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Volare Marcopolo, Owner'S Manual

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Volare Marcopolo Owner'S Manual Download Page 108

108

Brake Diagram 

1- Pedal valve
2- Dual manometer
3- Parking brake valve
4- Interrupter
5- 4-way valve
6- Dry air reservoir
7- Rear chamber - Spring brake
8- Front chamber
9- Front chamber
10- Air compressor
11- Pressure regulator
12- Drain valve
13- Humid air reservoir
14- 2-way valve
15- Rapid discharge valve
16- Serpentine

Engine Brake

15

15

12

11

16

Summary of Contents for Marcopolo

Page 1: ...1...

Page 2: ...2...

Page 3: ...SPECIFICATIONS 34 VOLARE IDENTIFICATION POINTS 34 COMMANDS CONTROLS AND MAINTENANCE 37 PANEL PANEL IDENTIFICATION 37 OPTICAL WARNING INDICATORS 38 PANEL SWITCHES 43 INTERRUPTORS 44 STARTING SWITCH 45...

Page 4: ...s Reaction 82 Check of the Lubricating Oil Level in the Engine 82 Changing of Oil and Lubrication Filter in the Engine 82 FEED SYSTEM 83 Air Feed System Maintenance 83 FUEL SYSTEM 85 Fuel Supply Syst...

Page 5: ...ife of your vehicle Before operating your vehicle for the first time read the information contained in this manual The durability of your Volare depends on how you operate it considering that the sati...

Page 6: ...6...

Page 7: ...n the warranty for this unit transmission is valid for 36 thirty six months without limitation in kilometerage 2 6 Wooden floor Navy color covering is warranted for 24 twenty four months unless improp...

Page 8: ...POLO S A Volare Division 4 6 Allow only legally authorized people to drive this vehicle 4 7 Use only adequate fuel and lubricants recommended by MARCOPOLO S A Volare Division 4 8 Require and execute i...

Page 9: ...enoid valves diodes micro switches enter into composition of parts with determined period of service having the term covered by the warranty of 90 ninety days since the date of the tax invoice emissio...

Page 10: ...13 The warranty does not cover equipment or alterations made and applicated by third parties that were not authorized by MARCOPOLO S A Volare Division 5 14 Replacement of defected parts or components...

Page 11: ...tabilizers springs etc 6 3 3 If there are hollows on the underbody 6 3 4 If the vehicle got into an accident or collision 6 3 5 If the structure of the vehicle was repaired or altered not in one of th...

Page 12: ...DELIVERY CHECK LIST the document that guarantees your rights to the WARRANTY when signed by you and registered by the manufacturer The WARRANTY TERM comprises the contract information that ensures you...

Page 13: ...bligatory to perform periodic inspections at the Volare Representatives in the specified intervals The check of the maintenance chart execution is made by virtue of the authentification by the executi...

Page 14: ...14 14...

Page 15: ...ivery Name and Signature Volare Representative s Stamp Herewith I declare that this vehicle has been delivered to me this day completely inspected and in perfect external and operating conditions I ha...

Page 16: ...16...

Page 17: ...and Signature Volare Representative s Stamp Herewith I declare that this vehicle has been delivered to me this day completely inspected and in perfect external and operating conditions I have also rec...

Page 18: ...18...

Page 19: ...no Engine No Owner Address No District Zip Code Telephone City State e mail Overhaul Date Trade Note No Volare Representative s Code Person responsible for Technical Delivery Name and Signature Volar...

Page 20: ...20...

Page 21: ...s no Engine No Owner Address No District Zip Code Telephone City State e mail Overhaul Date Trade Note No Volare Representative s Code Person responsible for Technical Delivery Name and Signature Vola...

Page 22: ...22...

Page 23: ...system front axle clutch coupling tyres 1 4 Lubricating and Re tightening Chart 1 5 The Veicle s Performance 1 6 Safety precautions concerning lead seals for example tachograph gearbox high pressure...

Page 24: ...r from the washer reservoir expansion chamber and mixture 3 2 Liquid from the clutch and brake reservoir 3 3 Oil from the engine crankcase gearbox differential gear and hydraulic system 3 4 Oil from t...

Page 25: ...pare Tyre Jack Wheel Wrench and Triangle 5 12 Towing Pin 5 13 Emergency Hammers 5 14 Internal and External Conservation 6 General Safety Regulations 7 Daily Inspection before starting the engine ex dr...

Page 26: ...ing gaps of the mechanism latches rubber seals attachment and functioning Driver s Seat Check functioning of the components finishing of the fiberglass and noise Internal lining overhead luggage racks...

Page 27: ...d the product Havoline XLI Green in the proportion of 10 Change every 350 000 km or 3 years 4 When the vehicle is used in more than 100 000 km year conditions the frequency of the maintence must be in...

Page 28: ...High pressure Pump Maintenance is not performed Note 9 Every time when a fault or a problem occurs check at a BOSCH service station Cones electro injectors Lubricating Oil Filter Fill 1 2 litres Chart...

Page 29: ...er At every 2 refuelling and necessarily when the indicator lamp starts glowing on the panel Replace the element ENERGY SUPPLY Battery Re tighten the terminals Check level of the electrolytic solution...

Page 30: ...SYSTEM Brake Compressor Lubricate with grease Chart 1 Note 6 Axle Expansion Support Lubrificate with grease Chart 1 Check the state of brake shoe lining and change if necessary Note 2 Check the gap of...

Page 31: ...grease COUPLING CLUTCH Axle Fork Clutch Lubricate with grease Chart 1 Lubricate only when fulfilled the maintenance of the coupling clutch system Hydraulic Clutch Reservoir and change of Clutch Fluid...

Page 32: ...ightening and lubrications mentioned and suggested in this chart are related to the preventive maintenance and are not covered by the warranty RE TIGHTENING CHART ITEMS TO BE RE TIGHTENED ASSEMBLING 5...

Page 33: ...ions Grease Windshield Wiper Assembly Oil Windows Sliding Mechanism Graphite Front Grille Oil Towing Hook Grease Pantographic Door Mechanism and Butt Oil Hatch Mechanism Oil Air Inlet Mechanism Oil Se...

Page 34: ...situated on the following points 1 Column of the Hatch of the Battery Compartment 2 On the Panel Structure to the left of the Steering Wheel under the panel identification of every vehicle used for re...

Page 35: ...l Information Plant Factory Serial Number 1 On the Structure 1 1 On the column of the hood To reach it open the hood and check on the column under the hood coupling 1 2 On the Front Wheelset is situat...

Page 36: ...pper part of the engine To see it open the hood as showed in the photo Gearbox Rear Axle Air Conditioner The Air Conditioner s serial number is situated on the air condenser or also in the Air Conditi...

Page 37: ...01 03 12 12 12 13 PANEL IDENTIFICATION 01 Panel Indicators 08 Air Conditioner 02 Control Switches 09 Electric Switchboard 03 Starting Switch 10 Multifunctional Switch 04 Parking Brake 11 Selector Swi...

Page 38: ...ep the button during a few seconds The time must be adjusted on the tachograph To this effect consult the tachograph s manual that accompanies the vehicle 3 Manometer The manometer features hands that...

Page 39: ...he vehicle is in motion immediately switch off and find out the reason Do not start the engine without finding out and eliminating the failure 7 Alarm Light Activated High Beam The blue light when sta...

Page 40: ...hen it starts glowing it means that the air filter is overfilled with dust Stop the engine and replace the prime element of the air filter 12 Brake Light Engine started This light starts glowing only...

Page 41: ...ndicates when the engine is operating with rotations above the maximum recommended Description of the Bands White Band low rotation range Green Band maximum torque and economy range Yellow Band maximu...

Page 42: ...ngine Temperature Indicator The Engine Temperature Indicator records temperature of the water in the motor cooling system Besides the low cool and very hot indications it has a red band to indicate ex...

Page 43: ...ge Heating Fridge Steps Gangway Lightening Maintenance Light Night Light passenger compartment Nest Stop Request Button Taillight Front Door Reading Light Clearance light headlight Position Light Bagg...

Page 44: ...situations Signal Lights and Headlights Interrupter The headlights and signal lights interruptor has three positions a Headlights and signal lights are switched off b Panel instruments lights and rea...

Page 45: ...r reasons of safety stops your vehicle switching off all the electric equipment except for the radio and tachometer IMPORTANT Switch off the master switch every time when it is necessary to perform an...

Page 46: ...nies the vehicle IMPORTANT The air conditioner is calibrated by the device s manufacturer to provide comfort ambient air temperature for the passengers and driver If it is necessary to alter the tempe...

Page 47: ...Defroster with Vaporizer Filter Unloading Activation Switch of the airconditioner and air diffusers In vehicles equipped with the defroster optional with air conditioner we recommend to carry out per...

Page 48: ...s the vehicle Selector Switch Comand The selector switch is situated on the panel in vehicles equipped with microphone radio DVD CD Video Monitor The selector switch is optional for the vehicles that...

Page 49: ...y 7 during 8 secods 3 Push Aux or DVD key 6 ELECTRIC SWITCHBOARD The electric switchboard is located on the panel near the driver s station To access the electric switchboard remove the panel s cover...

Page 50: ...rve the following External side lamps low beam headllamps Internal side lamps hight beam headlamps The lamps replacement is performed accessing the respective compartments on the back ends of the head...

Page 51: ...windshield wiper SPEED SELECTOR LEVER GEARBOX The speed selector lever features 5 forward gears and 1 reverse gear The lever positions are shown below NOTE The Volare gearbox is equipped with a coupli...

Page 52: ...m is hydraulic and hydrostatic providing easy operation and less physical depreciation Clutch Pedal The coupling clutch is activated hydraulically providing easiness and flexibility To change the rout...

Page 53: ...ER S SITE A Driver s Seat The driver s seat features multiple adjustments to provide comfort and safety to the driver It allows performing of the driver s seat adjustments sideways forward and backwar...

Page 54: ...capacity identification is located near the driver B Driver s Seat 1 3 4 5 6 Sit down pull totally adjust the inclination of the back seat with the body and return the lever Adjust the height in accor...

Page 55: ...belts should always be fastened before moving off This measure applies to all passengers driver auxiliary driver etc Seat belts offer maximum protection only when they are correctly fastened How to Fa...

Page 56: ...ll always be well attached to the body If necessary re tighten the seat belt strap To Shorten the Seat Belt Just pull it through its free end The excessive length portion shall be tied through the pla...

Page 57: ...focus Air Inlet Equipped with an air inlet intergrated to the emergence exit it is located on the ceiling center with access through the internal area of the vehicle When closed interrupt the air inl...

Page 58: ...ng properly Always try to give orientations to your passengers of the emergency meusures Emergency Mechanism In case of emergency pull the two levers and push the window with both hands Emergency Hamm...

Page 59: ...ir Convector Hot air Radiator Air diffusers Left Side Convector Right Side Convector Radiator Expansion tank Engine hot water Engine hot water Valve Valve Defroster Bus body front IMPORTANTE The heati...

Page 60: ...iew mirror is convex for easier vehicle operation DOORS Door Opening and Closing System Activating the Doors The door activating through the front grille Emergency Mechanism The emergency valve is loc...

Page 61: ...ion NOTE Always keep the air reservoirs drained to avoid faults in the pneumatic system Rear Hatch To open the rear hatch insert the key into the lock eye turn and remove the key press the lock eye wi...

Page 62: ...be immediately repaired to not compromise the entire paint system When damages with asphalt splashes occur remove them applying cleaning solvent Then wash it and use conservation wax Prevention and C...

Page 63: ...8 1195 Flat Salcomix BASF Gray Steel Gray 96 Fiat 4166 Metallic 55 BASF Yellow Yellow M 10L3 Massey Fergusson 3355 1007 Flat Salcomix BASF Yellow Chrome Yellow 85 Ford 5032 Flat Salcomix BASF Blue Mun...

Page 64: ...If during the washing you see that the water does not form drops on the painting the vehicle may be waxed after the drying It is recommended to use a neutral biodegradable detergent very foaming tens...

Page 65: ...ater and common soap rubbing the window panes with a flannel until they get clean Clean the window gutters with a brush and then apply a small amount of industrial talc or graphite powder Clean the ru...

Page 66: ...tly Neutralizer Ink Isopropyl Alcohol Rub until the stain disappears Solvent Benzene Apply slightly Solvent Wisky Detergent 1 20 Wash the residues with a sponge Emulsifier Ammonia 1 3 Apply slightly N...

Page 67: ...datory procedure 5 If the differential gear is damaged remove the axle spindles from the wheels Vehicles Equipped with Automatic Transmission IMPORTANT Before towing the vehicle disconnect the cranckc...

Page 68: ...your vehicle be careful to not exceed the load capacity of the vehicle and follow instructions regarding weight distribution These procedures will ensure the stability and safety of your vehicle Neve...

Page 69: ...ons for automotive vehicles Non observance of the established laws by manufacturers of vehicles non conformity with the emission standards leads to refusal or termination of the licence to use the veh...

Page 70: ...ion control Model Slow Running Rotation RPM Maximum Free Rotation RPM Free Acceleration Fumes Index 350m below sea level Label Value m 1 350m above sea level Label Value m 1 Volare W8 W9 770 50 2 780...

Page 71: ...r changing most softly and sincronizingly possible providing comfort and security for the passengers 4 Always use the clutch pedal to change gears Incorrect use of the coupling clutches will cause pre...

Page 72: ...on one side than on the other In the rear axle besides the loss of vehicle s stability the differencial gear may be danificated 17 Swamps or areas covered with water in these situations be careful Do...

Page 73: ...ul manner avoiding frequent and unnecessary accelerations Vehicle speed should be compatible with traffic conditions and the gears should be selected in an estimating manner to providing engine operat...

Page 74: ...ngine and start the vehicle STARTING WITH COLD ENGINE a Check if the parking brake is activated b Get the speed selector lever in neutral position dead point or get the lever of the automatic gearbox...

Page 75: ...ate only by means of the contact switch IMPORTANT Setting the starting switch from position 2 to 3 the indicator light starts glowing for a system test It stays glowing for about 5 seconds and then st...

Page 76: ...heir deformation 5 Cover in hermetically the engine air inlet and outlet 6 Pulverize wax based conservation products on the chassis engine if necessary on pulverize wax on the painting of external sur...

Page 77: ...Do not add the master key in the electric circuit supplying the electric module If it is necessary to disconnect or connect the electric module keep the ignition key in the switching off position PRE...

Page 78: ...y contains an acid that causes burns Do not contact this acid If there is an accidental contact of the acid with your eyes or skin wash the surface with plenty of water and immediately see a doctor To...

Page 79: ...watch bracelets etc Eventual erros in the operation may result in explosion of the batteries causing physical injuries Keep away open fire and cigarettes from the batteries and avoid electric sparks D...

Page 80: ...e injection system problems in the supply system Precautions with the Electronic Module Avoid touching the electronic connectors of the electronic module If necessary the blocking system may be easily...

Page 81: ...consult the neares Volare Representative at the first opportunity Level 2 Switched ON Reaction immidiate motor degradation With loss of capacity and rotation limitation of 2200rpm Loss of capacity Sto...

Page 82: ...switch OFF To check which case of the abovementioned relates to your vehicle STOP in a safe place activate the parking brake do not couple the gear and then speed it up 100 After it it is possible to...

Page 83: ...ith a humid cloth ATTENTION Take care to prevent the motor entrance duct or the secondary filter from dust and dirt 4 5 2 3 4 5 3 a At normal engine operating temperature and with the leveled vehicle...

Page 84: ...on in item a and b of Procedure for replacing the primary filter element b Pull out the element 6 C TEST OF THE RESTRICITON SENSOR The restriction sensor 7 indicates by means of warning light 1 on the...

Page 85: ...sure system may lead to accidents 3 Contact a Representative to continue the maintenance at the fuel lines 4 Your vehicle s engine is equipped with a last generation injection system managed electroni...

Page 86: ...1 Element A Base A 2a Filter 1 Filter 2 on the next page g Activate the engine and check for possible leakage FUEL FILTER DRAINAGE Input Filter The water separating filter is located in the front part...

Page 87: ...FUEL SYSTEM BLEEDING The bleeding is performed by manually activating the fuel pump Procedure 1 Release the switching arm A of the bleeding pump turning it counterclockwise 2 Loosen the bleeding bolt...

Page 88: ...e fuel tank is located on the left side of the vehicle The cap to get access to the fuel tank float is located in the passenger compartment The fuel tank features a fuel indicator situated near the wa...

Page 89: ...1 intercooler 1 d Fill in and check for possible leakage IMPORTANT Entrust this procedure to the trained personnel NOTE Try to fill up the vehicle at the end of every working shift This procedure wil...

Page 90: ...n the engine is cold the level should not be lower than the minimum mark MIN When the engine is hot the level should not exceed the maximum mark MAX Cooling Liquid Level Check Procedure is as follows...

Page 91: ...ULIC CLUTH SYSTEM CLUTCH COUPLING Clutch Pedal The clutch coupling features hydraulic auto adjuschart command therefore it is not needed to be adjusted In case of superheating do not disactivate the e...

Page 92: ...the clutch fluid deposit it into a clean recipient without water and free of both mineral and vegetal impurities in order to avoid the oil contamination And if it is necessary to add more oil always...

Page 93: ...of natural wear which damage these components Moreover the oil alters because of repeated cycles 2 1 2 Some internal adjustments and change of the master cylinder and or auxiliary cylinder cover TRAN...

Page 94: ...and or maintenance of some item in the transmission box or because of any other reason Stop the vehicle by means of the brake of heating and cooling that occur in the transmission in service Oil Drai...

Page 95: ...e is operating at a low gear rotation Make sure that the handbrake is not activated Block the wheels and take all the precautions necessary to avoid the vehicle motion To let the vehicle operate at a...

Page 96: ...safe place where it is permitted to park c Declutch the gearbox and immobilize the vehicle by means of the service brake d Activate the parking brake e Switch off the engine WARNING LIGHTS AND CONTRO...

Page 97: ...to the air outflow Oil Level Check it weekly with the niveled vehicle and swithed off engine by means of the gage rod Switching ON OFF the Vehicle Select gear N before switching ON OFF the engine Dep...

Page 98: ...er its configurations ALLISON GEABOX WARRANTY WARRANTY TERM IS 36 MONTHS WITHOUT LIMITATIONS IN KM AND ASSISTANCE IS VIA THE ALLISON REPRESENTATIVE ASSIST NCIA T CNICA ALLISON TRANSMISSION TEL 55 1156...

Page 99: ...mall holes contact a Volare Representative If the suspension produce bumping noise apparently coming from the pocket it is necessary to demount the rubber part of the pocket to inspect the state of th...

Page 100: ...is between the minimum and maximum marks of the gage rod c If the level is below the minimum mark fill the oil according to the lubricating chart chart 1 avoiding the system operation with oil deficie...

Page 101: ...hen at torque 50 to 100 km If not they may fall off causing an accident with severe injuries and material damage Reinstallation Before the wheel installation make sure that the support surfaces on the...

Page 102: ...the pressure value it is necessary to control the wheels pressure during a travel never blow off the tyre to correct the value See the wheels pressure ticket that is located on the upper left part of...

Page 103: ...ibration is very IMPORTANT for a good performance of the vehicle and its operation life If the pressure of the wheels calibration is lower than the recommended there will be an excessive wear on the b...

Page 104: ...re wheel varies in accordance with a Volare model Models Volare W8 and W9 On the right side of the vehicle near the side hatch To remove the spare wheel turn the pin counterclockwise It is located in...

Page 105: ...the brake system periodically Always use authentic parts besides higher security they are more durable and compatible with a lot of components Perform adjustment of the brake system every 2 000 km NOT...

Page 106: ...ressur drop at least for 3 minutes Service Brake Adjustment a Posicion the vehicle on a plane site b Lift the wheels of the vehicle until they stay free of the ground it is not necessary to perform a...

Page 107: ...Check Remove the internal covers from the wheel 1 and check the brake shoe lining conditions every 5 000 km IMPORTANT Brake gaskets impregnated with oil or grease or those that whith thickness equal o...

Page 108: ...e 4 Interrupter 5 4 way valve 6 Dry air reservoir 7 Rear chamber Spring brake 8 Front chamber 9 Front chamber 10 Air compressor 11 Pressure regulator 12 Drain valve 13 Humid air reservoir 14 2 way val...

Page 109: ...odel W9 2 330 Model W8 2 200 Model W9 2 330 External Height 2 700 2 700 Model W8 2 990 Model W9 2 995 Model W8 2 990 Model W9 2 995 Model W8 2 990 Model W9 2 995 Internal Height 1 800 1 800 Model W8 1...

Page 110: ...Compression Ratio 16 8 1 Rated Load Capacity According to NBR ISO 1585 110 rW 150 hp at 2 200 RPM Torque According to NBR ISO 1585 550 Nm 1 300 to 1 700 RPM Operating System 4 stroke Fuel System Elec...

Page 111: ...res Cooling Liquid Water 90 Additive Agent 10 Havoline XLI Green Total Capacity of the System 20 litres 5 FEED SYSTEM MODEL VOLARE W8 and W9 Fuel tank Capacity 150 litres Position Left frame rail Air...

Page 112: ...Series 1480 8 a MANUAL TRANSMISSION GEARBOX MODEL VOLARE W8 and W9 Brand EATON Model FSO 4405 C Gear Number 05 forward and 01 reverse Reduction Ratio First Gear 5 762 1 Second Gear 2 640 1 Third Gear...

Page 113: ...W8 and W9 Brand Model MERITOR MS 13113 8 b AUTOMATIC GEARBOX AUTOMATIC TRANSMISSION CONTINUED Reduction Ratio First Gear 3 10 1 Second Gear 1 81 1 Third Gear 1 41 1 Fourth Gear 1 00 1 Fifth Gear 0 71...

Page 114: ...spring and telescopic shock absorber Amortecedores Double action Spring Width 70 mm Assembly Height Right 78 mm Left 86 mm 10 TRACTION AXLE CONTINUED MODEL VOLARE W8 and W9 Coupling Ratio 4 10 1 Opc...

Page 115: ...idth First Stage 80 mm Second Stage Assembly Height Right 118 mm Left 118 mm 14 WHEELS MODEL VOLARE W8 and W9 Model 6 00 x 17 5 Load Capacity 1 700 kg 15 TYRES MODEL VOLARE W8 and W9 Size 215 75R 17 5...

Page 116: ...ity 1 7 litres 18 SERVICE BRAKE MODEL VOLARE W8 and W9 Type Drum S CAM pneumatic 19 PARKING BRAKE MODEL VOLARE W8 and W9 Type Brake spring 24 Mode of funcitoning Modulator Valve Actuation Rear Brake 1...

Page 117: ...NUAL GEARBOX MODEL VOLARE W8 and W9 Tachograph Reference VDO MTCO 1390 Type Electronic Register Capacity Weekly Opt Daily Speed Warning 80 km h 20 b INSTRUMENTS WHEN BUS IS EQUIPPED WITH AN AUTOMATIC...

Page 118: ...ies 2100 Oil Castrol Transynd Fluid for Hydraulic Brake and Clutch Fluid DOT 4 5 Joint assemblies of the Accelerator Steering Rod Brake Accelerator Pedals Grease Lithium based grease with extreme pres...

Page 119: ...gh adherence to metallic surfaces that permits to lubricants stay on the lubricated points Re tighten the fixing screws and nuts of your bus body supports and components according to the periods speci...

Page 120: ...C CAPTIONS CONNECTOR CENTRAL ELECTRIC MOTHER CARD GROUND STRUCTURE GROUND ANTENNA RELAY R3 12V INVERTER SELECTOR MODULE SELECTOR MODULE RELAY R3 ANTENNA CONVERTER 12 24V RELAY R3 12V INVERTER RELAY R3...

Page 121: ...R MODULE DRIVERS RADIO ANTENNA ANTENNA SELECTING PANEL BATTERY POSITIVE POLE FRONT RIGHT SIDE REAR RIGHT SIDE FRONT LEFT SIDE REAR LEFT SIDE FRONT RIGHT SIDE REAR RIGHT SIDE FRONT LEFT SIDE REAR LEFT...

Page 122: ...UMATIC COMMAND OF THE DOOR Door emergency activation valve Air output adjustment in the piston Sedan door activation piston Door activation valve button left side of the panel Door activation external...

Page 123: ...123 Reservoir Panel open and close valve Front grille open and close valve Emission valve Door piston 1 1 2 2 3 2 AIR TUBES COLOR Item Color Function 1 Blue Open 2 Green Close 3 Red Pressure...

Page 124: ...124 DESCRIPTION Owner s Manual Code 10055903 PREPARATION Volare Technical Assistance EDITION September 2008 Group 02 PUBLISHING TRANSLATION Viacheslav Yakovlev...

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