Foton Series Light Bus. Service Manual — part 5

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

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Category

Location

Check results

Faults

Additional services

Valve spring broken

Replace valve spring

Noise--camshaft bearing Remove to check camshaft

bearing

Abnormal

sound

-

valve

mechanism

Worn timing gear

Replace timing gear

Larger

crankshaft

axial

clearance

Worn crankshaft thrust

washer

Replace thrust washer

Oil leak at crankshaft oil seal

Oil seal failure

Replace oil seal

Abnormal sound-- water pump Water

pump

shaft

bearing

damaged

or

shaft broken

Remove to check water

pump, replace bearing or

water pump

Engine

Engine over heated

Radiator pipe restricted Remove to check, remove

pipe restrictions.

Clutch

Clutch failure

Clutch skipping, worn

friction

plate,

incomplete

release,

unstable engagement

Remove to check clutch,

replace friction plate or

return spring

Abnormal

sound － clutch

release bearing

Bearing damaged

Replace release bearing

Transmission

Abnormal sound or frequent

repair--transmission

Worn or broken shaft,

gear, bush

Remove

to

check

transmission

Enlarged meshing clearance or

abnormal sound－final drive’s

drive/driven gears

Worn gear face or larger

meshing clearance

Adjust meshing clearance,

check gear fitting.

Axle

abnormal

sound-differential,

final

drive,

axle

case

temperature ＞ 60 ℃ (frequent

minor repair)

Incorrect gear meshing

or tooth broken

Remove to check final

drive and differential

Steering

gear

steering wheel free travel＞10
º, stuck or heavy

Larger

meshing

clearance, worn gear,

ball groove worn to stick

Adjust steering wheel free

travel, remove to check

steering gear

Abnormal

and

free

play-propeller shaft counter

bearing

Radial play or bearing

worn to stick

Remove to check counter

bearing

Brake failure (adjustment does

not work)

Worn-out brake pad

Remove

to

check

or

replace pad / shoe

Body deformed, serious paint

peel-off

Metal crack, rust

Repair, weld and paint

manual

check

Others

tyre side wear

Front

axle

distorted,

steering knuckle kingpin

play, axle parts distorted

Perform

front

wheel

alignment,

remove

to

check or replace kingpin

or bush, correct or replace

distorted parts

Chapter 2 Vehicle Technical Maintenance

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Category

Location

Check results

Faults

Additional services

Serious leakage at oil seals on

transmission, steering gear, axle

case.

Aged oil seal, poor

sealing

Replace oil seal

General

comments

Engine or

vehicle

Engine power and reliability

decreased,

fuel

and

oil

consumption increased. Chassis

and body conditions turn to

worse

Engine passably service or

overhaul vehicle

2.3.4 Basic service procedures during 2

nd

level maintenance

Professional technician performs the 2

nd

level maintenance that includes these services in 1

st

level

maintenance, mainly focuses on check and adjustment, and also on check tyres rotation. The basic service items

see chart 2-4.

Chart 2-4 Basic service procedures of 2

nd

level maintenance

Category

Description

1. Check lubrication, fuel and cooling systems for leakage

2. Check exhaust system for leakage or damage

3. Replace engine oil or oil filter

4. Check coolant level and coolant performance, add coolant or adjust concentration if necessary

5. Check belt tension and condition, adjust tension or replace it if damaged

6. Clean air filter, replace element if necessary

7. Replace fuel filter

8. Check clutch pedal free travel, adjust if necessary

9. Check and clean fuel injector

Engine and

clutch

10. Check advanced angle of injection, adjust if necessary

11. Check transmission for leakage

Drive system

12. Check propeller shaft and UJ

Steering

system

13. Check tie rod ball joint for fastening and clearance, adjust if necessary

14. Check brake system for leakage or damage

15. Check pad lining thickness, replace pad if necessary

16. Check and adjust parking brake unit

17. Check assisted exhaust brake system performance

18. Check tyre pressure

19. Check tyre for tread depth and wear

Brake system

and wheel

20. Check wheel lug torque

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Category

Description

21. Check performances of headlights, alarm light, turning lights and horn

22. Check performances of windshield wiper and washer devices

23. Check windshield fluid level, add if necessary

24. Check battery fluid level, add distilled water if necessary

Electrical

system

25. Check air filter

A/C system

26 check A/C’s performance and refrigerant amount

Heating unit 27. Check heating fan performance, and any leaks at pipeline and connectors

Road test

28. Check performances of speedometer, brake, shift mechanism and steering mechanism.

2.3.5 Flow chart of 2

nd

level maintenance

Figure 2-3 Flow chart of 2

nd

level maintenance

2.3.6 Requirements to 2

nd

level maintenance

1. Engine’s three filters (air, fuel and oil) are clean, engine starts easily and runs smoothly, exhausts normally,

temperature and oil pressure are within normal range; engine is sensitive to rpm changes without abnormal noise;

all drive belts are complete with proper tension and without abnormal wear.

2. Clutch pedal free travel is up to standard; clutch operates easily and releases completely, engages smoothly

and reliable; no leakages at pipelines on hydraulic operating systems; there is proper amount of fluid in reservoir

and fluid is clean and clear.

3. Parts in transmission, axle and UJ drive unit are lubricated and connected well, no abnormal noise and

overheating; no jump-gear and shift difficulties; their exterior surfaces are clean and no sign of fluid leaks.

4. Steering wheel free travel and wheel toe-in are up to standards, steering maneuver is light, flexible and

reliable; front wheels do not dive or incline to one side.

Workshop check

Check before maintenance

Collect owner’s brief

Instrument test

Process check

Service operation

Decide additional operation

Description

F

ill

ou

t

te

chn

ic

a

l

fil

es

Finish check

Delivery

Material and labor time

calculation

Manual check

Chapter 2 Vehicle Technical Maintenance

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5. Brake pedal free travel and brake clearance are up to standards; brake, parking brake and assisted exhaust

brake all work well without lagging and misalignment; no air leak in brake systems; inertia proportional valve

works well.

6. Tyres are mounted correctly with right pressure; shock absorber system is clean and well, fixed tightly;

wheel hub bearing with right torque and gets well lubricated.

7. Battery is clean and works well, fixed tightly; battery fluid level, gravity and load voltage are up to

standards.

8. Alternator, starter, gauges, lights, signals, switch/button and all other accessories are complete and work

well; all circuit is complete and well and fastened tightly.

9. Vehicle is clean, vehicle body’s pose is sound with well paint; no oil, water, air and electricity leaks. All

lubricating spots are well fed and all connections are tight and reliable.

10. A/C/heating fan work well, their connecting pipelines have no water or fluid leakages.

2.3.7 Required check and diagnosis before 2

nd

level maintenance

Required check and diagnosing Description before 2

nd

level maintenance see following chart 2-5.

Chart 2-5 Required check and diagnosing Description before 2

nd

level maintenance

Category

No.

Description

Check items

1

Engine power

No load power, power output balance among cylinders

2

Parameters of starting

system

Starting current and voltage

3

Cylinder sealing

Cylinder pressure, crankshaft case leak, cylinder leak and

vacuum

4

Port timing

Open and close angles of inlet/exhaust valves

5

Engine noise

Crankshaft bearing, rod bearing, pistons, piston pins and valve

mechanism

6

Cylinder surface

condition

Cylinder scratch, piston head burnt, coke and piston side wear

Parts

tested

7

Engine oil lab test

Contaminated index, water content, flash point, PH value and

motional viscosity

1

Engine

Seals on engine (oil/water), FR/RR crankshaft, radiator, water

pump, water jacket; crankshaft axial play and abnormal sound

2

Steering system

Steering wheel free travel, steering gear performance and

sealing; road test steering stability (if necessary)

3

Transmission system

Clutch performance, transmission, final drive housing surface

conditions and their oil seals; road test; abnormal sounds from

transmission, differential, final drive, bearing on propeller

shaft; case temperatures on transmission and final drive.

4

Drive line

Tyre side wear, leaf spring bracket, pin and bush

5

Meters and signals

Correct indication

Parts

checked

6

Others

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

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2.4 Run-in maintenance

2.4.1 Vehicle during run-in period

To prolong vehicle’s operating year, it is required to let vehicle “break in “ when it is first put into use. Only

after break- in period can a vehicle be put into normal use.

Requirements during run-in period:

1. Run-in mileage: 1500-2000 km;

2. Select better road to drive vehicle with moderate speed, and vehicle’s load and speed should be less than

rated values.

3. Driver should comply with operation rules, keep engine in normal working temperature;

4. Keep vehicle’s routine maintenance checks and fasten outside bolts/nuts regularly; watch closely

temperature changes of each assembly and their sound; and make proper adjustment timely.

5. When run-in period is finished, vehicle should be sent vehicle for run-in service.

2.4.2 Maintenance services during run-in period

Newly purchased or overhauled vehicle must have run-in period. To keep vehicle’s reliable operation and

prolong its operation year, there must be a forced service. BJ1049, BJ1043 vehicle in its “Maintenance Manual
“ enlists detailed requirements to maintenance.

A forced maintenance to find and remove faults after run-in period, which includes complete checks,

fastening and lubricating is crucial to drive vehicle safely.

Vehicle run-in period maintenance includes following cleaning, checks, fastening and lubricating services:
① Change engine oil, transmission and rear axle fluids;
② Change oil filter and fuel filter elements;
③ Check transmission, rear axle, steering gear and engine for leakages, fasten half shaft bolts, steering

drop arm nuts, tie rod ball joint nuts;

④ Check engine coolant and windshield washer fluid levels;
⑤ Check propeller shaft and FR-RR suspension systems, fasten propeller shaft bolts and suspension

U-bolts.

⑥ Check tyre for pressure and technical conditions, fasten wheel lugs;
⑦ Check brake system performance, add brake fluid, check and adjust brake pad clearance;
⑧ Check and adjust engine valve clearance.

Note: Detailed content please see “Maintenance Manual”

2.5 Seasonal Maintenance

Weather conditions affect vehicle’s operation. In the area where lowest temperature drops under 0℃ in a

year, there must be seasonal maintenance before summer and winter. In-using vehicle’s seasonal maintenance is

usually performed by driver, and can also be sent to service workshop for help. Main services for seasonal

maintenance include oil, coolant (according to seasonal temperature requirements) changes, and adjustment on

fuel supply system & power supply system.

1 Change lubrication oil

BJ1049, BJ1043 engine& chassis use multi-level oil that can be applied both in summer and winter. This

makes oil change easy at seasonal maintenance by just selecting relevant oil with same viscosity and by following

changing interval requirement.

Chapter 2 Vehicle Technical Maintenance

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Chart 2-6 Viscosity and ambient temperature

Engine oil viscosity rate

Lowest operation temp.

（℃）

Gear fluid viscosity rate

Lowest operation temp.

（℃）

5W、5W/30

-32

70W

-55

10W、10W/40

-23

75W

-40

20W、20W/50

-12

80W

-26

85W

-12

90、140、250

above 0℃

Chassis gear fluid is mainly used on transmission and final drive assemblies. To change lubrication oil, one

can only adjust its viscosity, and obey all quality and rate requirements in owner’s manual. No alteration is

allowed.

2 Change engine coolant

One can formulate coolant by him or buy it with relevant brand/specification from market. Ethylene

glycol/water coolant is commonly seen. It is rated by icing point as -18℃、-35℃and -45℃. One should select

coolant with rated temperature is 5℃ lower that actual environment temperature.

3 Clean fuel system and select diesel of right rate

Before winter, fuel system should be cleaned thoroughly. Clean all filtering grids, clean and change filter

element and turn to use right-rated diesel. According to their quality, vehicle diesel is rated into three levels as

premium, 1

st

class and qualified, and classified into 6 rates as 10、0、-10、-20、-35、-50 according to their icing

points. One should select diesel whose rated temperature is 5℃ lower than actual environment temperature to

keep diesel from freezing (paraffin seeping out).

4 Battery maintenance

Before winter, one should clean battery, add distilled water or adjust battery fluid gravity. Right gravities

according to local temperature are as follows:

Below 0℃: 1.24 above -20℃: 1.27 above -30℃: 1.28 above -40℃: 1.29 below -40℃: 1.31

Use battery sulphate with a gravity of 1.853 (15℃) and clean distilled water to adjust a battery gravityIf

battery capacity becomes low due to longer operation, it should be recharged as follows:

Constant current charging: Current: 0．1C20 (C20：20hours capacity). When end voltage reaches 14.4V, go

on charging for 5 hours.

Constant voltage charging: Voltage: 14.4±0.1V, allowed max. current 0.5 C20, keep charging for 16 hours.

Perform these operations could be difficult in cold winter, it is suggested to do some of those works before winter,

which include adjustments, fastening and cleaning on various locations. A thoroughly maintenance may let a

vehicle pass through winter safely.

2.6 Vehicle lubrication

▲ Follow these rules to lubricate assemblies and parts:

1. Clean and remove dirt on oil cap, plug and nozzle to avoid them from entering parts.

2. Use grease gun to inject grease till parts interior is full and grease overflow at seam is seen.

3. Use standard grease that can be used year round.

Assemblies& parts lubrication mileage and requirements see chart 2-7

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

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Chart 2-7 Assemblies& parts lubrication mileage and requirements

No.

Lub. location

Lub. rate

Run-in

maintenance

（1500～

2000km）

1st level

maintenance

（7500～15000

km or 6 month）

2

nd

level

maintenance

（30000km or

12 month）

1

Engine oil

Select as per engine manual

and local temperature

Change

Change

Change

2

Transmission

Select as per engine manual

and local temperature

Change

Add

Change

3

Rear leaf spring pin No.2 lithium grease

Add

Change

4

Between FR/RR leaf

springs

Lithium grease

(molybdenum disulfide)

Add

Change

5

Propeller shaft UJ

No.2 lithium grease

Add

Change

6

Propeller

shaft

spline

No.2 lithium grease

Add

Change

7

Mid propeller shaft

bricking bearing

No.2 lithium grease

Add

Change

8

Battery terminals

Industrial Vaseline

9

Steering knuckle pin General lithium grease

Add

Change

10

Alternator bearing

General lithium grease

Add

Change

11

Drag link ball joint

General lithium grease

Add

Change

12

Tie rod ball joint

General lithium grease

Add

Change

13

Steering gear

Select as per engine manual

and local temperature (same

as that of transmission)

Add

Change

14

FR leaf spring pin

No.2 lithium grease

Add

Change

15

Front

wheel

hub

bearing

General lithium grease

Change

16

Rear

wheel

hub

bearing

General lithium grease

Change

17

Water pump bearing General lithium grease

Add

Add

18

Transmission input

shaft FR bearing

General lithium grease

19

Oil filter (element)

Change

Change

Change

20

Rear axle

Select as per engine manual

or local temperature

Change

Add

Change

21

Door hinges

Engine oil

add 3～4

drops

22

Wiper motor and

driving rod pin

Engine oil

add 3～4

drops

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

·63·

Chapter 3 Structure, Adjustment and Service of

BJ491EQ1 Gasoline Engine

Knowledge of structures of the gasoline engine parts, master of adjustment and maintenance essentials and

correct service, and maintenance to the gasoline engine can let the gasoline engine maintain its performance and

quality in long term. Following is a brief description of structures, adjustment and maintenance essentials for parts

of BJ491EQ1 multi point electronic fuel injection gasoline engine.

3.1 Cylinder head parts

The cylinder head parts of BJ491EQ1 multi-point electronic fuel injection gasoline engine is as shown in

Figure 3-1.

Figure 3-1 Cylinder Head Parts of BJ491EQ1 Multi Point Electronic Fuel Injection Gasoline Engine

1-PVC; 2-Valve keeper; 3-Intake valve spring top cap; 4-Exhaust valve spring top cap; 5-Valve spring; 6-Valve oil seal; 7- valve

spring bottom cap; 8-Valve; 9-Rear engine lug; 10-Rear cover of cylinder head; 11-Cylinder head; 12-Cylinder gasket; 13-Hydraulic

valve tappet; 14- Engine front lug; 15-Engine front water pipe assembly; 16-Exhaust pipe connector and gasket; 17-Valve guide;

18-Valve rocker arm shaft; 19-Valve push rod; 20-Spark plug cover; 21-Spark plug; 22-Valve rocker arm and spring; 23-Cylinder

head cover

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3.1.1

In order to prevent gas and water leakage from cylinder gasket, operator should check tightening torques

of cylinder head bolts with a torque wrench at every 500km and 2000km (for a new vehicle). The tightening

torques: 10 M12 bolts-- 93~105N·m; 3 M8 bolts--20~25N·m.

Tighen the bolts after the gasoline engine has cooled down. The tightening sequence is as shown in Figure

3-2.

Figure 3-2 Tightening Sequence of Cylinder Head Bolts

● Note: A cylinder head bolt can only be used twice. If the bolt has been used twice, replace with a new one.

3.1.2

Follow the sequence indicated in figure 3-3 to disassemble the rocker arm shaft, unscrew the bolts and

nuts of rocker arm shaft in 2~3 times to avoid breaking off of rocker arm shaft and damage the bolts.

Follow a sequence that is reversed to these indicated in figure 3-3 to assemble the rocker arm shaft assembly,

tighten the bolts and nuts in 2~3 times. The final tightening torque is 25~32N·m.

After a new vehicle has driven 500km and 2000km, its bolts and nuts on rocker arm shaft should be tighened

as per above torque requirements.

Figure 3-3 Sequence for Disassembly of Rocker Arm Bolts

3.1.3

After the gasoline engine has cooled down, follow the sequence that is reversed to these indicated in

figure 3-2 to disassemble the cylinder head. Unscrew the bolts of cylinder head step by step in 3 times to avoid

distortion of cylinder head.

3.1.4

When to mount a cylinder gasket, apply high temperature resistant sealant on surfaces of its both sides so

as to ensure sealing performance. The gasket must be replace each time cylinder head has been dismantled (see

figure 3-4).

Front

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

·65·

Figure 3-4 Installation of Cylinder Gasket

3.1.5

After a cylinder head has been dismantled, clear gasket leftovers embedded on surfaces of cylinder head /

block with a cutter. Be careful not to scratch contact surface and prevent entry of gasket leftover into tappet hole,

water jacket hole and bolt hole (see Figure 3-5).

Figure 3-5 Clearing of Cylinder Head / Block

3.1.6

Check cylinder head for crack, and follow procedures indicated in figure 3-6 to measure warpages of

cylinder head base and sides where intake and exhaust manifold are installed.

Figure3-6 Cylinder Head warpage Mesurement

Maximum warpage:

Cylinder head base: 0.15mm;

New cylinder gasket

Front

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

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Manifold side: 0.10mm.

If its warpage exceeds the maximum value, cylinder head.should be replaced.

3.1.7

Check the fitting clearance between valve stem and valve guide hole (see Figure 3-7, Figure 3-8)

Diameter of valve guide inner hole: Φ8.010~Φ8.030mm;

Diameter of intake valve stem: Φ7.970~Φ7.985mm;

Diameter of exhaust valve stem: Φ7.965~Φ7.980mm.

Nominal fitting clearances:

Intake valve: 0.025~0.060mm;

Exhaust valve: 0.030~0.065mm;

Maximum fitting clearances:

Intake valve: 0.10mm;

Exhaust valve: 0.12mm.

If the clearance exceeds the maximum value, replace the valve and valve guide.

Figure 3-7 Check Diameter of Valve Guide

Figure 3-8 Check Diameter of Valve Stem

3.1.8

Check valve cone and plate for depression, groove and carbon deposit. If necessary, grind to correct the

valve cone angle (correct angle is 44.5º). The grinding extent should be as small as possible.(see Figure 3-9).

Nominal edge thickness of intake valve: 1.0~1.4mm;

Nominal edge thickness of exhaust valve: 1.3~1.7mm;

Minimum edge thickness of intake valve: 0.5mm;

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

·67·

Minimum edge thickness of exhaust valve: 0.8mm.

Figure 3-9 Check and Grind Valve Cone

If the edge thickness of valve head is less than minimum value, valve should be replaced. (see Figure 3-10).

Nominal length of intake valve: 108.2mm;

Nominal length of exhaust valve: 108.5mm;

Minimum length of intake valve: 107.7;

Minimum length of exhaust valve: 108.0mm.

If total length of valve is less than the minimum value, valve should be replaced.

Figure 3-10 Check the Edge Thickness of Valve Head

3.1.9

Check valve seat for wear, damage and carbon deposit. If necessary, grind and clean the valve seat. The

grinding extent should be as small as possible.

Coat a thin layer of Prussian blue (or white lead) on the valve cone, install the valve, gently press and turn

the valve to check its seating condition. If the valve cone along 360º is covered with blue, the valve must be

coaxial; otherwise replace the valve. If the valve along 360º is covered with blue, the valve guide and valve seat

must be concentric; otherwise grind the valve seat. The contact annulus should be at the middle of valve cone with

a width of 1.2~1.4mm (see figure 3-11).

Edge thickness

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Figure 3-11 Check of Wear Status of Valve Seat

If the contact annulus fails to comply with above requirements:

(1) If the contact annulus is on top of the valve cone, grind the valve seat with 30º and 45º mill (see figure 3-12).

Figure 3-12 Grinding the Valve Seat with 30º and 45º mill

(2) If the contact annulus is at the bottom of the valve cone, grind the valve seat with 60º and 45º mill (see

figure 3-13).

(3) Grind the valve and valve seat with valve grinding compound to make them join closely without gas

leaking (see figure 3-14). After grinding, clean the valve, valve seat and inner hole of valve guide thoroughly.

Figure 3-13 Grinding the Valve Seat with 45º and 60º Mill

Width

Width

Width

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

·69·

Figure 3-14 Grinding of Valve and Valve Seat

3.1.10

Measure the free length of valve spring with a caliper, the reading should be 47mm ± 0.5mm; measure

perpendicularity of valve spring with a surface plate and a square, the reading should be less than or equal to 2mm.

If free length or perpendicularity of valve spring exceeds the specified limit, replace the valve spring.

Measure the elastic force of valve spring at nominal installation length 40.6mm with a spring tester, the

reading should be 292~336N. If the elastic force of valve spring at nominal installation length does not comply

with the specified value, replace the valve spring (see figure 3-15).

Figure 3-15 Measue elastic force of valve spring

3.1.11

Check valve rocker arm and rocker arm shaft:

(1) Check for wear on contact surface between valve rocker arm and valve, if necessary, polish this surface

or replace the rocker arm.

(2) Push and turn the rocker arm by hand along the direction shown in figure 3-16, if a relative movement

margin is felt, disassemble and check the fitting clearance between the valve rocker arm and the rocker arm shaft.

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Figure 3-16 Check Valve Rocker Arm and Rocker Arm Shaft

Inner diameter of valve rocker arm: Φ18.500~Φ18.515mm；

Diameter of rocker arm shaft: Φ18.474~Φ18.487mm;

Nominal fitting clearances: 0.02~0.051 mm;

Maximum fitting clearance: 0.08mm.

If the clearance exceeds the maximum value, replace the valve rocker arm and rocker arm shaft.

(3) Make sure the direction of rear end boss (valve rocker arm shaft) is correct, and follow figure 3-17 to

assemble valve rocker arm and spring. Use special tools to install and clamp during assembly.

Figure 3-17 Installation of Valve Rocker Arm

3.1.12

Check push rod

(1) Follow figure 3-18 to check run-out at middle of push rod. The maximum value is 0.30mm. If the value

exceeds the maximum, replace the push rod.

(2) Check oil passage hole of push rod for clogging. If clogging is present, use compressed air to clear up.

Forward

Heave

Up

Special tool

With heave

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine

·71·

Figure 3-18 Check Run-out at Middle of Push Rod

3.1.13

Use special tools (figure 3-19) to disassemble and assemble the valve. The valve spring end with white

paint faces down at mounting.

Figure 3-19 Disassembly and Installation of Valve Spring

3.2 Cylinder block parts

See Figure 3-20 for cylinder block parts and crank-connecting rod mechanism parts in BJ491EQ1 multi point

electronic fuel injection gasoline engine.

Special tool