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BCI One Door Urban Bus 2019, Owner'S Manual

The BCI One Door Urban Bus 2019 comes with a comprehensive Owner's Manual to guide you in operating and maintaining your vehicle efficiently. This invaluable manual is available for free download from our website, ensuring easy access to all the necessary information you need to get the most out of your urban bus.

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April 2019 
 – Issue 4 

Page 

40 

of 

48 

 

 

 

7A.2 - Rear Axle and Propeller / Tail Shaft 

Fault 

Possible causes 

Trouble shooting 

 
 
 
 
 
 
 
 

 

Noise or 

vibrations from 

transmission or 

drivetrain 

 

Failed or dry propeller shaft universal joints 

Inspect and lubricate grease nipples of propeller 

shaft – replace joints if any freeplay is found 

Low oil level in transmission or rear axle 

Check oil levels and top-up as necessary 

 

Loose bolts on propeller shaft coupling flange 

Re-tension fasteners of propeller shaft coupling 

flanges 

 

Propeller shaft universal joints not in phase 

Check propeller shaft has been phased correctly. 

If not, rectify 

 

Air conditioning belt ‘anti-slap’ tensioner failed 

bearings 

Check tensioner for failed bearings and ensure 

there is at ;east a 5mm gap between the belts 

and pulley roller 

Loose or collapsed engine or transmission 

mountings 

 

Tighten or replace mountings 

 

Metal to metal contact causing a ‘drumming’ noise 

through the cabin 

Inspect mountings such as engine, transmission, 

exhaust, engine fan and air-conditioning 

compressor for areas of contact 

 

Worn, loose or damaged rear sway bar bushes 

Check and replace bushes as required or tighten 

fasteners 

 

 

7A.3 - Steering: 

Fault 

Possible causes 

Trouble shooting 

 
 
 
 

 

Steering still / 

noisy and / or 

not self - 

centering after 

turning 

Low tyre pressure 

Check tyre pressure and adjust as required 

 

Lack of lubrication in king-pins and steering ball 

joints 

Raise the front axle onto stands ensuring the 

king-pins have no load on them. Grease the king 

pins and steering ball joints 

Lack of power steering oil 

Check oil level in reservoir is sufficient 

Steering shaft universal joints seized on shaft from 

steering wheel or shaft to steering box 

 

Inspect universal joints and replace if failed 

Failed steering pump 

Replace steering pump 

Stiff or seized tie rods ends 

Replace tie rod ends 

Loose fasteners on tie rod ends, drag link or steering 

box 

 

Check and re-tension if necessary 

 

Steering wheel 

not centralized 

or too much 

free-play 

Wheel alignment incorrect 

Reset wheel alignment 

 

Worn tie rod ends or damage to the steering link 

Check steering system for damage or wear and 

repair as necessary 

Loose nuts on tie rod ends or drag link 

Check and re-tension as necessary 

Loose steering wheel retaining nut 

Re-tension nut 

 

 Owner’s Manual 

Summary of Contents for One Door Urban Bus 2019

Page 1: ...April 2019 Issue 4 Page 1 of 48 One Door Urban Bus OWNER S MANUAL Bus and Coach International Pty Ltd Owner s Manual ...

Page 2: ...mfortable and safe service which will add value to your business Please ensure you operate and maintain the vehicle with care and attention BCI will not be responsible for any loss caused by improper use of the product Should you have any doubts about the operating or maintenance of the vehicle please do not hesitate to make contact with your Service Agent or Dealer in your area to discuss it BCI ...

Page 3: ...Pages 11 19 D Passenger Door Operating Instructions Page 20 E Emergency exits Page 21 F Master Control Switch Page 21 Section 4 Startup and Driving A Routine Checks Before After Driving Pages 22 23 B Checks Before After Every One Week Driving Pages 23 24 C Checks Before After Every Two Weeks Driving Page 24 D Startup Engine Page 25 E Moving Driving the Vehicle Pages 25 26 F Shutting down the Engin...

Page 4: ... Page 31 A First Service Schedule 5000km Pages 31 32 B Service Schedules Pages 32 34 C Recommendations for Lubricants Pages 34 35 Section 7 Trouble Shooting A Chassis Pages 36 39 B Body Page 39 C Electrical Equipment Page 40 Section 8 Appendix CAN Instrument Panel Guide Pages 41 48 Owner s Manual ...

Page 5: ...er details Please ensure all users STRICTLY follow the Operating Instructions of the vehicle so that it is used and maintained correctly The BCI body warranty is limited to 150 000km or three years whichever comes first Other Supplier Warranties such as engine transmission and air conditioning etc will be covered directly by the Supplier s Warranty and can be taken to a Supplier s outlet for recti...

Page 6: ... 12490 2495 3325 Wheelbase 6460 Front overhang 2750 Rear overhang 3280 Approach angle departure angle full load 8 8 2A 2 Vehicle Mass kg Body Mass approx Vehicle with 43 seats 10600 Gross Vehicle Mass GVM 18000 Maximum axle laden mass front rear 7 500 11 000 2A 3 Performance Parameters Maximum Speed km h 100 Maximum angle of grade ability 25 Minimum diameter of turning m 22 5 Owner s Manual ...

Page 7: ...0 Fifth gear 0 75 Sixth gear 0 65 Reverse gear 5 026 2B 3 Tail Shaft Model Exposed two universal joints Universal joint Rigid cross shaft needle bearing 2B 4 Front Axle Model Fangsheng Type I Beam axle air bag front suspension system air pneumatic control braking system Knorr disc brakes 2B 5 Rear Axle Model Fangsheng EQ153 Type Integrated forged welded axle housing full floating axle shaft Final ...

Page 8: ...auge Air pressure gauge Indicators for high beam lights etc 2B 11 Fuel Tank Capacity 250 Litres approximately 2B 12 AD Blue Tank Capacity 35 Litres approximately 2C Body Structure 2C 1 Structure type Monocoque Body Frame 2C 2 Structure of the Vehicle Body The structure of the vehicle body is fully welded and made with Australian Standard high tensile galvanized steel tube The main components of th...

Page 9: ...gurations with two types of seat belts 2C 7 Interior trim The following items can be found inside the vehicle Driver s side sun visor electric front windshield sun visor interior rear view mirror Electrical devices Driver s microphone FM AM CD 12v lighter jack CD Radio PA 2C 8 Air Conditioning System Type TK Standard otherwise please refer to the relevant A C operator s manual Optional Thermoking ...

Page 10: ...ease handle to lock 7 Lumbar Adjustment press the buttons to individually inflate or deflate the upper and lower area of the back rest 8 Fore Aft Adjustment pull the lever up slide the seat forward or rearward to desired location and release the handle 9 Armrest Adjustment turn the knob to adjust the armrest to desired location stow away when not required 10 Seat Heater press the button to turn ON...

Page 11: ...ired position then turn knob clockwise to lock Attention NEVER attempt to adjust the steering column whilst the vehicle is in motion 2 Figure 4 3C Driver s controls figure 5 4 1 Steering wheel horn buttons 5 2 Headlight direction indicator stalk 3 3 Windscreen wiper retarder stalk 6 4 Combination instrument panel CAN 2 7 5 Dash display controls 6 Drivers switches 1 8 7 Transmission control 8 Door ...

Page 12: ... will flash in this position the stalk is spring loaded and will return to normal position when released This is the turn signal indicator sign Move the lever away to engage right turn signal move the lever closer to engage left turn signal Red button Hazard indicator switch Push the red button on the end of the indicator stalk switch to turn the hazards on and off 3C 3 Windscreen wiper retarder s...

Page 13: ...ant temperature gauge 9 Fuel gauge Figure 9a 3C4 1 1 Instrument panel map figure 9b 10 Additional camera plug 11 Camera 1 plug rear door 10 13 12 Power CAN plug 13 Camera 2 plug mid door 14 Camera 3 plug reverse 15 Programmer plug Figure 9b 11 12 3C4 2 Instrument panel display figure 9c 1 Air pressure 1 2 Main interface 3 Gear 4 Air pressure 2 1 2 3 4 5 Time 6 Date 7 Urea indicator 8 Total km 9 Tr...

Page 14: ... 5 1 Passenger alight indicator This blue light when ON notifies the Driver that passengers wish to alight the vehicle 3C 5 2 Toggle for rearview mirrors Toggle left or right to adjust either nearside or offside mirror position 3C 5 3 Destination unit Please refer to destination SD Controller Guide 3C 5 4 Interior saloon light switch 2 stage high low Press down the lower end to turn the lamps on l...

Page 15: ...w mirror defrost is operational press down the upper end to turn off the power Air horn Electric horn switch Press down the lower end to use the air horn press down upper end to use the electric horn Kneeling switch Press down to activate the vehicle kneeling function this lowers the vehicle to allow easy access for passengers entering the vehicle 3C6 Driver s console switch button and indicator f...

Page 16: ...pedal pressing the RESUME position of cruise set resume coast accelerate switch will re engage the cruise control and resume the last driving speed 3C6 2 2 Quick speed ups To increase the vehicles speed without using the accelerator the driver simply has to press the accelerate of the Cruise Set Resume Switch The cruise control must be turned on and the vehicles speed to be over 50km h in order fo...

Page 17: ...o be taken to a service centre When the red indicator is on the driver MUST stop the vehicle and have the problem resolved before the vehicle is driven any further 3C 6 7 ASR indicator Disabled ramp indicator When the top indicator is on the ASR is on the bottom indicator shows the disabled ramp is in an open position 3C 6 8 Kneeling switch Press down to activate the vehicle kneeling function this...

Page 18: ...E The first number displayed is the highest forward range available and the second number is the range attained in a selected position Visually check to confirm range selected if the display is flashing the shift is inhibited NOTE TO SELECT FORWARD OR REVERSE GEAR THE FOOT BRAKE MUST BE DEPRESSED 3C 13 Park Brake Control figure 13 The Park Brake control is located within easy reach on the driver s...

Page 19: ...b Thermoking ClimaAIRE II 1 Digital display 2 Thermostat control 3 Air mode 4 Speed 5 Mode setting 6 Display temperatures 7 Power on off 1 2 Figure 15b 3D 3 Destination Sign Central Controlling Device Function of the Keys figure 16 1 Function Selecting 2 Cancel and Return 3 Page up 4 Page down 5 Shift Up Down 6 Trigger SOS 7 SD card interface 8 Photosensitive Probe 9 Direction indicator Note Pleas...

Page 20: ...y unlocking the doors figure 17a and then pressing the open close buttons figure 17b which are located outside the vehicle on the bottom right hand side of the doors Figure 17b 3E 2 Passenger door EMERGENCY operation 3E 2 1 Internally Use the emergency exit valves figure 18 These are located above the passenger door rotate clockwise to release the air pressure in the door and then pull push the do...

Page 21: ...de the vehicle NB All windows can be broken with the hammer 3F 2 Two roof hatches marked with an emergency exit label see figure 19c The roof hatches can be used in an emergency as follows Pull plastic cover see figure 19d to access the red release lever then rotate the lever left or right to unlock and then push the hatch up to open Figure 19c Figure 19d Pull plastic cover to remove 3F 3 The near...

Page 22: ... be opened when adding any coolant this is to exclude the air in the coolant pipe ALWAYS be sure to use the correct coolant for the engine as specified by the engine manufacturer Coolant level 4A 3 Check the fuel level The fuel level can be seen from the fuel gauge on the instrument panel Add clean diesel as required If the vehicle operates in a humid area it is advisable to keep the fuel level as...

Page 23: ...April 2019 Issue 4 Page 23 of 48 Regularly clean the outside of the various lights and indicators to maintain clarity ...

Page 24: ...e checked for excess water every two weeks Pay particular attention to the tank nearest the engine Note The air drier cartridge MUST be replaced at least once each year Figure 24 Pull ring downwards to dispel any residue from air tank 4A 12 Check whether the foot brake and the hand brake operate normally and if there are any leaks 4A 13 Check the steering box free play Steering box free play allow...

Page 25: ...April 2019 Issue 4 Page 25 of 48 F i g u r e 2 5 c W i n d s c r e e n w a s h e r f l u i d ...

Page 26: ...n the oil tank figure 27 To fill with oil start the engine slowly add oil through the top of the reservoir until the oil level reaches midway in the reservoir viewing mirror Some air may be drawn in during the pouring process it is important to turn the steering wheel to the two full lock positions several times so as to exhaust any air bubbles from the oil storage tank 4C 2 Check the tension of t...

Page 27: ...n of the bearings 4E Moving driving the vehicle After starting the engine the pressure in the braking system should be above 6kg cm2 a buzzer will sound until the air pressure reaches this level The various instruments and indicators should be normal the outlet water temperature should be above 60 DO NOT move out with the vehicle until the brakes have been fully released When driving the vehicle n...

Page 28: ...UST NOT be shut down immediately Operate the engine for a while DO NOT shut down the engine until the temperature of water has dropped to a normal value Select the neutral position on the transmission control pad and then turn off the power After shutting down the engine engage the parking brake WARNING If you leave the vehicle with the engine running the vehicle could move unexpectedly and people...

Page 29: ...he radiator fins or any Electronic Control Unit ECU 5C Maintaining the engine For up to date and correct engine maintenance information please refer to the engine Supplier s Operation Handbook For cleaning steam is the best method for an engine and its components ENSURE that all electrical components such as ECU s alternators starters openings wiring and terminals are protected from the full force...

Page 30: ...ement ONLY DO NOT start the engine after the filter has been removed Clean the cover and the inside of the shell using a dry clean cloth Do prevent water entering the air filter directly Expel the dust in the blurter valve Clean the filter elements by using compressed air at maximum 2 5bar to lightly blow the dust off without tearing the paper element The elements may be washed but please check wi...

Page 31: ...ure 31e 5H 3 Remove the filter cover figure 31f and twist the end of the filter to disengage seal figure 31g Gently remove the filter element1 from the housing Inspect the filter for foreign material on the sealing surface and potential marks of dust on the clean air side Note If servicing a system that contains a secondary element apply the same procedure Figure 31f Figure 31g 5H 4 Thoroughly cle...

Page 32: ... oriented downward figure 31k Twist the cover to the right into the locked position figures 31l m ESSENTIAL TO ENSURE THE COVER IS SECURELY LOCKED BEFORE DRIVING THE VEHICLE Figure 31k Dust ejection valve Figure 31l Figure 31m Changing the air filter has been extracted from the Cummings Fleetguard Optiair Service instruction 5J DEF tank remote breather filters Extracts from Cummins Maintenance Man...

Page 33: ...m air tanks greasing and checking of the fluid levels etc MUST be done in between these recommended services For buses operating under arduous conditions these service intervals must be reduced Confirm details from the Supplier s maintenance booklet prior to commencement 6A ENGINE CHECKS FIRST 5000KM No TICK IF OK 1 Air cleaner restriction check 2 Air compressor mounting check 3 Charge air cooler ...

Page 34: ...functioning correctly 41 Check emergency exit lights and stickers for wear and damage 42 Check operation of air conditioner 43 Check operation of wipers and washers 6B ENGINE CHECKS A B C D BOXES NOT FILLED IN WITH BLACK ARE TO BE ACTIONED IF THEY LINE UP WITH THE RELEVANT SERVICE COLUMN A B C D EVERY 15000KM EVERY 30000KM EVERY 60000KM EVERY 120000KM No TICK REQUIRED SERVICE DUE IN BOX OPPOSITE 1...

Page 35: ...adjust as necessary 14 Check all hoses pipes and wires for wear damage or leaks 15 Check driveline for damage or leaks 16 Check engine transmission mountings for damage and tension 17 Replace air drier filter minimum once per year 18 Replace oil in fan angle drive assy and grease in shaft CV joints 19 Air filter check clean or replace if necessary 20 Replace differential oil 21 Replace Transmissio...

Page 36: ...oil used to lubricate the pistons will be burnt consumed due to the high temperatures This burning causes the engine oil to deteriorate and the burnt oil contaminates the lubricant It is therefore important that the engine oil is replaced after a certain period Such deterioration depends on the operating conditions as well as the quality of the oil used So the time interval for replacing the oil i...

Page 37: ...assis Lithium based Extreme Pressure 2 grease LX EP 2 should be applied to the various components 6C 6 Parker Fan Angle Drive Oil For vehicles fitted with the Parker hydraulic fan angle drive Check the oil level by viewing the sight glass figure 32a If necessary remove cap figure 32b and top up oil level as required with Shell Tellus semi synthetic hydraulic oil S2M 46 Figure 32a Figure 32b Owner ...

Page 38: ...select a gear with the foot firmly applied Engine not starting Rear engine door not closed firmly Ensure rear engine door is fully closed and the door warning light on dash for open rear door is no longer illuminated Vehicle in gear Select neutral on transmission control selector Bus isolator switch has not been turned back on Turn on bus isolator switch Red engine safety isolator switch in engine...

Page 39: ...he bus urgently as soon as it is safe to do so and turn off the engine Call a BCI or Cummins Dealer for assistance Engine loss of power Possible binding of brakes Stop driving and position the vehicle on a slope and release the foot brake to see if the bus rolls freely and brakes are not dragging If brakes are dragging stop and call a BCI Dealer forguidance on how to proceed Engine lamp illuminate...

Page 40: ...reas of contact Worn loose or damaged rear sway bar bushes Check and replace bushes as required or tighten fasteners 7A 3 Steering Fault Possible causes Trouble shooting Steering still noisy and or not self centering after turning Low tyre pressure Check tyre pressure and adjust as required Lack of lubrication in king pins and steering ball joints Raise the front axle onto stands ensuring the king...

Page 41: ...y in steering Possible steering box adjustment required Adjust steering box freeplay 7B Body Fault Possible causes Trouble shooting Entry door not opening or closing No air pressure in system Start engine and build up air pressure Incorrect setting of RT146 entrapment AU Eastern States Emergency door valve is in the on position Turn off the emergency door valve under front nearside of bus Door rem...

Page 42: ...ut To repair or replace them The engine rotation speed is very low while starting The battery power is insufficient The terminals have become loose or soiled To charge the battery To clean fasten repair or replace the terminals The connecting points of the switch on the engine have been burned out and eroded The armature shaft has bent or the copper sleeve has burnt out To replace the switch Repai...

Page 43: ...More Accurate Data Because the instrument panel transmits data and displays it using digitizing methods it has complete error correction and does not produce additional errors Higher Reliability The CAN has data reliability because of the digitizing methods it also has a low failure rate as it is designed for certain poor working conditions It only communicates with the vehicle and provides a reli...

Page 44: ... will alight When the water level alarm speed alarm rotational speed alarm and oil pressure alarm and so on occur the buzzer will make the sound Dee Dee Seq Name Sign Comments 1 Offside indicator 2 Nearside indicator 4 Retarder Since 2014 ONLY 5 ASR 6 Air suspension warning 7 Air suspension error 8 Transmission error 9 ABS error 12 Oil temperature alarm 13 Water temperature alarm 14 Oil pressure a...

Page 45: ...ht failure etc Camera surveillance information 8 1d Button Operation see figure 2 Also refer to figure I page 41 ZB277 Outline The basic function is as follows Figure 2 The operation buttons of the instrument panel from left to right are respectively 1 MENU short time press Display instrument panel main menu 2 UP short time press choose up long time press LCDbacklight 3 DOWN short time press choos...

Page 46: ...n Menu list for the instrument panel The results are as shown in figure 5 Figure 5 Operation Volumes and Alarm Display Interface The top column shows the instrument panel operation when it cannot display all the operations a white arrow will appear on the right Press the UP button and DOWN button to move to the white arrow at this point the white arrow will go green and means that you can now page...

Page 47: ...s hold the LEFT button to clear If the clear function is not required press the MENU button to quit When the user chooses to enter the sub menu for vehicle temperature information in the main menu the screen display is shown in figure 7 vehicle temperature information Figure 7 Vehicle temperature information The user can see the temperature values in this screen to exit this screen press the MENU ...

Page 48: ... by pressing the MENU button to confirm and exit When the user chooses to enter the sub menu Diagnoses information in the main menu the screen display is shown as figure 10 Menu of Diagnostic information Figure 10 Menu of Diagnostic information The user can review the available diagnostic information by choosing each module displayed The diagnostic information is shown as figure 11 Diagnostic code...

Page 49: ...creen display is shown as figure 13 Tyre pressure indicator Figure 13 Tyre pressure indicator The user may wish to examine a tyre by pressing toggling the UP button When a tyre is selected the corresponding tyre icon will become green and the corresponding pressure and temperature will be displayed on the screen If a tyre lacks pressure the corresponding tyre icon will become red at the same time ...

Page 50: ...3 6 5 Camera 3 plug reverse 6 Programmer plug The 3 separate camera interface connections to the AV output are for monitoring the real time condition for reverse the middle door the rear door and so on These images can be displayed on the screen controlling the cut with the pressed key The video wiring uses 75 ohms shield coaxial cables CAN Instrument panel technical parameters Operating voltage 2...

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