
12. AC system
Clean air conditioner return air filter
C C C C C C C C C C C C C C C C
screen
Clean the filter screen of condenser and
C C C C
evaporator core
Check and fasten parts in air conditioning
I&T I&T
cover assembly
Check whether the evaporating fan and
I I I I I
condensing fan are working normally
Check air conditioning wiring harness and
I I I I I
connectors
Check that the compressor has no
I I I I I
abnormal sound during normal operation
Check AC belt tensioning I I I I I I I I I
Check the refrigerated oil of the
I I I I I
compressor
13. Heat system
check fuel supply system before use
(independent heat system)
Check the pipeline of heat system before
use
Notes:
1. The axle and transmission case involved in the schedule are made in China. The oil change period of the main decelerator is
every 60,000 km or 6 months, whichever comes first. For the maintenance period and oil selection of ZF product, please refer to
the standards specified by ZF company.
2. The replacement period of the coolant is every 300,000 km or 2 years, whichever comes first;
3. The air filter element can be cleaned with compressed air of 0.4 MPA or less after the vehicle runs for a certain mileage. The
cleaning cycle shall be properly adjusted according to the conditions of use. Under condition of heavy dust, the interval shall be
properly shortened. The air filter element shall be cleaned immediately when the air filter blockage alarm light is on. The
cleaning cycle can also be extended properly in a clean environment, and the number of times of dust removal with compressed
air cannot be more than 5 times. (Blockage of the air filter element can increase the fuel consumption. The possibility of the filter
paper breakage increases while cleaning with compressed air, and the small holes on the filter paper can lead to early wear of the
engine).
 Part 4: Lubrication oil request
1. Fuel recommendation
A. Diesel (diesel vehicle only): diesel with cetane value not less than 45 specified in GB 252-2011 standard only. The sulfur
content shall not be higher than 0.2%.
B. No. 0 light diesel: applicable to areas with risk rate of 10% and the minimum temperature is above 4 °C
C. No. -10 light diesel: applicable to areas with risk rate of 10% and the minimum temperature is above -5 °C
D. No. -20 light diesel: applicable to areas with risk rate of 10% and the minimum temperature is above -14 °C
E. No. -35 light diesel: applicable to areas with risk rate of 10% and the minimum temperature is above -29 °C
F. Natural gas (only for natural gas vehicle): Natural gas with a methane value of low to 65 can be used.
2. Engine oil
The quality grade and viscosity grade of the oil must be considered when the engine oil is selected
A. Engine oil quality level:
For Euro engine: It is recommended to use the engine oil equivalent to the API CH-4 of the American Petroleum Institute or
higher quality;
For Euro 3 engine: It is recommended to use oil equivalent to the API CH-4 of the American Petroleum Institute or higher
quality;
For Euro 4 engine (without EGR): It is recommended to use oil equivalent to the API CI-4 of the American Petroleum Institute or
higher.
For Euro 4 (with EGR) and Euro 5 engine: It is recommended to use the engine oil equivalent to the API CJ-4 and above of the
American Petroleum Institute.
Special engine oil for the natural gas engine is required rather than the oil used for diesel engine;
Note: If the engine oil is specified in the engine instruction, the instruction shall prevail.
B. Engine oil viscosity:
The viscosity grade of the lubricating oil is of the same importance as the quality grade. It is recommended to select the suitable
viscosity grade according to local temperature. Lower viscosity oil can help the engine start under low temperature conditions,
but frequent using of it, which may reduce the service life of the engine. The following figure shows the temperature application
range of each type of oil (as shown in the figure).

0W

5W‐20

10W‐30

15W‐40

20W‐50

20

30

40

‐30 ‐20℃ -10℃ 0℃ 10℃ 20℃ 30℃ 40℃

10W-30 engine oil can be used in winter, and 5W-20 engine oil can be used in extreme cold season, and 15W-40 oil is
recommended for all other seasons.
3. Gear oil
As with the engine oil requirements, the transmission and the main decelerator gear also require the gear oil of certain quality and
viscosity grade.
A. Quality grade: Mechanical gearbox made in China (bus length more than 6 meters) requires the Grade API GL-5 gear oil,
such as ZF6S500, QJ5S400, QJ5S500, QJ5S600, WLY5S100，ZF6S1650,ZF6S1700，QJ805,QJ1205,QJS6-100, QJS6-90，
QJS6-160 etc.
Mechanical rear axle made in China (bus length more than 6 meters) requires the Grade API GL-5 gear oil.
Oil for imported transmission and axle, see part 5 Lubricating Oil and Replacement Cycle of Imported Products.
B. Viscosity grade:
For bus (length more than 6 meters), it is recommended to use the SAE 80W-90 (in winter) or SAE 85W-90 (in summer) gear
oil; In tropical areas, 85W-140 is recommended; In cold area, the appropriate viscosity grade of gear oil can be selected according
to the ambient temperature;
 75W

80W‐90

85W‐90

90

‐40 ‐30℃ -20℃ -10℃ 0℃ 10℃ 20℃

4. Power steering hydraulic oil:

The ATF DEXRON III is recommended as power steering oil. For the oil of the ZF direction machine, please refer to part 5
Lubricating Oil and Replacement Period of Imported Products.
5. Clutch oil:
The Grade DOT3 synthetic brake fluid is required and to be replaced every 80,000 km or 1 year, whichever comes first.
6. Chassis lubricating grease:

1) It is recommended to use high temperature class 2 lithium-based grease for wheel hub (for example: Mobil XHP222,

temperature range: -30 ~ 280°C,best working temperature range: -20 ~150°C), and the end customer should replace the grease of

wheel hub bearings in running-in maintenance of new vehicle, afterwards, the hub bearing shall be cleaned and the grease shall

be replaced for every 20,000 Km;

2) ZF axle has special provisions for brand and model and replacement cycle of grease, please refer to Part 5.

3) For other grease points of the chassis, it is recommended to use class 2 lithium-based grease (the temperature range of -30 ~ +

120 °C).

4) For automatic centralized lubrication system, it is recommended to use 0#, 00# or 000# lithium-based grease. The common

grease shall not be used， otherwise the pipeline could be blocked due to excessive viscosity.
7. Coolant for cooling system

Long-acting organic antifreeze should be added to cooling system. The coolant can reduce the freezing point and also increases

the boiling point of cooling system, at the same time, it has ability to prevent scale formation and prevent corrosion of cooling

system components.

It is recommended to use the Great Wall YF-2A organic antifreeze(Mobil or Shell Glycol organic coolant) with a freezing point

below -45 °C and its replacement cycle is 300,000 km or 2 years (whichever comes first). It is also possible to select antifreeze

with similar performance, but the different type coolant should not be mixed.

Notes: The antifreeze of certain brands may have a corrosive effect on the water seal of the engine water pump of a specific brand.

In use, if water pump leakage happens is encountered after replacement of the anti-freezing solution, the anti-freezing solution

factor shall be taken into consideration..

 Part 5: Lubricating oil and replacement cycle for the imported product
1. Oil and replacement cycle for ZF product
No. Product Oil Table Recommended oil Note
Mobil ATF DEXRON III is recommended
For hydraulic oil replacement period
Replace hydraulic oil at first: 500,000 km.
1 Steering box TE-ML 09 of other hydraulic oil products, please
After the hydraulic oil is replaced at first, replace the hydraulic oil only
see oil products table.
when steering system is repaired or the parts are replaced.
No. 2 lithium-based grease is recommended.
Front wheel hub: It has been already filled with class 2 lithium-based
grease at ZF factory, the customers do not need to make running-in For grease replacement period of
2 Front axle TE-ML 12 maintenance. other grease products, please see oil
Replace grease for kingpin: every 80,000km or 1 year (whichever comes products Table.
first, the following same).
Replace grease for wheel hub bearing: every 2 years.
Gear oil: It has been already filled with gear oil at ZF factory, the 1. For gear oil replacement period of
customers do not need to make running-in maintenance. Ecofluid X is other oil products, please see oil
recommended. products table.
TE-ML 12 2. For tropical area, please see oil
Replace gear oil: normal operation (every 150,000 km or 3 years),
hot-country or region (every 60,000 km or 1 year). And need to check products table.
3 Rear Axle 3. Hot country or region:
gear oil level regularly. 1) The monthly average temperature
Rear wheel hub: It has been already filled with grease at ZF factory (must exceeds 25°C in more than 2 months
use Fuchs Renolit LX-PEP 2), the customers do not need to make within a year.
TE-ML 12 2）or if temperatures rise above 40°C
running-in maintenance.
Replace grease for rear wheel hub: every 250,000 km or 2 years. on more than 7 days in a year.
Ecofluid M is recommended.
Replacement period:
1. On the poor road and with speed of 0-20 km/h, the oil change period is
Mechanical 200,000 or 2 years, whichever comes first. For oil change period of other oil
4 TE-ML 02 2. For short-distance passenger bus or bus, of which speed is 20-60 km/ h,
transmission the oil change period is 360,000 or 3 years, whichever comes first. products, see Oil Table
3. For bus or passenger bus for long-distance operation of which the speed
is above 60 km/h, the oil change period is 540,000 or 3 years, whichever
comes first.
Automatic It is recommended to use Ecofluid A+. For oil change period of other oil
5 TE-ML 14
transmission Replacement period: 150,000 km or 3 years, whichever comes first. products, see Oil Table
Note:

1). All oil tables can be downloaded from ZF official website (www.zf.com)..

2) Running-in maintenance of new vehicle is no need for all ZF products. The oil and filter shall be replaced according to ZF oil

products table.
2. Other imported parts
(1) Allison transmission: It is required to use the special oil for TES 295 Allison transmission with an oil change period of
120,000 km or 3 years.
Note: Running-in maintenance is not required for the Allison transmission.
(2) VOITH transmission: It is recommended to use the Mobil ATF DEXRON III automatic transmission oil with an oil change
period of 60,000 km or 2 years, whichever comes first. The oil change period shall be 120,000 km or 3 years, whichever comes
first, if oil is changed as recommended in the VOITH oil product list H55. 633638.
Note: Running-in maintenance is not required for the VOITH transmission.
 Part 6: Maintenance Items at All Stages
1. 5000 km maintenance items
System Maintenance item Main technical parameters
Check the engine oi l and filter (1) Check the oil level of the oil in the specified range; (2) Check the oil seal of the
engine for no oil leakage
Check the belts (1) Check the deflection of the belt. Under the force of 98 N, the deflection is 10 –
12 mm. (2) The belt is free of crack and damage.
Clean the debris adhered to the water tank and check the No leakage of the coolant, lack of coolant, good fastening of the water pipe clamp.
Engine coolant Remove the paper piece, leaves etc adhered to radiator.
Clean air filter element Use compressed air to blow it from inside to outside, air pressure not more than
0.4Mpa.
Check the inlet and exhaust pipes There is no air leakage, and each clamp is well fastened.
Check the oil supply system Remove the accumulated water from the oil-water separator, and the oil pipe joint is
free of leakage.
Check and adjust free travel of clutch slave cylinder.
Clutch Add grease to clutch release bearing. 2 # Lithium-based lubricating grease
Check whether clutch oil is enough. DOT3 brake fluid
Transmissi Check whether there is leakage. Handle it and add lubricating oil.
on
Propeller Lubricate universal joint pin, split joint of the Propeller 2 # Lithium-based lubricating grease
shaft shaft
Lubricate the steering kingpin, adjuster arm and the 2 # Lithium-based lubricating grease
camshaft bush
Front and Check and tighten bolt and nut of half axle Refer to vehicle parameter control list.
rear axle Check and tighten wheel bolts and nuts. Refer to vehicle parameter control list.
Lubricate tie rod ball joint. 2 # Lithium-based lubricating grease
 System Maintenance item Main technical parameters
Check the power steering hydraulic system There is no oil leakage in the pipeline, and the oil level of the oil pot is between the
Steering upper and lower scale lines.
system Lubricate the ball joint of the steering drive shaft and drag 2 # Lithium-based lubricating grease
link.
Check air reservoir and drain water.
Brake
Check the operation of service and parking brake Lining clearance: 0.60 - 0.80 mm; when fully braking, the pedal stroke should not
system
exceed 1/ 2 of full stroke;
Suspension Check and lubricate leaf spring bush. 2 # Lithium-based lubricating grease
Check and adjust AC belt.
AC system
Clean the filter screen of air conditioner return air outlet.
Lubrication Add grease to all lubricating points. The grease nozzle is complete and effective, and the 2 # lithium base grease is filled.
CNG Drain water of CNG pipes. Applicable to CNG and LNG vehicle.
system

2. 15,000 KM maintenance items

1) This item is applicable to the vehicle equipped with Euro 2 diesel and CNG engine.

2) In addition to the maintenance according to the operation item of 5000 km, the following items are added.
System Maintenance item Main technical parameters
Replace the oil as recommended in the above and check whether
Replace engine oil
Euro 2 diesel there is any oil leakage.
Engine Replace oil filter element Use genuine spare parts only.
Replace fuel filter element Use genuine spare parts only.
CNG/LNG Replace engine oil Use special oil for CNG engine.
engine Replace oil filter element Use genuine spare parts only.
 System Maintenance item Main technical parameters
Check gas cylinders, gas panels, gas line connectors and seals
Check whether the gas leak alarm device is working normally
Check and replace gas filter element and filter element seal ring Replace gas filter element every 30,000km.
Clean and inspect engine gas system parts. Follow engine manual for maintenance.
Clean and check the ignition distributor and high voltage cable

4. 20,000 KM maintenance items

In addition to the completion the items of 5000 Km, the following items are added.
System Maintenance item Main technical parameters
Replace the oil as recommended in the above and check whether there is
Replace engine oil
any oil leakage.
Replace oil filter element Use genuine spare parts only.
Replace fuel filter element Use genuine spare parts only.
Diesel Engine The rotor of the supercharger is flexible in rotation, without jamming, the
Check turbocharger and lubricating oil pipe
(Euro 3 and above) clearance is within the specified range, and there is no oil leakage.
Check crankcase ventilation Normal operation, no leakage.
Cushion should not be askew, crack, it is recommended to replace once
Check engine mounting and tightness
every 2 years.
Check cooling pipes No leakage.
For areas with bad roads and more dust, the replacement mileage of air
Intake system Replace air filter element
filter element should be shortened appropriately.
 System Maintenance item Main technical parameters

If the clutch is shaking and slip, the clutch shall be disassembled and the
clutch plate must be replaced when the depth of the rivet head of the
Clutch Check clutch operating conditions clutch plate and the surface of the friction plate is less than 0.2 mm, and it
is recommended to change the front bearing of the transmission on the
crankcase at the same time when the clutch plate is replaced.

Normal operation of the control mechanism, no noise, jump gear,

Check the control mechanism and clean the air vent
disorderly gear phenomenon; Free vent.
Transmission
Check countershaft flange lock nut. Flange no clearance, no shaking.
Check all transmission connection bolts and tighten Refer to vehicle parameter control list.
1）Connect reliably without air leakage.
Check and clean the air cylinders, air dryer assembly 2）The safety valve works normally, and the air pressure is 0.8Mpa or
and safety valve. 1.0MPa.
Brake system 3）Replace the air dryer filter if there is water in the air cylinders.
Check and tighten brake valve and the joints of brake
The pipeline joints are connected reliably without air leakage.
pipeline.
Check ABS condition. Check whether ABS light is on in the instrument cluster.
1) Check the air pipe around the retarder, and check the wiring harness for
scorched marks; The clearance between the rotor and stator of the retarder
is normal.
Auxiliary braking Check retarder system or exhaust brake system 2) Check the air pipe around exhaust pipe, and check the wiring harness
for scorched marks;
3) The exhaust brake or retarder is working normally
Front axle Toe in of leaf spring suspension: 0～+2mm, toe in of air suspension: 0～
Check and adjust the front toe in.
+1mm
 System Maintenance item Main technical parameters
1) Use the dial gauge to measure the radial runout of brake drum. The
radial runout of brake drum against the axis should be less than 0.1 mm,
and the difference between left and right brake drums should be less than
Disassemble front wheel hub and brake drum 1 mm. If any of above cases has happened, we need to boring the brake
assembly, Check the wear of brake drum and brake drums.
friction lining. Boring the brake drum or replace them 2) When the inner diameter of brake drum is larger than 4 mm to the
if necessary. original size, replace the left and right brake drum at the same time.
3) If the distance between the surface of the friction lining and rivet head
is less than 0.5 mm, replace the left and right friction lining at the same
time.
Disassemble the brake shoe and support pin. Clean
the parts such as knuckle, bearing, support pin, and Clean and no greasy dirt.
brake floor plate, etc.
Front axle The brake floor plate is not deformed and the fixing bolt is no looseness.
Check brake floor plate and fasten connecting bolts. Tighten according to the torque value in "The Vehicle Parameter Control
Table"
1） The steering knuckle shall be no crack and damage, and the screw
thread shall be in good condition with the nut. It shall be free of radial
looseness, and the anti-loose washer shall be in good operation and the oil
Check steering knuckles and oil seal, check lock
seal is in good condition without oil leakage.
washers and nuts, check steering knuckle arms and
2） The fit gap between the steering knuckle shaft and bearing shall be
kingpin bush.
less than 0.1mm, and the bolts of knuckle arm are no looseness.
3） The kingpin bush shall be replaced when the fit gap between kingpin
bush and kingpin is greater than 0.2 mm.
The bearing roller cage is not broken, the rollers don’t fall off and has no
crack and ablation, and the inner ring of bearing is no crack and ablation,
Check inner and outer hub bearing.
and the bearing does not run around outer circle and is closely matched
with bearing seat.
 System Maintenance item Main technical parameters
1） The brake shoe is no crack and no obvious deformities, the friction
lining is not broken and the riveting is reliable.
Check brake shoe and support pin. 2） There is no excessive wear on the support pin, and the fit gap
between the support pin and brake shoe support hole is not more than 0.2
mm.
Check brake shoe return spring. No obvious deformation and good tensile force.
1） The hub is no crack, and the outer ring of bearing is no crack, no
pitting, and no damage.
Check front wheel hub, brake shoe and bearing outer
2） The brake drum is no crack.
Front axle ring, and tighten the bolts of wheel.
3） The wheel bolts are completely intact and the specifications are the
same. Tighten the bolts according to the tightening torque table.
1） Assemble the support pin of brake shoe, and grease the support pin
hole, and the cotter pin or circlip shall be complete and effective.
2） Fill grease into the hub bearing and apply some grease in the inner
cavity of wheel hub, we recommend using Mobil XHP 222.
3） The surface of the brake drum and brake shoe shall be clean and no
Assemble front wheel hub, replace the grease of hub
greasy dirt.
bearing, and adjust the tightness of front wheel
4） The gap between the brake lining and brake drum is 0.3-0.6mm at the
bearing and adjust brake clearance.
end of cam. At the end of same side, the gap difference between the brake
lining and brake drum is less than 0.2 mm.
5） The wheel hub is very flexible rotation and can be rotated without
axial clearance (First tighten the locking nut, and then rotate the lock nut
counterclockwise by 90 degrees).
Check and tighten the bolts and nuts of rear axle
Tighten according to the torque value in vehicle parameter control list.
housing and final drive assembly.
Rear Axle Check and tighten the flange nuts of final drive
Tighten according to the torque value in vehicle parameter control list.
assembly.
 System Maintenance item
Dissemble wheel hub assembly and brake drum
assembly, disassemble the brake shoe and support
pin. Clean brake floor plate and half axis sleeve pipe
and all other parts.
Check brake floor plate and brake camshaft.
Assemble the brake floor plate and tighten the
connection bolt.
Check half axis sleeve pipe, locking nuts and oil seal. 2) The oil seal is in good condition, and the oil seal is no leakage.
Rear Axle
Check inner and outer hub bearing.
Check brake shoe and support pin.
Check brake shoe return spring.
Check half axis
Check and clean the vent of rear axle housing.
Main technical parameters
1）The vent hole on the rear axle housing is unblocked.
2）Half axis sleeve pipe and all other parts shall be clean and no greasy
dirt.
1） Tighten according to the torque value in vehicle parameter control
list. The camshaft is very flexible rotation and free of clamping, the axial
gap of camshaft should be less than 1 mm, and the radial gap is not more
than 0.3 mm.
1) The sleeve pipe should have no obvious crack and looseness, and be
close fit with the locking nut and no radial looseness.
3) The fit gap between the sleeve pipe and hub bearing is less than 0.1
mm.
The bearing roller cage is not broken, the rollers don’t fall off and has no
crack and ablation, and the inner ring of bearing is no crack and ablation,
and the bearing does not run around outer circle and is closely matched
with bearing seat.
1) The brake shoe is no crack and no obvious deformities, the friction
lining is not broken and the riveting is reliable.
2) There is no excessive wear on the support pin, and the fit gap
between the support pin and brake shoe support hole is not more than 0.2
mm.
No obvious deformation and good tensile force.
The half axis has no obvious bending, crack, does not grind the sleeve
pipe, its spline has no excessive wear or distortion.
No blockage.
 System Maintenance item
Check rear wheel hub, brake drum and outer ring of
hub bearing. Check half axis bolts and wheel bolts.
Tighten half axis bolts and wheel bolts.
Rear Axle
Fill hub bearing grease, assemble rear wheel hub 4) The brake shoe and brake drum surface shall be clean and no greasy
assembly, and adjust brake clearance.
Main technical parameters
1) The brake drum and wheel hub is no crack, and the outer ring of hub
bearing is no looseness and damage.
2) We use the dial gauge to measure the radial runout of brake drum. The
radial runout of brake drum against the axis should be less than 0.1 mm,
and the difference between left and right brake drums should be less than
1 mm. If any of above cases has happened, we need to boring the brake
drums.
3) When the inner diameter of brake drum is larger than 4 mm to the
original size, replace the left and right brake drum at the same time.
4) If the distance between the surface of the friction lining and rivet head
is less than 0.5 mm, replace the left and right friction lining at the same
time.
5) The half axis bolts and wheel bolts are complete and effective, Tighten
them according to the torque value in vehicle parameter control list.
1) Assemble the support pin of brake shoe, and grease the support pin
hole, and the cotter pin or circlip shall be complete and effective.
2) Fill grease into the hub bearing and apply some grease in the inner
cavity of wheel hub, we recommend using Mobil XHP 222.
3) The surface of sleeve pipe shall be coated with oil before the hub
bearing is installed.
dirt.
5) The gap between the brake lining and brake drum is 0.6-0.8mm at the
end of cam. At the end of same side, the gap difference between the brake
lining and brake drum is less than 0.2 mm.
6) The wheel hub is very flexible rotation and can be rotated without
axial clearance (First tighten the locking nut, and then rotate the lock nut
counterclockwise by 90 degrees).
 System Maintenance item
Tighten the fixing bolts of the steering parts.
Steering system
Check the sealing of steering system pipelines.
Check the working condition of cross shaft.
Check and tighten the connecting bolts and nuts of
the propeller shaft.
Propeller shaft
Check middle bearing damping gasket.
Check middle bearing and bracket.
Check and tighten the U bolts or I bolts.
Check the tightening of leaf spring, hoist eye, hoist
eye brackets and bracket rivets.
Check wheelbase of the vehicle with air suspension
system.
Suspension system
Check the working condition of the air bellows.
Check the tightening and working condition of shock The fastening bolts of the shock absorber are not loosened, and the shock
absorber.
Check the wear of the rubber bushes of the stabilizer
bar and hanger bar.
Check other connecting bolts of suspension system
Check the wear of tyres pattern, replace the tyres Air pressure of tyres: Refer to air pressure indicated on the tyre. The four
Tyre assembly when the wear is serious; install the tyre assemblies tyres are cross transposition on every 20,000 km. If the depth of tyre
with cross transposition.
Main technical parameters
1) The steering rocker arm and knuckle arm have no bending or cracking,
the connecting bolts of each part are fastened reliably, and the steering
ball joints are not obviously loose. 2) Tighten according to the torque
value in vehicle parameter control list.
No leakage.
The cross shaft is no looseness and no stick and abnormal noise.
Tighten according to the torque value in the vehicle parameter control list.
If there is any looseness, apply anti-loosening glued to the threads before
tightening.
No crack and damage.
The bracket is not loose, and the clearance of the middle bearing is not
more than 3mm.
Tighten according to the torque value in the "The Vehicle Parameter
Control Table".
1) No looseness, no crack, no fragment, no dislocation.
2) Tighten according to the torque value in the vehicle parameter control
list.
We can add or take away the washer of push rod to adjust left and right
wheelbase, the diagonal error should be controlled within 10mm
Adjust the air bellows height to the standard height, the air bellows should
be clean, no oil and other dirt, no scratches, no twisting defects.
absorber works normally without oil leakage.
Replace them if necessary.
Tighten according to the torque value in the vehicle parameter control list.
treads is less than 3.2 mm. The tyre should be replaced. The left and right
 System Maintenance item Main technical parameters
tyres shall be replaced at the same time, and the brand, specification and
pattern shall be consistent.
The unbalance of wheel and tyre assembly is less than 2000g.cm after
Check dynamic balance of wheel and tyre assembly.
dynamic balance.
1) Headlight, horn, combination instrument and signal device are
Low voltage functional and effective.
electric parts and Check, adjust and replace if necessary 2) The wiper motor is in good operation and the linkage rod is
wire harness connected reliably.
3) The wire harness is fixed reliably, and the insulation is good.
Check the sealing of the passenger door and
The sealing is good.
compartment doors.
Vehicle body/ Check the support rod or oil-gas spring of the
Work properly.
Chassis frame compartment doors.
Check the chassis frame and body frame for The chassis and body frames, body cover skin and weld are no cracks and
corrosion or cracking. no rust.
The installation is firm, and the front and rear locking functions are
Check driver's seat
reliable.
The installation is firm and reliable, and the rear angle adjustment locking
Check passenger's seat
function is effective.
Check the duct of A/C system and control panel of The installation and fixing of duct is reliable, and the control panels are
reading lamp. effective in function.
Interior facility The installation is firm and no water leakage, and the working condition is
Check ventilation device of the interior roof.
normal.
1) The safety belts have good performance and reliable connection.
Check the safety equipment. 2) The fire extinguisher and emergency hammer are complete and
effective.
Check the interior roof, seat cover, carpet and curtain
Clean, complete and firm.
and handrail.
 System Maintenance item Main technical parameters

Check the electromagnetic clutch and fill the grease. Normal operation, no noise.

AC system Clean the condenser and evaporator. Clean, no dust.

Check cooling fan of condenser and evaporator.
Check refrigerant and refrigerant amount.
Check the fuel and water heating pipeline.
Heating System
Check the electric unit of heating system
Normal operation, no noise.
In accordance with the request and add if not enough.
No crack, oil leakage, air leakage, water leakage. Joints are tight, oil and
water lines are unblocked.
The line connection is reliable and works well

6. 60000 KM or 8 months maintenance items

In addition to the implementation of all maintenance items of 5,000 km and 20,000 km, the following items are added.
System maintenance item Main technical parameters
Transmission Replace transmission oil. Use API GL-5 SAE 80W-90 or 85W-90 gear oil.
Rear axle Replace final drive oil Use API GL-5 SAE 80W-90 or 85W-90 gear oil.
Front and rear
axle (for free Replace front and rear wheel
Use API GL-5 SAE 80W-90 or 85W-90 gear oil.
maintenance hub oil
wheel hub)

7. 80000 KM or 12 months maintenance items

In addition to the implementation of all maintenance items of 5,000 km, 20,000 km and 60,000 km, the following items are

added.
 System Maintenance item Main technical parameters
Engine Check valve clearance The clearance of intake valves and exhaust valves is within the specified range.
Clutch Replace brake liquid DOT3 standard brake liquid.
Replace steering hydraulic oil. Recommend using ATF DEXRON ⅡD or ATF DEXRON Ⅲ。
Steering system
Replace steering oil filter.
Check the safety pressure of fire extinguisher and replace it if necessary; replace the
Fire extinguisher system Check and replace extinguish device.
automatic fire extinguisher.
Check ignition system and replace
sparking plugs
CNG vehicle
The effective period of gas leakage alarm sensor is 1 year. It shall be replaced when it
Replace gas leakage alarm sensor
expires.

Part 7: Maintenance request for body

1. The vehicle body shall be kept clean, and shall be cleaned in time after daily running, and the tools shall not be used for
scraping, so as not to scratch the paint and cause the skin to be damaged.
2. The sealing rubber strip of the door and window shall be intact, and shall be replaced in time when it is damaged.
3. Do not wash the body paint section with hot water, alkaline water, kerosene, and other oil that is detrimental to the paint.
4. The connection between the vehicle body and chassis frame is often checked, and if any abnormality is found, it shall be
repaired in a timely manner.
5. Check the interior fasteners of the vehicle, and fasten them in a timely if there are looseness.
6. Check the working condition of the passenger door frequently; check and adjust timely if there is any abnormality.
7. Check the working condition of all lamps of the vehicle, and replace it in time if there is damage.
 Part 8: Other cautions
In addition to regular maintenance in accordance with the above maintenance items, the following tips are particularly
important for normal operation of vehicle:
1. Correct operation of the vehicle
1.1 Vehicles are strictly prohibited from slide running on neutral gear.
1.2 Do not allow the engine to idle for a long time (better to turn off the engine if the idle is more than 5 minutes), and the engine
will turned off after idle 1 - 2 minutes when the engine is operating at high speed so as to protect the turbocharger;
1.3 If the vehicle needs to be parked for a long time, the grounding wire of low-voltage battery should be disassembled to extend
the life of low-voltage battery.
1.4 The same fuse as that of original vehicle can only be replaced. It is forbidden to replace the fuse with copper wire or other
substitute material.
2. Correct maintenance
2.1 Please maintain your vehicle in accordance with the maintenance cycle and oil recommended by this Guide.
2.2 In addition to the ZF products mentioned in this Guide, the Allison transmission and the VOITH automatic transmission are
not required to be maintained for running-in, the rest of the assembly shall be maintained for running-in in accordance with the
requirements, and we strongly recommend that the running-in maintenance shall be conducted in accordance with the
requirements of this Guide.
2.3 When the welding and plasma cutting are carried out, all plug connectors and cable glands of the electric components of
vehicle (such as engine ECU, ABS control unit, ECAS control unit etc.) must be fully pulled out. Afterwards, disconnect the
positive and negative connecting wires of low-voltage battery to avoid the electrical devices damage.
.3. The tightening torque request
The tightening torque of all bolts and nuts shall be executed in accordance with the vehicle parameter control list.