Maintenance Manual
General Principles
General Maintenance Principles for Higer Bus 3906_M0001_General Maintenance Principles for Higer Bus
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Higer BUS
Maintenance Manual
General Principles
Contents
1. 3. 3.1 3.2 4. 5. 6. 7. 8. 9. 9.1. 9.2. 9.3. 9.4. 10. Subject and scope ...................................................................................................................................................................................................................................... 3 Definition ....................................................................................................................................................................................................................................................... 5 Definitions adopted by the manual: .....................................................................................................................................................................................................5 Terminology................................................................................................................................................................................................................................................ 6 Maintenance purpose for Higer bus ...................................................................................................................................................................................................... 8 Maintenance principles for Higer bus ................................................................................................................................................................................................... 8 Maintenance classification and period for Higer bus ....................................................................................................................................................................... 8 Maintenance instructions for key procedures of Higer bus ............................................................................................................................................................ 9 Higer bus elementary maintenance ....................................................................................................................................................................................................... 9 Higer bus complete maintenance ......................................................................................................................................................................................................... 9 Inspections in the complete maintenance .........................................................................................................................................................................................9 Complete maintenance............................................................................................................................................................................................................................9 Complete maintenance process validation......................................................................................................................................................................................10 Acceptance inspection of complete maintenance .........................................................................................................................................................................10 Supplements: ........................................................................................................................................................................................................................................... 10
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2. Referenced standards
The following standards contain provisions which, through references in this text, constitute provisions of this standard. All the indicated editions are valid since the issue of this standard; however, parties using this standard are encouraged to investigate the possibility of applying the most recent editions of the referenced standards indicated below. GB/T183442001 GB56242005 GB72582004 Specification for the Inspection and Maintenance of Motor Vehicle
Motor vehicle maintenance and repair terms Safety specifications for power driven vehicles operating on roads
GB185652001 Multiple performance requirements and inspection methods for commercial vehicles GB14952002 GB74541987 HJ/T240-2005 Allowable noise limits for motor vehicle Technical regulations for operation and beam adjustment of motor vehicle head-lamp Emission standard for smoke at free acceleration from vehicle with diesel engine
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3. Definition
3.1 Definitions adopted by the manual:
Running-in maintenance New vehicles or Higer buses with overhauled engine or new assembly such as transmission, final drive and etc., should be thoroughly inspected and properly adjusted and maintained according to the corresponding provisions for new vehicles. The maintenance mainly includes cleaning, lubricating and fastening, so as to keep the vehicle in good technical condition, and should be carried out by the Higer authorized service stations. Daily maintenance Clean vehicle appearance and engine surface to keep it tidy, visually check such working mediums as lubricating oil (grease), fuel, coolant, hydraulic fluid, power steering oil, battery electrolyte, A/C refrigerant, as well as tyre pressure, and add them if necessary; visually check and tighten such safety-related positions as brake, steering gear, transmission, suspension, lighting, signal and etc., and check engine running conditions so as to guarantee the driving safety. The maintenance work should be conducted by the customer (driver). Elementary maintenance In addition to the daily maintenance, this maintenance, carried out by the Higer authorized service stations, mainly focuses on cleaning, lubricating, tightening and the inspection of safety parts related to braking and controlling. Complete maintenance (mandatory maintenance) In addition to the elementary maintenance, this maintenance, carried out by the Higer authorized service stations, mainly focuses on the checking the clutch, steering system, braking system, suspension and etc. for any worn or deformed parts after a certain period of operation and adjusting if necessary. It also covers the disassembly, inspection and transposition of tyres, the inspection and adjustment of engine operation and emission control devices and etc.
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3.2
Clean
Terminology
Operations to remove the carbon deposit, dust, oil sludge and other dirt from the vehicle parts and assemblies with efficient methods Wash Operations to remove the rust, oil sludge and other dirt from the vehicle parts and assemblies with efficient methods and special cleaning agents Lubrication Operations to fill with qualified lubricating oil or grease according to specified methods after the cleaning of vehicle parts and assemblies according to the technical specifications. Inspection Operations to observe and examine the reliability and effectiveness of vehicle parts and assemblies according to the technical specifications and to repair or renew the unqualified ones Tightening Operations to check and tighten the fasteners of vehicle parts and assemblies according to the technical specifications Adjustment Operations to adjust vehicle parts or assemblies according to the technical specifications so as to make their positions with respect to each other or the calibration values meet the technical specifications Assembly and disassembly Operations to remove assemblies from vehicle and reinstall them on the same vehicle after carrying out relevant work Measurement Operations to measure with qualified instruments and measuring implements in a specified manner Completeness
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Status that the model, specification, quantity and requirements of a vehicle part or assembly all comply with the relevant standards or provisions Intactness Status that there is no missing, damaged or abnormal vehicle part or assembly Abnormal wear Phenomenon that the wear rate of a vehicle part exceeds the range specified by the design or the technical document Ageing Phenomenon that the material performance of a vehicle part declines as time goes by Deformation Phenomenon that the shape and poison of the element of a vehicle part changes permanently during service Abnormal noise Noise, from a vehicle assembly or mechanism during operation, that exceeds the level specified in the technical document Leakage Phenomenon that the leakage on a sealed vehicle part exceeds that specified in the technical document
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Elementary maintenance Every 5,000-6,000 km. For the vehicles not used often, the longest interval should not be more than 2 month Complete maintenance (mandatory maintenance) Every 10,000-12,000 km. For the vehicles not used often, the longest interval should not be more than 4 months Seasonal maintenance See Seasonal Maintenance for details
Engine Repair according to the engine technical and financial conditions Body In principle, repair should be carried out as required in the fifth year
Note: the above mileage or interval, whichever comes first, must not be exceeded, and may, however, be advanced.
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9.
When a vehicle is driven to the service station for the complete maintenance, the first thing, if conditions permit, is to determine the inspection items according to the vehicle technical records (including running, maintenance, inspection and assembly repair records) and the customers (drivers) description of the vehicle technical conditions (including the dynamic property, abnormal noise, steering, engine performance, fuel and lubricant consumption and etc.). After the inspection, the fault diagnosis can be carried out on the basis of the inspection results and the actual technical conditions to determine some additional maintenance items, which, combined with the elementary maintenance items, will be included into the complete maintenance. During the complete maintenance, it is required to carry out the process validation according to relevant technical standards and specifications; and after the maintenance, the customer needs to sign on the process sheet for confirmation. 9.1. Inspections in the complete maintenance
If conditions permit, the inspections should be carried out with those special inspection instruments whose accuracies meet relevant provisions, and if not, visual inspection and road test are allowed. For the technical requirements of the complete maintenance inspections, refer to the relevant standards of the country in question or factorys requirements. 9.2. Complete maintenance
The complete maintenance covers the elementary maintenance, centers on inspection and adjustment, and also conducts local disassembly, cleaning,
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lubricating and etc. so as to achieve the improvement of lubricating conditions, reduce the wearing of parts, ensure the function of safety parts and reliable braking, and thus satisfy technical conditions for the vehicles safety operation. 9.3. Complete maintenance process validation
The manual only list the main inspection items and technical requirements of the basic maintenance item of the complete maintenance. As for the process validation in addition to the complete maintenance, it should be carried out according to corresponding repair standards or technical requirements on the basis o f the actual conditions during the whole maintenance procedure. 9.4. Acceptance inspection of complete maintenance
The inspection should be carried out according to the technical requirements after all the basic items specified by the complete maintenance have been carried out on the vehicle.
10.
Supplements:
The document is compiled by the Service Manual Team of the Overseas Service Department. The previsions come into effect as of the publication day. 2011.03.01 1st March, 2011
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