Foton Series Light Bus. Instruction — part 14
OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS
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Sn
Description
Data
7
Lubricant volume (L)
0.4
8
Power assisted steering fluid
ATFⅢ automatic
transmission fluid
Q/SH038.501
9
Torque of track bar front end nut (N.m)
120.5±5
10
Tightening torque of cam nut (N.m)
200±8
11
Tightening torque of steering tie-rod locknut (N.m)
88±4
12
Tightening torque of ball joint of steering knuckle arm and tie-rod (N.m)
73.5~108
13
Maximum tangential force of steerer wheel
<200
14
Driving deviation
When driving straight
along center line of test
track at 40km/h for
30m, the left
deviation<2m while the
right <1m (steering
wheel is released).
15
Minimum turning radius (m)
5.75
10.6.2 Structure Overview
Vehicle in driving needs to change direction (steering) often. Driver turns wheels (steered wheels) to an angle
with vehicle longitudinal axial line via steering axle (usually front axle). Beside, vehicle driving straight line are
often subjected to side interference on its steered wheels from road. The force makes steered wheels swinging to
change driving direction. Driver can turn steered wheel to reverse direction then, returning vehicle to its original
driving direction.
Steering system is composed mainly by steering operating mechanism, steering gear and steering driving
mechanism. Steering operating mechanism consists of steering wheel, steering spindle and steering column.
Steering gear changes steering wheel’s rotation into steering arm’s swing, and amplify steering operating force.
BJ6536 vehicle adopts ball rack and pinion steering gear with a ratio of 46.67. It has two stage driving sets: the
first stage is screw and nut driving sets, and second stage is rack and pinion driving sets. Steering mechanism
transmits output from steering gear to knuckle, turning wheels according to certain arrangement. The mechanism
consists of steering arm, drag link, tie rod and knuckle arm.
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Figure 10-6-1 Steering Column-1
1-Steering column assembly;2-Steering column seat assembly;3,4Bolt;5-Nut;6-Steering wheel assembly
Figure 10-6-2 Steering Column-2
1-1-Upper & inner shaft assembly; 2- circlip-Type A; 3-Bearing; 4-Rigid plastic flat gasket; 5-Spring; 6-washer;
7-Hexagon bolt and spring washer M16×8; 8-Upper Steering Column assembly; 9-Ignition switch lock; 10-Clips for upper
bracket; 11-Taper head bolt; 12-Intermediate steering column assembly; 13-Hexagon bolt, spring washer and flat washer set M8
×20; 14-Gimbal assembly; 15-Hexagon bolt, spring washer and flat washer M8×30-8.8; 16-Bolt M8×1.5×30; 17-Base for
steering column
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Figure 10-6-3 Steering Column-3
1-Steering drive shaft assembly; 2- snap ring; 3-Bearing; 4-Thrust ring; 5-Lower steering shaft compression spring; 6-Upper
column assembly; 7-Lower column assembly; 8-Upper bracket assembly; 9-Lower bracket assembly; 10-Cone bolt; 11-Nut; 12-Bolt;
13-Stud; 14-Universal joint assembly; 15-Steering base assembly; 16-Compression spring seat; 17-Return spring; 18-Tilt control
lever assembly; 19-Bolt; 20-Left ratchet stopper assembly; 21-Auxiliary tilt lever; 22-Left ratchet assembly; 23-Right ratchet
assembly; 24-Big washer; 25-Spring washer; 26-Hexagon nut; 27-Lever shaft; 28-Spring; 29-Tilt lever; 30-Right ratchet stopper
assembly; 31-Tension spring (2); 32-Protect panel of tilt lever; 33-Bolt shaft; 34-Split washer; 35-Tension spring (1); 36-Hexagon
flange nut; 37-Stud.
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Figure 10-6-4 Steering reducer
1-Steering reducer assembly; 2-Bolt M10×1.25×42; 3-Reducer support assembly; 4-Nut M10×1.25×8; 5-Bolt M10
×1.25×22; 6-Nut M10×1.25×25; 7-Nut M8×1.25×8; 8-Decelerator housing; 9-Dust coverⅡ; 10-Oil seal assembly;
11-Adjusting gasket/shim; 12-Bevel pinion; 13-Adjusting screw base; 14-Fixed yoke; 15-Hexagon bolt and spring washer M6
×12; 16-Bolt; 17-Bottom cover assembly; 18-Hexagonal nut type 1 -fine thread M8×1; 19-Adjusting screw; 20-Spring
seat; 21-Spring, Pull-out piece spring II; 22-Bigger bevel shifter; 23-Angular contact bearing 46103; Deep groove ball bearing
60202; 24-Spring stop; 25-Conical spring, Pull-out piece spring I; 26-Adjusting plug screw; 27-Lock nut; 28-Dust boot 1;
29- needle bearing 941/20; Deep groove ball bearing CHK182416; 30-Oil tight assembly, Oil tight/seal; 31-Double track needle
bearing, Deep groove ball bearing CHK182416
Figure 10-6-5 Steering Gear-1
1-Assembly of redirector with draw bar; 2-Left support bushing; 3-Bolt; 4-Left support assembly; 5-Right support
assembly; 6-Right support bushing; 7-Split Pin 3.2×22; 8-Nut; 9-Assembly for redirecting movable bushing B; 10-Bolt;
11-Down steering shaft assembly; 12-Bolt; 13-Assembly for redirecting movable jacket A; 14-Bolt; 15-Support sealing
assembly for steering drive axle jacket; 16-Left baffle for redirector B; 17-Bolt; 18-Right baffle for redirector; 19-Former
jacket; 20-Ormer protective clip
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Figure 10-6-6 Steering Gear-2 (Mechanical Steering Gear)
1-Rack pull-rod subassembly; 2-Rack lock plate; 3-Rack; 4-Joint support; 5-Nut; 6-Bar clasp; 7-Left protective
bushing; 8-Rack pull-rod subassembly; 9-Casing sleeve assembly; 10-Sleeve bushing; 11-Right jacket clip assembly;
12-Right protective jacket; 13-Angular contact bearing 46103; 14-Gear wheel; 15-Left jacket clip assembly; 16-Oil seal;
17-Locknut; 18-Jacket for oil seal of gear wheel; 19-Rack supporting base assembly; 20-O-shaped lock ring 45×2; 21-Spring
for supporting base; 22-Adjusting plug screw; 23-Locknut
Figure 10-6-7 Steering Gear-3 (Power Steering Gear)
1-Inner ball joint assembly; 2-Pull-rod lock sheet; 3-Rack piston assembly; 4-Oil sealing assembly φ46×φ28.2×8;
5-Bushing; 6-O-SHAPED RING 42.5 × 1.8; 7-Caging turnbuckle at end of cylinder; 8-Piston ring φ 46 × φ 42 × 2;
9-O-SHAPED RING 38.5×1.8; 10-Cone-shaped joint III; 11-Left oil tube assembly; 12-Right oil tube assembly; 13-Outer
ball joint assembly; 14-Hexagon nut -Grade C M15×1.5; 15-Bar clasp; 16-Protective case/Shield; 17-Clip assembly;
18-Gasket; 19-Oil cylinder casing assembly; 20-Tile-shaped parts for bracket; 21-Bracket; 22-Spring; 23-Spring cap;
24-Luck nut; 25-Bottom cover; 26-Oil sealing assembly φ38×φ27×7; 27-O-SHAPED RING 43.7×1.8; 28-Spool
assembly; 29-Oil sealing assembly; 30-Ball bearing; 31-O-SHAPED RING 53×1.8; 32-Coned-shaped joint I; 33-Valve
body; 34-Dust cover; 35-Hexagon bolt M8×25-6h; 36-Spring washer 8; 37-Coned-shaped Joint II; 38-Seal ring
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Figure 10-6-8 Power Steering cable
1-Steering cable assembly; 2-Bolt; 3-Oil pump washer; 4-Bolt; 5-Vacuum hose Ⅳ; 6-Joint; 7-Tee; 8-Vacuum hose
III; 9-Filter cleaner; 10-Bar clasp; 11-Vacuum hose Ⅰ; 12-Hoop; 13-Oil pipe; 14-Steering oil tank/can; 15-Bolt;
16-Steering oil pump; 17-Oil pump pulley; 18-Bolt; 19-V-shaped belt for vehicle; 20-Hoop; 21-Subassembly of bolts;
22-Support for oil pump; 23-Bolt; 24-Nut assembly 25-Bolt; 26-Idler wheel support; 27-Nut; 28-Bolt; 29-Idler wheel
belt support assembly; 30-Bolt; 31-Crankshaft belt pulley
10.6.3 Check, Maintenance and Repair
1. Check and repair – steering column tube supporter and steering shaft
(1) Check steering column tube supporter and steering shaft for bending and distortion. Correct if they are
bend, and shaft linearity error should not exceed 1.5mm.
(2) Replace parts if steering shaft spline is worn-out and spline has over two distort or damaged teeth.
(3) Replace steering bearing if it cannot rotate freely, and there is ball loss on inner/outer race or retaining
device is distorted.
2. Check and repair -- steering gear UJ and spline shaft/bush
(4) Steering gear cross shaft assembly
① Replace bearing if its needle is broken or needle number is insufficient.
② Replace cross shaft bearing if its fitting clearance with shaft journal exceeds 0.25mm, or it cannot
rotate freely.
③
Replace bearing if its sealing gasket or cover is failure.
④
Minor peel-off on cross shaft journal surface can be corrected by grinding. Replace it if there are
dent on journal surface and severe peel-offs, or shaft has crack on it or it is worn seriously.
(2) UJ fork spline, spline shaft and bush
① Replace part if UJ fork spline, spline shaft and bush are corroded seriously, or they have injuries or
cracks on them.
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② Replace spline shaft and bush if there are over two distort or damaged teeth.
3. Check and repair of steering gear assembly
Use pure light diesel, gasoline or cleaning fluid to wash the parts disassembled from the steering gear
thoroughly. Decrust the packing paper and dried sealant on steering gear connecting surfaces and side cover.
Check gear, rack, housing, rack pull rod and joint bracket for crack by using the methods such as oil impregnation,
knocking or magnetic particle checks. Replace if necessary. The oil seal and gasket are not reusable, replace with
new ones. If the protecting cover and O ring is aged, replace with new ones.
4. Maintenance of power steering system
① A new power steering gear needs change steering fluid after the vehicle has run for 2,500km. Meanwhile,
the filter in the reservoir should be washed. Since then change fluid and wash filter for every 50,000km or one
year.
② Monthly check the volume of fluid for fluid consumption, deterioration or excessive impurities. Replace
deteriorated fluid timely.
10.6.4 Typical Faults and Troubleshooting
1. Heavy steering wheel, see table 10-6-1.
Steering wheel is found heavy during driving. Jack up front axle, steering wheel still feels heavy after having
separated steering arm from drag link, the fault may come from steering mechanism due to over tighten moving
parts sets.
Table 10-6-1 Heavy steering wheel
Causes
Solutions
1. Bend steering spindle or over tighten bearing
1. Adjust or replace
2.Incorrect steering gear adjustment
①
Steering nut rack meshes too tightly with pinion
arm shaft
②
Excessive steering screw bearing pre-tension
2.Re-check and adjust
3. Damaged or stuck steering driving parts
① Worn out or damaged screw nut race and ball
② Damaged screw bearing retaining bracket
3. Repair or replace
4.Insufficient lubrication inside steering gear
4. Add gear fluid
2. Steered wheel oscillating and steering wheel shivering, see table 10-6-2.
Steered wheels oscillate and steering wheel shivers while vehicle is driving or during manufacturing and
assembling. These are due to that steered wheels keep swinging around kingpin.
Steered wheel oscillation has two types: self-simulated vibration and forced vibration.
Tyre deformed to sides creates self-stimulated vibration. Forces from road input eternal energy to steering
system during a vibration cycle. If energy input amount exceeds dumping energy inside steering system, the
system will increase its vibration to offset till balance is obtained. In this case, system keeps continuous vibration
in certain amplitude to create oscillation, its frequency is almost the same as system own frequency but different
from wheel rotation speed. This happens within a wider vehicle speed range. Usually, self-stimulated oscillation
happens at low speed.
In the event that steered wheels and steering system are under cycling stimulations, such as wheel
misalignment, excessive end face play, incorrect tyre geometrical/mechanical properties and motional interference,
they will form cycled interference as long as wheels are rolling. These continuous interferences create forced
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vibration. Once interference frequency matches system frequency, resonance is then created. Under resonance,
steered wheel oscillates with a frequency that is the same as that of wheel rotating speed, and usually comes with
obvious resonance speed, and its resonance range is narrow (3-5km/h). Oscillation happened at high vehicle speed
is usually of forced vibration type.
It is very complicated to pinpoint the cause and effect of steered wheel oscillation. It may be due to defects
during design and manufacturing such as wheel misalignment, incorrect wheel mechanical property, weak system
stiffness and damping, wrong steered wheel location angle and gyro effects. Mis-mounting and mis-adjustment
may be other causes, such as incorrect clearances among front axle steering system (it affects system stiffness) and
wrong friction coefficient (it affects damping) etc. There are many ways to restrain front wheel oscillation, such as
to select right parameters, make and assemble parts carefully. Other effective solutions include improving stiffness
of steering gear assembly/tie rod, vertical stiffness of suspension and tyre side stiffness, and adding transverse
shock absorber to increase damping ability etc.
Table 10-6-2 Steered wheel oscillating and steering wheel shivering
Causes
Solutions
1. Excessive fitting clearance between steering worm and nut,
or worn out
1. Readjust or replace
2. Loose or worn out steering bearing
2. Replace bearing
3. Excessive wheel dynamic unbalance
3. Perform dynamic balance check
4. Weak torsion bar spring
4. Replace
5. Incorrect front alignment angle
5. Adjust front wheel alignment angle
6. Failure shock absorber
6. Replace shock absorber
7. Distort vehicle frame (due to collision)
7. Adjust and repair
3. Insufficient steering wheel turns, see table 10-6-3.
While vehicle is driving, front wheel max turning angle becomes smaller (to RH or LH) while turning radius
becomes larger with poor steering sensitiveness. This is mainly due to incorrect adjustment and wrong mounting
location of parts such as steering gear, steering drive mechanism and front wheel turning angle-locating bolts.
Table 10-6-3 Insufficient steering wheel turns
Causes
Solutions
1. Incorrect steering screw rotation numbers
1. Remount and adjust
2. Parts in steering mechanism is distort due to force
2. Check and replace damaged parts
3. Mis-adjust front wheel turning angle locating bolt
3. Correct to right position according to specified
front angle
4. Excessive steering wheel turning number difference to
left and to right from center -- front wheel max turning
angle becomes small (to left or right)
4. While steering arm mounting angle is correct,
adjust front wheel turning angle locating bolt to
standard
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10.7 Suspension
10.7 Main Technical Parameters of Suspension
Main Technical Parameters of Suspension (with BJ491EQ1 Engine)
Sn
Description
Parameters
Type
Dual cross arm torsion bar type
independent suspension
Distance between locknut of track bar and fixing
bolt (mm)
445±3
Ground clearance (mm)
At front side 277mm; at rear side
305mm.
Torque of tire nut (N.m)
120~150
1
Front
suspension
Torque of front damper and lower cross arm (N.m)
88~97
Type
Rigid suspension of hydraulic type
shock absorber with vertical
arrangement semiellipse leaf
spring and bilateral action cylinder
Rear leaf spring section
Rectangle
First main leaf size (length x width x thickness)
(total number of leafs)
1200×60×8(5), flat spring eye
structure
Clamping center distance of U-bolt (mm)
90±0.5(Φ12)
Free static camber (to center of spring eye) (mm)
130
Tightening torque of U-bolt under flattening state
of the leaf spring (N.m)
123±5
Tightening torque of leaf spring pin (N.m)
147±5
Tightening torque of leaf spring shackle pin (N.m)
91±5
Torque of tire nut
120~150N.m
Top nut of rear shock absorber (N.m)
21.6~26.4
2
Rear
suspension
Toe nut of rear shock absorber (N.m)
38.7~47.3
Type
Bilateral action cylinder type
hydraulic shock absorber
Tightening torque of tightening nut of rear shock
absorber (N.m)
At top 21.6~26.4, at toe 38.7~47.3
Working stroke (mm)
205
Minimum length (when compressed through,
distance from the shackle center to top dust boot)
(mm)
320
+3
-8
Maximum length (when pulled off, distance from
the shackle center to top dust boot ) (mm)
525
+8
-3
Type of connection
Dual shackle
3
Shock
absorber
Designation of damping fluid
Q/SY11509-79 damper oil
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10.7.2 Structure Overview
If vehicle frame or body is directly mounted on axle, they will vibrate up and down on road. This will make
passenger uncomfortable or damage cargo. A suspension device must be adopted. The suspension refers to all
connecting devices between vehicle frame / body and axle, it is used to connect elastically axle to frame or body,
damping jerk to vehicle during driving to protect cargo and keep human comfort. The suspension reduces
vibration caused by spring system, transmits vertical, longitudinal and side counter force and moment of force; it
also guides wheel jump at certain trace corresponding to that of body.
Front suspension of BJ6536 series light bus is of independent type and its rear suspension is of rigid
semiellipse leaf spring vertical arrangement type.
See figure 10-7-1, figure 10-7-2, figure 10-7-3 for front and rear suspensions of BJ6536 series light bus.
Figure 10-7-1 Front Suspension Assembly-1
1-Left top across arm, shaft and pin assembly; 2-Right top across arm, shaft and pin assembly; 3-Top across arm shaft; 4-I
hexagon nut-small thread; 5-Small end cover; 6-Small outer collar, Small outer collar assembly; 7-Left top across arm seam;
8-Right top across arm seam; 9-Big outer collar, Big outer collar assembly; 10-Big end cover; 11-Nut; 12-Left top across arm
ball pin assembly, Right top across arm ball pin assembly; 13-Bolt; 14-Left bottom across arm assembly; 15-Right bottom
across arm assembly; 16-Rubber collar assembly; 17-Left bottom across arm seam; 18-Right bottom across arm seam;
19-Bottom buffer block assembly; 20-Metal lock nut with hexagon flange face, Spring washer; 21-Cam shaft assembly for
bottom across arm; 22-Bottom across arm cam shaft; 23-Spring washer; 24-I hexagon nut; 25-Bolt M10×1.25×31;
26-Heavy spring washer; 27-Heavy spring washer; 28-Heavy spring washer; 29-Nut M12×1.25; 30-Bolt M12×1.25×50;
31-Bolt M14×1.25×66; 32-Flat washer; 33-Hexagon-flange-faced bolt; 34-Top buffer block; 35-Left knuckle disc brake
assembly; 36-Right knuckle disc brake assembly
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Figure 10-7-2 Front Suspension Assembly-2
1-Bolt M12×1.25×98; 2-Torque bar seal assembly; 3-Metal lock nut with hexagon flange face; 4-Hexagon-flange-faced
bolt; 5-Torque bar dust cover; 6-Left torque bar; 7-Right torque bar; 8-Torque bar-rear bolt; 9-Top pad; 10-Left torque bar
fixing arm assembly; 11-Right torque bar fixing arm assembly; 12-Bottom pad; 13-Torque bar fixing bolt; 14-Torque bar
cover; 15-Hexagon bolt, spring washer and flat washer set; 16-Fixing plate for left stabilizer bar; 17-Fixing plate for right
stabilizer bar; 18-Stabilizer bar rubber collar; 19-Fix bracket for left stabilizer bar; 20-Fix bracket for right stabilizer bar;
21-Hexagon head bolt; 22-Hexagon head bolt; 23-Stabilized bar; 24-Bolt M10×1.25; 25-Stabilized bar pad; 26-Stabilized
bar rubber pad; 27-Stabilized bar connection shaft; 28-Stabilized bar pad (middle); 29-Thrust bar; 30-I hexogen nut-fine
thread; 31-Thrust bar pad; 32-Thrust bar rubber retainer ring; 33-Thrust bar rubber pad; 34-Thrust bar collar; 35-Undee
spring washer; 36-Hexagon head bolt; 37-Heavy spring washer; 38-Nut M12×1.25; 39-Front damper assembly; 40-I
hexogen nut –fine thread; 41-Bottom pad; 42-Top attachment assembly; 43-Front damper; 44-Spring washer 12;
45-Hexogen head bolt M12×1.25×55
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Figure 10-7-3 Rear Suspension Assembly
1-Rear stopper assembly; 2-Hexogen head bolt; 3-U bolt; 4-Rear steel plate spring assembly; 5-Steel plate spring pin;
6-Steel plate spring pin nut; 7-Rear plate splint assembly; 8-Flat washer; 9-U bolt nut; 10-Hexogen head bolt-fine thread;
11-Top pad for small hole; 12-Top ring for rear damper; 13-Top pad for big hole; 14-Rear damper assembly; 15-Bottom pad
for small hole; 16-Bottom ring for rear damper; 17-Bottom pad for big hole; 18-Lifting eye pin for plate spring; 19-Outer
plate for plate spring lifting eye; 20-Lifting eye pin collar for plate spring
10.7.3 Technical Specifications for Check and Repair
1. Repair of front suspension
① Check front suspension: compress and extend the shock absorber, check for abnormal resistance or
working sounds. If any, replace with a new shock absorber.
② Repair torsion bar spring: make fitting marks on torsion bar spring, torsion arm and fixed arm; measure
the length of extended bolt end A as shown in figure 10-7-4. The value of which will be a reference when
adjusting height of the vehicle; there are left and right index marks at rear end of torsion bar spring. Do not
install it to opposite direction.
Figure 10-7-4 Measurement of Length of Bolt A
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③ Mount and secure a new torsion bar spring onto the torsion arm, and adjust the nut seat and adjusting
nut. Note: When to install the fixed arm onto the torsion bar spring, tighten the adjusting nut by hand to make
the extended length of bolt being about 5mm, as shown in figure 10-7-5. Tighten the adjusting nut to screw down
the bolt by 60.5mm(C). The measured value of which will be a reference during vehicle height adjusting.
Figure 10-7-5 Installation of Torsion Bar Spring (1)
Figure 10-7-6 Installation of Torsion Bar Spring (2)
④ Check vehicle height. If the height is off standard, adjust it by using the adjusting nut of the torsion bar
spring.
⑤ Check front wheel alignment by wheel alinger.
⑥ When to install the stabilizer bar, tighten the nut until the extended length of the bolt reaches 4.5~6mm,
as shown in figure 10-7-7.
Figure 10-7-7 Installation of Stabilizer Bar
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2. Leaf Spring
(1) Check each leaf for crack, breaking and scratch; check center bolts and leaf clamps for distortion and
damage. Replace if necessary.
(2) Check each leaf’s laterally twisting. Measure by using center of leaf center hole as basis, the difference
to each end should not exceed 0.8% of leaf thickness.
(3) Measure leaf spring assembly performance after leafs have been clamped. The specifications for
front/rear/auxiliary leafs should be as indicated in chart 10-7-1. Replace part if arc height and stiffness of each leaf
change greatly (especially LH/RH changes) under static load.
(4) Leaf spring pin and bushing
Check front/rear leaf spring pins for uneven wear or damage by measuring their diameters. Replace parts if
wear exceeds limit. See table 10-7-2.
Table 10-7-1 Performance of Leaf Spring Assembly
Description
Free arc height (coil center)
Rear spring
156±6
Table 10-7-2 Service Limit of Rear Leaf spring Pin (mm)
Description
Standard
Limit
Rear leaf spring pin
φ14
φ13.8
Rear shackle pin
φ14
φ13.8
3. U-bolt
Check it for distortion, crack and damaged thread. Replace if necessary.
4. Leaf spring bracket and front shock absorber upper bracket.
Check and remount loose rivets. Check bracket for distortion. Repair bracket that has crack. And replace part
if necessary.
5. Front /rear leaf damper and auxiliary leaf bracket pad
Check them for damage, peeling or crack. Replace if necessary.
6. Rubber bushing of shock absorber shackle
Check shackle rubber bushing for aging, distortion and crack, replace if necessary.
10.7.5 Typical Faults and Troubleshooting
1. Broken or sounding leaf springs, see table 10-7-3.
Table 10-7-3 Broken or sounding leaf springs
Causes
Solutions
1. Boken leaf spring due to overload or driving on
rugged road
2. Loose U-bolt or worn-out pin/bush disturb wheel
alignment, or incorrect front/rear wheel base, which lead
to brake leaning and hard steering
3. Short lubrication — among leafs and on leaf pins
4. Elasticity diminishing varies among leafs, or certain
broken leaf make vehicle body slant.
5. Broken leaf or failure shock absorber, or damper lost
to disturb vehicle ride.
1. Load vehicle as specification, adjust vehicle
speed.
2. Fasten U-bolt as per specification while leafs
are pressed to flat, repair or replace worn-out
parts
3. Re-lubricate or replace parts
2. Check replace broken leaf or assembly
5. Replace broken leaf, shock absorber or damper
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2. Leaking or failure shock absorber, see table 10-7-4.
Table 10-7-4 Leaking or failure shock absorber
Causes
Solutions
1. Worn-out oil seal — shock absorber connecting rod
2. After long driving on rugged road, shock absorber
cylinder tube becomes hot
3. Failure shock absorber
4. Worn-out or lost absorber upper rubber bush,
absorber can not work normally
1. Repair or replace assembly
2. Remove to check shock absorber, replace if
it is failure
3. Replace
4. Replaced damaged parts
10.8. Brake System
10.8.2.1 Main Technical Parameters of Brake System
Main Technical Parameters of Brake System (with BJ491EQ1 engine)
Sn
Description
Data
1
Type of service brake system
Hydraulic operation dual-circuit brake system with
vacuum booster, front disc and rear drum brake
Front wheel
Disc brake
2
Brake
Rear wheel
Drum brake
Standard thickness
25
Service limit
22.5
3
Brake disc (mm)
Lateral run-out
tolerance
0.07~0.12
Standard thickness
10
4
Front friction lining (mm)
Service limit
1.6
Nominal values
φ270
Service limit
φ272
Taper
0.15
5
Inner diameter of brake
drum (mm)
Out of round
0.15
Standard thickness
5.5
6
Rear wheel friction lining
(mm)
Minimum service
thickness
1.0
Diameter
φ25.41
7
Dimension of brake master
cylinder (mm)
Stroke
30
8
Rear wheel cylinder diameter (mm)
φ23.81
9
Brake fluid
V-3QC/T670
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Sn
Description
Data
10
Type of parking brake system
Mechanical operation, rear wheel brake
supplemented with the parking brake
11
Brake pedal height (mm)
151.5±2
12
Free travel of brake pedal (mm)
1~3
13
Margin distance of pedal travel (pedal travel
from the ground) (mm)
58
14
Fit clearance between brake drum and brake
shoe (mm)
0.6
15
Road test the braking distance ( at 30km/h on
cement road surface) (no part of the vehicle is
allowed to be beyond the test track by 2.5m).
Braking distance≤8m; error≤60mm
16
Requirements for parking brake
Parking brake unit creates required braking
performance when it operates within 2/3 travel of
operating devices
10.8.2 Structure Overview
I. Brief Introduction of the Structure
The device sets used to force vehicle to stop by applying force from road on wheels are called brake system.
It is used to force vehicle to decelerate and stop, or park a vehicle firmly on various road conditions (including on
hill), and keep stable vehicle speed at driving down hill. BJ6536 light bus adopts two independent brake systems:
service brake system used on FR/RR wheels (dual hydraulic circuits with vaccum booster) and parking system
used on transmission mechanism.
Service brake system consists of wheel brake and hydraulic driving mechanism, and is operated by human
foot. Parking brake system consists of central drum brake and parking brake transmission mechanism, used at
parking or starting up on uphill, is operated by hand. In emergency braking situation, parking brake system and
driving brake system are used at the same time. In the event service brake system is faulty during vehicle driving,
driver should move vehicle by using parking brake system to a safe place or service station for check and repair.
Front disc brake is shown in figure 10-8-1.
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