GDW6115HKD GDW6115HKD Series Bus

Operating Instructions Manual

Guilin Daewoo Bus Co., Ltd

Please read these operating instructions carefully before using the bus.

PREFACE


Dear customers: Thank you for purchasing and using Guilin Daewoo buses.

Guilin Daewoo Bus Co. Ltd, which is located in the world famous city Guilin with beautiful scenery, is on the highway of development with introduction of advanced technology and production philosophy from South Korea Daewoo Co., Ltd. Strong power in research, development and production, perfect quality assurance system and aftersale service system make sure that Guilin Daewoo Co., Ltd can provide high quality service for you. For many years, Guilin Daewoo has drawn the attentions of more and more clients by upholding the business philosophy of people first, customer centered.

GDW6115HKD
Major technical parameters, operation and service of GDW6115HKD series buses are described in this document. For the detailed information for operation, maintenance and service of this series buses, please refer to the operating instructions of all the assemblies and parts provided by the suppliers. The normal service life and environmental protection requirements can be ensured only by adhering to all the service requirements specified in these instructions strictly.

In order to provide better service for you, our company set up sales and service hotlines. In case of any doubt during the use, please contact us in time, and we shall provide warm, sincere and timely service for you.

: 10

:541003

Address: #10, Jingping Rd., Xiangshan District, Guilin, Guangxi Zip: 541003

0773-3626218

0773-3605961

Email: sales@gldaewoo.com
Sales Tel: 07733626218 Email: sales@gldaewoo.com Fax: 0773 3605961

0773-3626258

0773-3605579

Email: service@gldaewoo.com
Aftersale service Tel: 07733626258 Fax: 0773 3605579 Email: service@gldaewoo.com

We will appreciate it very much for any valuable advice and suggestion you put forward during the use of this operation and maintenance manual.

Thanks again for your choice of Guilin Daewoo Buses!

:
Note: Some of configurations mentioned in this instruction are optional. They will be equipped with your option during the purchase. 

Guilin Daewoo Bus Co., Ltd

2011 10
Oct. 2011


DECLARATION
Honored customers, we compiled this operating instruction for your convenience of using and maintaining your buses. It is distributed for free by Guilin Daewoo Co., Ltd without hindrance from any enterprise or person. So users shall all make the demand to sales branch in purchase of bus.

During the maintenance and care of this series buses, please use the genuine Guilin Daewoo parts and components or those recommended by Guilin Daewoo. Any vehicle damage caused by the use of unauthorized or fake parts and components and all resulted consequences shall be at the owners own risk, and Guilin Daewoo has no responsibility for it.

Guilin Daewoo reserves the right to alter or revise these instructions due to continual technical innovation, and some of the items will be changed from time to time without notice. So we beg your pardon. If the data, illustrations and narrative descriptions described in these instructions dont correspond with reality, please refer to reality. In any case, its not accepted to make any claim to Guilin Daewoo by taking the data, illustrations and narrative descriptions in this instruction as legal basis.

Contents
...............................................................................................................................1 2 .............................................................................................................1 Chapter 2 Vehicle Label and Print Position.......................................................................................1 . Chassis nameplate and its VIN code .............................................................................................1 ...........................................................................................................1 Chapter 3 Running and operating management................................................................................1 I. Driving during new vehicle running-in period................................................................................1 IXKey points noticed for vehicle service in winter......................................................................15 ...............................................................................................................1 5 ......................................................................................................................1 6 ..................................................................................................................1 Chapter 6 Notice when use electric equipment..................................................................................1 7 ..............................................................................................................1

Annexes: List of tools furnished with vehicle Principles of Air piping


Chapter 1 Technical Parameter
1

6115HKD1-1 6115HKD1-2 6115HKD2-1

.Main Technical Parameter of bus

Major technical parameters

Chassis model

GL6111DR1 11330 3450(), 3610

3450 (without A/C), 3610

(mm)
Overall length mm

(mm)
Overall height mm

(mm)
Overall width mm

2500 2040 2360 5950 2084 1860 2150 3230 10 9 230

(mm)
Inner height mm

(mm)
Inner width mm

(mm)
Wheel base mm

(mm)
Front wheel track mm

(mm)
Rear wheel track mm

(mm)
Front overhang mm

(mm)
Rear overhang mm

()
Approach angle ()

()
Departure angle ()

(mm)
Minimum ground clearance mm

()
Seats (person)

24-51 16480 1250012100

(kg)
Max. gross weightkg

(kg)
Curb weight kg
I-

(m)
Min. (m) turning diameter

20

(km/h)
Max. speed (km/h)

120 30 air suspension

air suspension

Band spring

(%)
Max. grade ability (%)

Suspension mode

. Engine major technical parameters

Euro Engine YC6L310-42 Engine Mode Engine type

DL08S 250

YC6L310-42

mm Cylinder borestroke mm L Displacement L kw/rpm Rated power kw/rpm Nm/rpm Max. torque Nm/rpm Generator Emission Manufacturer

BOSCH BOSCH Vertical; In-line; Vertical; 6,In-line; Vertical; In-line; Water-cooling; 4Water-cooling; 4Water-cooling; 4Stroke; Direct Stroke; high pressure Stroke; Direct injection; BOSCH common rail injection; BOSCH common rail common rail 113140 108139 113140

8.4 228/2200 1150/1200 1600

7.64 250/2200 1422/1200

8.4 228/2200 1150/1200 1600

150A

Euro Guangxi Yuchai

I2

Doosan Infracore

Guangxi Yuchai

Machinery Co., Ltd

Machinery Co., Ltd

3
.

Main Technical Performance of Chassis

Vehicle model

6115HKD1-16115HKD1-26115HKD2-1 GL6111DR1
Guilin Bus Industry Group Co., Ltd

Chassis model

Chassis manufacturer

Engine Mode

YC6L310-42

DL08S 250

Engine position

Rear position

Clutch

Type

430mm ,
430mm single dry-type, coil springs

Gearbox

Type

6 6 gear, definite ratios , Mechanical operation S6-90 T14DS6PR

Type

Front axle

Type

Forged steel piece ,H section, fist end type

Rear axle

Type

hyperboloidal gear single reduction

Steering mechanism

Type

Integral recirculating ball power steering

Suspension mode

Air suspensionBand spring

Brake

Service brake

Double circuit, air braking system

Parking brake

Energy storing spring acts on rear wheel

Car frame mode

Semi-integral type

Drive system

Tire

11R22.5 320L

Fuel tank

Note: The above-mentioned components are selected according to the detailed requirements during the purchase.

I-

VIN PLATE
. Bus nameplateVIN PLATE GDW6115HKD

Chapter 2 Vehicle Label and Print Position

The nameplate of GDW6115HKD series bus is fixed over the front door step in the vehicle compartment.

Engine number.

. Engine nameplate

EURO engine number is located at the upper of the cylinder side.

VIN
. Chassis nameplate and its VIN code

VIN
The nameplate and VIN code of vehicle chassis is fixed and typed on the rear position of the right side member of front axle.

The above figures are for your reference only, please refer to the actual objects.

II -


Chapter 3 Running and operating management

III-1
I. Driving during new vehicle running-in period

III-2
. Ordinary control matters for new vehicle

III-6
III. Check other devices

III-8
IV. Key points for starting bus

III-9
V. Key points while running

III-10
VI. Key points for emergency measures

III-13
VII. Traction

III-13
VIII. Measures taken after parking, backing and running

III-15
IX. Key points noticed for vehicle service in winter

III-16
X. Key points for vehicle service in summer

-1


Chapter 3 Running and operating management

1
I. Driving during new vehicle running-in period

2,0003,000km 2000km
The initial driving period of 2,0003,000 km is the maintenance period (running in period) for all the moving parts of a new vehicle. The distance of running in period specified by our company is 2000 km (appropriately extended to the destination depending on different case). During the running in period, the following regulations must be closely observed.

1)
Warm the engine after starting it to facilitate driving.

2)
No sudden acceleration at the idling speed.

3)
Pay attention to check the fluid levels of the engine, gearbox and rear axle assembly, add when insufficient, and check for oil leakage.

4) 2,0003,000km 70% 8090

Try to avoid over speed or sudden acceleration. In the initial driving period of 2,0003,000 km, the bus should be driven at up to 70% of maximum speed and the roads with good conditions should be chosen. Be sure that the gross weight of the bus does not exceed beyond 8090 of the max permitted gross weight of chassis.

5)
Check if the braking system works normally, if gas leakage occurs and working temperature is normal in each part (braking drum, wheel hub, rear axle, etc.). Please settle the problem in time if there is something wrong. In order to avoid various problems (temperature rise, severe wear or dramatic deterioration of braking performance) in the parts, such as the braking drum, which are caused by repeatedly braking, sudden braking should be avoided and auxiliary braking system should be used suitability.

6)
III1

Check whether all parts of the steering mechanism are loose and seized, whether the tyre pressure meets the requirements, and whether the electrical equipment and instrument work normally.

After the running in period, lubricating oil of engine, gearbox, steering gear and rear axle and other parts should be replaced. Try to flush all the parts out; clean the ventilation plug, and replace the core of engine oil filter; check and tighten all the connecting bolts according to the specified torque, especially all the parts connecting the engine cylinder head, air intake and exhaust manifold bolts, driving and steering systems. Check and clean the parts related to inlet system, cooling system, fuel oil system and braking system. In addition, remember to check all the lubricated points for filling.

2
. Ordinary control matters for new vehicle

GDW6119HKD
The Guilin Daewoos GDW6119HKD series buses are made of high quality materials by the highly skilled techniques, based on the scientific research and design, and strictly inspected and tested. However, for the purpose of the optimal vehicle performance and good economy, the following problems need to be particularly noted:

1
Adhering to the cycle of oil (fluid) replacement

For detailed engine oil specifications and main points of replacement, please refer to the section of bus maintenance.

Replace engine oil and filter

2000km
Initial: over 2,000km or arriving the users place

15,000km 10,000km
Later: every 15,000km (high speed, long-distance bus); every 10,000km (in the city, short-distance bus).

Replace gear oil of transmission and rear axle

2000km 20,000km
Initial: over 2,000km or arriving the users place

III-

Later: every 20,000km.

III-


Replace of power steering oil

2000km
Initial: over 2,000km or arriving the users place

24,000km
Later: every 24,000km.

Checking of cooling water

Check the level of cooling water and proportion of antifreeze.

,
WARNING: Dont open the cover of cooling water when the engine is heated, otherwise it is possible to be scalded. Therefore, its necessary to wait until it cooling down and open the cover draining all inner pressure by covering the cover with a towel or others and turning slowly.

NOTE: Rapid filling of cold water may lead to the crack of engine, etc, so the cold water must be slowly filled in. It would better to fill in it after a while.

Check clutch fluid

Check if the quantity of clutch fluid is reasonable and its consumption is too much.

Key points of checking

2050mm
III4

Check steering wheel (about2050mm)

/ 2.5
Check if the rotation of steering wheel is normal. (ca. 2.5 cycles in left/right direction)

Accelerator pedal

Check if the rotating speed of engine is up to the maximum value when stepping the accelerator pedal to bottom.

Check brake

Check if the pressure of barometer and operation of braking lamp is normal.

Check if the stroke of brake pedal is normal.

Check if the pedal returns to its original position freely after releasing it.

WARNING: Be sure to check the braking performance in a service station or on a flat, dry and open road. Its prohibited to check it at places where buses or persons exist.

NOTE: The checking of braking performance should abide by relevant regulations.

III-


Check clutch

Check if the free stroke or working stroke of pedal is rational and the pedal works flexibly.

NOTE: Since any speed change or running in case of abnormal operation of clutch (half clutch) can damage to the clutch system and transmission, pay special attention to it.

REFERENCE: Due to the application of a supercharged engine, the torque of bus is relatively smaller when the engine runs at a low speed, so the bus must start in the first gear.

III. Check other devices 1

Wheel & tire

Check the tire for damage and weariness condition as well as its air pressure for sufficiency.

Check the wheel for cracks or damage, its bolt for loosening or disengagement.

III-


WARNING:

1
The used wheel bolt may be loosened due to expansion force of tightening torque, dont use it any longer.

2
The same bus is prohibited to be equipped with the tires with different models or tread patterns or provided by different manufacturers.

REFERENCE

1
Always maintain the air pressure of tire at the normal level.

2
Change the position of tire regularly according to wheel running conditions and different worn positions of tire.

3
After knowing the correct grades of tires, use the tires according as these grades (maximum speed/weight/pattern shape, etc). 4

420~490 N.m 570~650 N.m

Tyre nut: standard torque of left & right tyre nut is 420~490 Nmstandard torque of right nut is 570~650 Nm. After tighten all nuts, use torque wrench to test, the torque should not be less or more than standard value.

300~500km
300~500km later after reinstall tyre, tighten the nuts as said torque again.

III-

Check of air conditioner

Check heater operation for smoothness (the water valve of engine compartment must be opened during the check).

Check refrigerating system operation for smoothness (in the winter, the refrigerator is not ordinary used, but in order to maintain its lubricating conditions and prevent it from rusting, it should be started once every week).

IV. Key points for starting bus

1. 5.3kg/cm2
Confirm if the air pressure is over 5.3kg/cm2, and check for air leakage.

2.
Unlock the parking brake.

3.
Confirm the forwarding direction of bus and nothing around it, especially walkers and children. 4.

60

When the lowest temperature of cooling water is at least 60, start the bus in the first gear.

NOTE: The half clutch of clutch can lead to the damage to relevant parts.

III-


V. Key points while running

1.
While the bus is running, its normal that all the indicators except battery indicator are out.

2.
The rotating speed of engine shall be maintained within the torque speed limit.

3.
Accelerate gently. Save the enough space in overtaking to maintain sufficient driving force.

4.
Make a speed change within the proper rotating speed of engine on the premise that the driving force of next gear cant be reduced.

5.
When the vehicle is travelling on a downhill road, DO NOT shift to the Neutral gear; and timely start the retarder unit (if installed).

6.
Dont put the feet on the clutch pedal (half clutch state) unless the speed is changed.

7.

Braking operation


Pay attention to keeping a proper driving distance, especially when the surface condition and forward visual field are dissatisfactory (try to avoid the emergency braking).

III-

8.

Driving on the ramp

1
In case of climbing along the ramp, put in the low speed gear as soon as possible to maintain the maximum torque and protect the engine.

2
Dont put the gear to neutral while going down the ramp. Drive in the high speed gear. Make a proper braking operation to prevent the engine from rotating too fast.

Warning: If only the main brake is used while going down the ramp, braking hub or braking shoe plate, etc. will produce too high temperature which will result in slip and braking force reduction, so the auxiliary braking devices should be properly used.

VIKey points for emergency measures

If some malfunctions occur to the bus during driving, keep away from other vehicles, park in a safe area, and take corresponding measures to inform other vehicles of this malfunction to warn them let by.

III-

10


The bus should be parked immediately when the instrumental warning lamp blinks while driving. Dont drive the bus before fixing the corresponding parts.

Overheated engine

When the engine is overheated, park the bus in time for checking. The malfunction must be settled, or it will cause damage to engine.

WARNING: If the water tank cover is suddenly opened to fill in cooling water, you may be scalded by the steam or cooling water. Be careful.

NOTE: If the bus engine is immediately stopped to reduce the temperature, the water pump will stop subsequently to work, and the engine will be overheated instead. Therefore the engine shall not be checked until the cooling water temperature is reduced.

Abnormal conditions occurred to electric system

,
When the battery is discharged, start with other batteries.

1
When the control lever of transmission is put to neutral gear, shut down all the electric devices.

2 (+)(+)
Connect the pole () of auxiliary battery to the pole () of discharged battery.

3 (-) (-)
III11

Connect the negative pole () of auxiliary battery to unpainted surface or the negative pole ( ) of discharged battery. 4 5

Startup

Remove the cables in the reversed sequence.

WARNING:

1
Keep the battery away from fire as it contains inflammable gas.

2
Dont splash the battery liquid to any part of eye, skin, clothes, bus or painting as it is toxic. Wash with abundant of clean water and see doctor as soon as possible in case it is splashed into eye or on skin.

NOTE

Dont startup by traction (possible to bump into other vehicles).

To turn off general power switch when the engine is still running may lead to the malfunction of electric devices. Therefore, the general power switch should not be turned off when engine is running.

REFERENCE: Readjust the electronic clock powered by the battery after replacing work.

The engine stops due to insufficient fuel

III12


If the engine stops due to insufficient fuel, it must be restarted after removing the air in the fuel system.

VII. Traction

When the bus is pulled due to failure, pay attention to the following matters:

1)
If the gear box is normal, put the control lever to neutral position.

2)
If the gearbox is failed, traction should be carried out after removing the driving shaft.

3)
If the air pressure of pulled vehicle is normal, unlock the parking (safety) brake with manual switch. If the air pressure is insufficient, unlock the parking brake by opening the rear dust cover of spring brake chamber, inserting the bolts (fixed on the plug hole of spring brake chamber usually) into the brake chamber, and turning the nut in clockwise direction.

4)
If the failure occurred in the rear axle, carry out traction after removing the half shafts on both sides.

NOTE:

1)
In case of lifting the bus body by traction, ensure the air spring disengaging from the body.

2)
The traction is carried out by a tractor specialized vehicle. Be sure to carry out the traction at a slow speed by keeping sufficient safe space in case only ordinary vehicles available. (The pulled vehicle should be controlled by driver to avoid any accident)

3) ,
When unlocking the parking brake manually, put a sprag against butt front or rear wheel to prevent the vehicle from moving...

III13

VIII. Measures taken after parking, backing and running

Backing

Use the parking (safety) brake to stop the bus while backing. Pay attention to the following matters:

Select a flat and clean place to park. Be sure that there are no inflammable or explosive materials around the parking place.

If the bus has to be parked on ramp, try to park at a place with even slope. In addition to put parking brake in position, put proper chock to stop moving of the tires and apply other measures (e.g. when the bus is parked on up ramp, put gearbox in the first or second gear; when the bus is parked on down ramp, put gearbox in the reverse gear) to prevent it from slipping. However, when the bus is restarted, pay attention to the gear shift of gearbox change lever.

Pay attention to the obstacles behind the bus while backing, especially children and walkers.

NOTE: The reverse gear must be put in after the bus completely stopped.

REFERENCE: For the vehicle unused for a long time, pay attention to prevent frostbite and drain water in winter, and avoid the direct exposure to sunshine in summer.

Flameout of engine

Turn off all electric devices (lamps or air conditioner, etc.) before flame engine out. If the engine felt overheated, let it run at idle speed and stop it after reducing the temperature of cooling water.

Check and fix the problems appeared in driving.

Maintenance & checking after operation

Check and clean the polluted parts of bus and compartment, and check whether there is any damage or oil
III14

leakage.

Check the conditions of fuel, oil and hydraulic oil.

IXKey points noticed for vehicle service in winter

Heat preservation of engine

Reducing the temperature of cooling water can lead to the increasing abrasion of engine and fuel consumption, so its necessary to check the temperature of cooling water and maintain its proper temperature with a radiator guard when its temperature is too low.

Antifreeze

Add in the antifreeze with proper proportion when leaving the storehouse. However, since its concentration can be changed due to evaporation or addition of cooling water during the use, make a proper adjustment after checking its concentration.

()
Air temperature ()

%
Cooling water (%)

%
Antifreeze (%)

)
Air temperature ()

%
Cooling water (%)

%
Antifreeze (%)

0
Room temperature0

85

15

-20-25

60

40

0-10 80 -10-15 73 -15-20 67

20 27 33

-25-30 -30-40

56 50

44 50

Key points noticed in using perdurable antifreeze:

1 -25 -30
Select the suitable antifreeze according to the lowest temperature of a certain region. If the lowest temperature of this region is -25, select the antifreeze with a condensation point of -30.

2
Try to add in the antifreeze of the same model provided by the same manufacturer to avoid deposit appearing.

3
III15

If the antifreeze is found to be deteriorated, replace it at once.

Fuel

Difference in temperature caused by the reduction of air temperature can produce the more moisture in oil tank, so the oil tank should be always full of oil.

Engine oil

Since the increase of engine oil density can make it difficult to start the engine, please replace the engine oil according to different seasons.

Battery

The reduction of air temperature can lead to the less capacity of battery and specific gravity of battery fluid. The battery may be broken due to freezing in cold area, so it should be always fully charged.

6
Condensate water draining out of compressed air reservoir

Temperature difference exists between the air released by reservoir and compressor. Even equipped with air dryer, the compressed air reservoir still has condensate water. Drain the water with a discharge valve if the temperature of air reservoir is not reduced after running. 1

NOTE: Use a needle valve of automatic discharge valve manually every month to check whether there is some water drained out. If a great deal of water is discharged, the automatic discharge valve must be out of use and it should be replaced by a new one as soon as possible.

III16

Key points for vehicle service in summer

The foreign materials in cooling water can reduce the cooling efficiency. Please fill in clean cooling water all the time. The foreign materials or dust in water tank can also reduce its cooling efficiency. Please clean the water tank regularly.

Cooling system

Evaporation is one of the character of battery liquid. Please check the level of battery liquid regularly.

BATTERY

The tire temperature can increase results from the increasing ground temperature. Please check the air pressure of tire regularly.

TIRE

Check the working states of ventilator and air conditioner as well as the quantity of refrigerant.

AIR CONDITIONER

III-

17


Chapter 4 Use and maintenance of bus

1
List of regular check items and check period.

5000km
All the check items listed below must be checked, the unlisted items should also be checked if necessary. The criterion of check period is based on 5,000km per month and normal running conditions. When the vehicles run with poor running conditions or average monthly mileage exceeding 5,000km, check period should be condensed. Please repair it or replace relevant parts in time if necessary.

Check period

I A B C D 2000km 5,000km 10,000km 20,000km 40,000km

After 2000km or has been used by consumer Every 5,000km Every 10,000km Every 20,000km Every 40,000km

Items

Initial period

Check period

Engine

Pollution and quantity of engine oil and oil leaking parts

Everyday check

Clean the air filter and engine oil filter.

A C
Everyday check

Replace the air filter.

Starting state and abnormal noise

Tension and damage of belt

Everyday check

Check and clean the filter elements.

A
Everyday check

States of idle speed and acceleration

Check the operation state of air compressor.

B
Initial period
1

Items

Check period


Check the turbocharger

D I B

Check torques of bolts relevant with cylinder head, air intake and exhaust for and integrality of gaskets.

Adjust the valve clearance.

B 60,000km
Every 60,000 km

Replace the spray nozzle.

Disassemble, check and repair the injection pump.

200,000km
Every 20,000 km

Clean the injection pump sieve and fuel filter.

Replace the fuel filter.

B C
Everyday check

Check the injection timing.

Check the oil lines for leakage.

Check the pollution of exhaust emission.

Everyday check

Check and adjust the engine.

45000km
Every 45000 km

Cooling system

Leakage and pollution of water tank

Everyday check

Leakage and abnormal noise of water pump

Everyday check

Clean the radiator core.

100,000km
Every 100,000km

Replace the cooling water.

Every year

Check and adjust the concentration of antifreezing fluid.

According to seasonal variations

Items

Initial period

Check period

( )
Check the operation state of cooling system (including perfect suspension of radiator)
2

Everyday check


Replace the cooling hose.

80,000km
Every 80,000km

Gearbox

Oil leakage

Everyday check

Replace the gearbox oil.

I I B

Tightening or wears of all the parts of link rod, and clean the ventilation plug.

Disassemble, check and adjust the gearbox.

45000km
Every 45,000km

Clutch system

Check its function and oil quantity.

Everyday check

Stroke and height of pedal

Everyday check

Check or clean the power steering pump.

C I
Every year

Replace the clutch oil.

Driving shaft

Looseness, damage connecting parts and lubrication of

Everyday check

Wears of spline

D C

Replace the clutch oil.

Rear axle

Replace the rear axle oil.

I I

B C
Check period

Clean the bleeding screw plug.

Items

Initial period

Check the oil leaks.

Everyday check

Tighten the connecting bolt of rear axle.


Clean the hub bearings or check their clearance.

Disassemble, check and adjust the main speed reducer or differential gear.

45000km
Every 45,000km

Front axle

Tightening of cross tie rod bolts

Everyday check

Suspension

Damages of air spring diaphragms

Everyday check

Leveling valve, link rod, tightening bolt or nut

Everyday check

Oil leak and function of vibration damper

Everyday check

Perfectness of all linkage members or rubber gaskets

Everyday check

Tightening and connection of all linkage members

Everyday check

Steering device

Free stroke of steering wheel

Everyday check

State of fixing and lubrication of transverse gear, steering wheel and steering column tube

Oil leakage of transverse gear

Everyday check

Check all the joints of crossbars and steering arms for wear.

Items

Initial period

Check period

Check for the consistency of front wheel toe ins.

I
4

Check the knuckle or king pin for perfect fitting.

Stroke of steering king pin and bearing

D
Everyday check

Check the functions of braking device.

C D
Everyday check

Stroke of brake pedal

A
Everyday check

Leak of compressed air

Emergency brake and control valve of manual brake

Check the operation of valve.

I A

C
If necessary

Check the brake shoe plate for wears.

Relay valve

C C A

Check the pressure control valve.

Clean the discharge outlets of brake valve relay valve and pressure control valve.

Check the pipeline of air compressor

Everyday check

Replace the core of air dryer.

1 50,000km
Every 1 year or 50,000km

Check the operation of adjuster.

/
Disassembly, check/replacement

Brake valve

80,000km
Every 80,000km

Items

Initial period

Check period

Check the braking force of energy saving spring chamber

80,000km
Every 80,000km


Relay valve

100,000km
Every 100,000m

Pressure control valve

100,000km
Every100,000m

Clearance adjuster

100,000km
Every 1 year or 100,000km

Brake lamp switch

C
Everyday check

Air reservoir

Oil filling of brake camshaft

Disassembly or assembly of hub

Check the braking force on the ramp

C D

Check the horizontal braking force.

Wheel, tire or frame

Damage and inflation pressure of tire

Everyday check

Tightening of wheel nut and damage of steel ring

Everyday check

Displacement of tire

B
B or as per the wears of tire

Check the steel ring for cracks.

6,000km
Every 6,000km, nondestructive check

Derusting and cleaning of steel ring

Disassembly or assembly of wheel

Balance of tire

If necessary

Replace the tire or its device.

If necessary

( )
Check the frame for perfectness (deformation or looseness or disengagement of bolt pins)

CD
C or D

The above periodical check items and their periods are for reference only. If the corresponding manufacturers supply the operating instructions for the assemblies, please be subjected to these instructions.

 Fault Diagnosis & Solution Measures

1 Engine Related
1 The start-up motor does not work or it spins slowly. Battery relay movement is not smooth Change or repair the battery relay Flat battery Battery terminal loosening Slack ground cable Engine oil is too thick Charge or replace the battery. Clean the rusty part of the battery terminal, secure the connection and apply grease on it. Secure the cable. Replace the oil with appropriate thickness oil. 2 The start-up motor is operational but it does not start up. Fuel shortage Refueling. Not enough warming-up Check the pre-heat system The fuel filter is blocked. When air leaks into the fuel system The fuel filter is blocked. 3 Low speed spinning will result in engine shut down. Low idle RPM Adjust idle speed Air cleaner element is Contaminated. Clean or replace the element Engine is over cooled
-

Release the air Clean or replace the filter element

Giving enough warming-up

7

 Engine is over cooled. Fuel filter is blocked. Valve gap is abnormal. 4 Engine power shortage Charger hose connection is not tight or intercooler leaks air. Air cleaner is blocked. The brake is applied constantly. Valve gap is abnormal Clutch slipping Fuel piping/diesel filter is blocked.

Clean or replace the filter element Adjust the valve gap

Clean or replace the filter. Maintain the brake lining gap to normal level. Adjust the valve gap. Adjust the gap or replace the clutch disc. Clean the fuel piping or replace the filter.

Inspect, clean and adjust. Replace when necessary. Atomization of injector is not good or injector pump fuel supply shortage. Clean up carbon. Exhaust pipe or silencer carbon deposition 5 Engine is over heated. radiation pins are covering with Dust. Coolant shortage Fan belt is loose. Clean the radiator. Refill coolant and check if there is leakage. CAUTION Dont open the cap when the coolant temperature is still high.

Rust particles or slimes are found in CAUTION Dont open the cap when the coolant. coolant temperature is still high. Thermostats are malfunctioning Adjust fan belt tension or replace the belt.
8

Overload due to hot weather

Coolant refreshing or clean the radiator interior. Replace the thermostat. Lighten the load and lower the speed. Inspect and clean oil cooler and relevant parts.

6 Black exhaust Air cleaner element is contaminated Clean or replace the element and inspect the and charger does not work smoothly. charger Valve gap is abnormal; fuel supply Adjust the valve gap and the fuel supply advance angle misalignment ECU Engine ECU faults. advance angle. Find out flash codes by using senses witch and replace damaged parts. 7 Fuel consumption rate is too high.

Fuel leakage, injection faults and fuel Check the fuel supply pump and check for supply advance angle misalignment leakage. Air cleaner element is contaminated Clean or replace the element and check and charger does not work smoothly. the charging intercooler system. Engine is over heated Tire pressure is too low The brake is applied constantly. Clutch slipping. 8 The engine oil pressure is too low.
9

Check the cooling system. Adjust it to standard pressure. Maintain the brake lining gap to normal level. Adjust the gap or replace the clutch disc.

Engine oil shortage. Refill as appropriate. Engine oil leakage, oil pressure gauge Check the lubrication system, repair leakage and sensor malfunction. parts or replace the oil pressure gauge and sensor. Parts of lubricating system malfunction Incorrect oil type Oil replacement period is delayed. Engine warming-up is ignored. Replace the oil with appropriate thickness oil. Replace it with standard oil. Change the oil according to the refreshing period. Perform standard warming up.

2 Power Train Related

Causes 1) Strange sounds from the gear box and rear axle Gear oil shortage Refill as required. Gear oil thickness is not appropriate. Relevant parts loosening or damaged. 2) Vehicles are badly vibrating while running Propeller shafts connection bolts and nuts are loose. Propeller shaft is badly shaking. Replace it with standard oil. Inspect and adjust; replace when necessary.

Examine and secure the bolts and nuts. Repair or replace the propeller shaft. Adjust the balance of wheel disc or check

Wheel discs are out off balance and tires. air pressure is irregular.

3
10

Steering Related
Causes Solution Measures

1) Steering feels heavy Relevant components in steering Lubricate and adjust. system lack oil or are too tight. Adjust it to standard pressure. Front tire pressure shortage Repair or replace Power steering unit is damaged. Refill as appropriate and release the air. Power steering oil shortage Replace the filter element. Power steering filter element is contaminated. Check and adjust Toe-in or front wheel alignment is not appropriate. 2) Steering wheel recovery is not smoothly. Steering wheel components are not Apply grease. greased enough. Repair or replace. Joint parts of drag links are interfered. 3) Steering wheel is shaking. Tire nuts are loose. Tighten as regulated. Tire pressures are different to each other. Adjust the pressures evenly as the standard. Tires are worn out unevenly. Exchange or replace. Steering wheels control gap is too much Adjust the steering wheel gap. Replace the ball or adjust the gap and tighten. Tie rod, drag link and knuckle ball are heavily worn out or tight nuts are loose.

4 Brake Related
11

 Causes

Solution Measures

1) Insufficient braking ability Tire pressure is too high. Adjust to regulated pressure Braking system air leakage; brake valve and brake chamber can not work smoothly. Too high lining gap Check, adjust and replace when necessary. Adjust the lining gap or replace the lining. Replace with new tires.

Tires are heavily worn out. 2) Tilted Braking Tire pressures are different to each Adjust the pressures evenly as the standard other. Replace Tires are worn out unevenly. Lining gaps are different from each other and oil dirt is found 3) Brake dragging Lining gaps are too small. Adjust the lining gap Check and adjust. Components such as brake valve, brake chamber and so on can not work smoothly. Adjust it to standard gaps and clean the dirt.

5 Electrical Devices Related

Causes
12

Solution Measures

1) Too much battery consumption Battery terminals become isolated, Clean the rusty parts, secure the connection loose and rusty. and apply grease. Battery fluid shortage. Old battery Engine belt slipping or cutting off Lights are turned on constantly Alternators are poorly charged. 2) Too much battery consumption Bulbs have burn out. Fuses are blown. Wiring and connections are poor. Refill Replace Adjust the tension of belt or replace. Turn off Inspect the alternator or the regulator.

Replace the bulb. Replace the fuse. (It is still blown after replacement, please check wirings and bulb holders. Please do not use unsuitable fuses or fuses of poor quality.) Repair the wiring and connections

. Maintenance of outer appearance and accessories

Outer appearance maintenance

In order to protect vehicle, maintain according to appropriate schedule periodically, making it accord with environment pollution control rule. Ensure cleaning material have no corrosive matter.

Clean
13


If the dust (having chemical substance) from road or stored remains on vehicle body for long time, paint and body may be damaged.

(
Often cleaning is the best method to avoid vehicle damage. Cleaning is also effective for protecting vehicle from environmental corrosion such as rain, acid, fog, etc

)
After clean the vehicle (including clean it on automatic washing machine), should clean places which are easy to store dust, such as door & covers connection, corner flange, etc.

Window glass

Window glass can be cleaned with sponge or clean water. Glass detergent can be used to eliminate oil, grease and dead insects. After wash the glass, use clean, dry & soft cloth to wipe it. Do not use the cloth that is used to clean glass and paint surface to wipe. Otherwise, the glass will be damaged and scratched, affecting its polish and definition. Do not use hot water to wash icy glass.

Brush

-7

Use soft cloth and glass detergent to eliminate oil, insects on brush. If brush performance is not good, should replace brush.

Decoration and inner accessories

In order to maintain new vehicles value, should manage decoration carefully and keep inside clean.

,
If body paint has a local damage, it should be applied or sprayed to avoid any corrosion.

,
When rotating shaft and door lock of passenger door are in first-level maintenance, should clean it and apply lubricant.

,,,
Should check connecting bolt between seat and floor, if there is looseness, tighten it.

If safety belt is loose, should tighten it on time, avoiding risk.
14


Check lubricating conditions on rotating shaft of compartment door hinge and other side door (battery door, engine repair door, radiator door) hinges. Replenish lubricant periodically (recommend to replenish once a week). Replace aging rubber tape of compartment door. Ensure outfall of compartment door unobstructed.

15

Chapter 5 Instrument and Control Unit

EURO engines instrument and control unit

()
. Different parts of instrument panel in cab (as said picture)

1
Four way switch

6
Four way switch

2
Six way switch

7
Three way switch

3
Four way switch

8
Three way switch

4
Four way switch

9
Three way switch

5
Vehicle running data recorder

10
Three way switch

Switch can be adjusted properly according to different configuration, optional configuration and special configuration.

2
. Combination instrument (for model of vehicle equipped with EURO engine)

1 (Tachometer) 2 (Direction indicator) 3 (Barometer) 4 (Speedometer) 5 (Water thermometer) 6 (Voltmeter) 7 (Fuel gauge) 8 (Engine oil pressure gauge) 9 (Indicator and warning lamp)
Indicator and warning lamp

When using various kinds of control levers or switches, the indicator and warning lamp blink.

A1) ABS ABSindicator

K1)
Engine indicator

J2)
Water-in-diesel warning indicator

B1)
-

L1)
2

K2)

Rear engine compartment door open indicator

Neutral gear indicator

Indicator of high beam

C1) ASR
ASR indicator

B2)
Parking brake indicator

B3)
Small lamp indicator

D1)
Charging indicator

C2)
Passenger door indicator

C3)
Main power switch indicator

E1)
Overheated engine water warning indicator

D2)
Left brake disc wear indicator

D3)
Automatic grease refilling

F1)
Engine oil overlow pressure warning lamp

E2)
Parking brake indicator

E3)
Exhaust-brake indicator

G1)
Engine compartment temperature warning lamp overhigh

F2)
Front fog lamp indicator

F3)
Overspeed indicator

H1)
Air cleaner clog warning indicator (for the Hangzhou Motors chassis only)

G2)
Rear fog lamp indicator

G3)
Retarder temperature High warning indicator

I1)
Water level LOW warning indicator

H2)
indicator

H3) (DV11 ) Right brake disc wear

Fuel heater indicator

J1)
Low brake air pressure warning indicator

I2)
Indicator of air dryer(for the Hangzhou Motors chassis only)

K3)
Low beam indicator

I3) OBD OBD indicator

J3) SCR SCR indicator

()
For the indicator (warning lamp) consisting of the components not selected by the user or with functions not suitable for the vehicle, it doesnt work.

3 ,
. Name of rocker switch (From the left to the right, the upper to the lower)

1. Drivers light switch 5.

Switch of engine compartment lamp

2. 1
Switch of compartment lamp 1

3. 2
Switch of compartment lamp 2

4.
Reading lamp switch

9. Switch of rear fog lamp 13. Passenger door switch

6. Switch of engine compartmen t lamp 10. Switch of ladder lamp 14. Middle passenger door switch 18. Idle speed enhancing switch 22. Switch of drinking machine 26. Standby switch cover 30. Switch of defroster 34. Standby switch cover

7. Head/clearanc e light switch

8. Switch of front fog lamp

11. Horn change over switch 15. Front ventilating fan switch 19. Cruise control

12. Passenger door switch 16. A/C switch

17. Standby switch cover

20. Engine test switch 24. Switch of rearview mirror defroster 28. Main power switch 32. Standby switch cover

21 Alarm Buzzer Switch 25. Standby switch cover 29. Emergency signal light switch 33. Standby switch cover

23. TV switch

27. Standby switch cover 31. Retarder Selecting Switch --

--

Chapter 6 Notice when use electric equipment

During driving, if red indicator illuminates, must stop to check whats the problem. After eliminate the malfunction, you can continue to drive.

Often check if wire connector is loose, harness fixing is tight, or contacts with exhaust manifold. If yes, eliminate immediately.

Main power switch: This switch is used to control the ON/OFF of the whole vehicles electric circuit. Press down this switch to turn on the whole vehicles circuit; and release this switch to turn off the circuit other than those of emergency warning light, turn signal light, recorder, engine compartment light, stop bell, front door pump, electronic clock; When the engine is working, do not turn off power supply switch, otherwise electric equipment will be burned out; When the engine is working, do not turn off power supply switch, otherwise electric equipment will be burned out;

Notice when use wiper In winter, temper dropping outside of vehicle will make detergent freeze. So, in winter, please use special detergent. If there is ice on wiper or front windshield, must clean the ice first and use wiper later. Otherwise, wiper will be burned out.

ABS
When weld the vehicle, please disconnect connecting cable of computer control box such as electric injection engine, retarder, vehicle data recorder, ABS, and disconnect battery cathode, avoiding instant high pressure damage electric equipment.

When weld the vehicle, please disconnect connecting cable of computer control box such as electric injection engine, retarder, vehicle data recorder, ABS, and disconnect battery cathode, avoiding instant high pressure damage electric equipment.

When park the vehicle for a long time, please disconnect battery cathode.

If the fuse is burned out, please use fuse with same capacity to replace it. Strictly prohibit use copper line, iron wire or bad fuse to connect. Otherwise, electric equipment or circuit will be burned out.

Strictly prohibit user add electric equipment or change electric circuit without permission, avoiding safety hidden trouble or fire.

Strictly prohibit user add electric equipment or change electric circuit without permission, avoiding safety hidden trouble or fire.

Chapter 7 Specification, capacity of lubricant and other oil

The service life of bus components is mainly dependent on lubrication. Therefore, lubrication in correct way duly to the whole vehicle during the use, service and maintenance is very important. Lubrication of whole vehicle, please observe closely the following rules:

1
Remove the fouling on oil cap, oil plug or oil nozzle, etc. before lubricate some items to prevent fouling from falling into the mechanism.

2
When replace the lubricating oil of all assemblies, operate under the hot engine state (but not allowed to startup or run) to ensure that the waste oil and dirt can be freely drained.

3
When our bus leaves the factory, current engine, transmission, rear axle, steering gear and antifreeze will be changed according to real production situation.

WARNING: It is prohibited to use oil of different brands or specifications.

4
During the season changing service in summer or winter, select the oil products of proper brands.

5 C.L.S
Before the bus leaves the factory, if it is installed automatic filling system of butterC.L.S, its lubricant, use and repair refer to relative documents provided by manufacturer.

6
Take care to reclaim lubrication oil. The reclaimed oil is stored according to different types respectively and kept away from impurity. It shall be delivered to the reclaiming processing office to handle in the right way and avoid pollution to environment.

Lubricating place

Name of oil

Change period

Refilling Capacity

Specification and grade

Recommended oil

 Engine

Engine oil

2000km YC6L310-42 24-28L 15,000km DL08S 21~27L 10,000km First time: 2000km or after at the user side Later:every15,000km (high speed, longdistance bus) Every10,000km (in the city, shortdistance bus) 13L 2000km S6-90 T14DS6PR 20,000 km 14L First time: 2000km or after at the user side Later:every20,000km 2000km 20,000 km First time: 2000km or after at the user side 16L

CH-4

Total

CI-4

Gearbox

Gear oil

GL-4 GL-5

Total

Rear axle

Gear oil

API GL-5 SAE 80W90

Total

Power steering

Later:every20,000km 2000km Power steering oil 24,000 km First time: 2000km or after at the user side Later:every24,000km

11L

Dexron IID

Total

Hub bearing

Grease

During disassembly assembly of hub

the or

Proper quantity

Chassis

Chassis grease
-

4000 km Every 4000km

2

Proper quantity

EP . 2 Multi purpose EP . 2 NLGI .2

Mobil grease Mobil

 Cooling system Clutch

Antifreezing fluid Brake oil

When the season is changed 1 60000 km Every year or 60,000 km

Proper quantity 1L

grease -45 Tongyi or Great Wall DOT-3 DOT-4 Mobil brake fluid
Prohibiting the use of Mineral-based brake oil

DOT-3 DOT-4

or

Remark: Lubricating period in the table is recommended value. In different area with different use condition, the bus user should determine lubricating period by reference to this table combining his experience. The quantity of the oil filled in the engine are judged by the scribed line of the engine oil rule as the transmission and the rear axle are judged by the lubricating oil are out of the prothhole

 Annexes

List of tools furnished with vehicle

Description

Qty

Specification

Flat blade screwdriver

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

6" 6" 8" 12" 68 17 2427 12-14 7 1719 2427

Cross head screwdriver

Adjustable wrench

Adjustable wrench

Hexagon wrench

Wrench

Wrench

Box wrench

Box wrench

Box wrench

Box wrench

Valve core wrench

Tire sleeve socket wrench

Chisel

L=1500 L=800

Crowbar

Crowbar

Tool kit

200g

Grease gun

Slipjoint pliers

8"

Hammer

2P


Wrench

1 1 1 1 1 1 1 1

10X12 14X17 19X22 10T

Wrench

Wrench

Jack

3/8,
English sleeve 3/8, Tool

Rocking lever for spare tire

1
Round steel 1

2
Round steel 2

 Principles of AIR PIPING

Principles of AIR PIPING