CHTC HT45 Operator's Manual

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FOREWORD

CHTC (USA), INC.

OPERATOR’S MANUAL

for

HT45 MOTOR COACH

12851 S. Reservoir Street

Chino, CA 91710

Tel: 909-325-8588 Fax: 909-993-0838

www.chtcusa.com

Every effort has been made to ensure accuracy and quality in publication of this document. At the time of printing, content is the most current available.

Due to technological advancements and continuous improvement of our products and the products of our component suppliers, CHTC (USA), INC. reserves the right to change specifications without notification.

PREFACE

Please allow us to express our thanks for your selecting our new HT 45 Motor Coach. We believe you will be impressed by the quality and performance of this product.

•

Our HT 45 Motor Coach is economical, safe and comfortable. This manual will introduce you to some important how-to about dri ving, operating, and maintaining your new HT 45 Motor Coach. Please read it carefully. Please operate and maintain your HT 45 Motor Coach in accordance with this manual, which will he lp you k eep your HT 45 Motor Coach in optimal condition and maximize its service life.

•

If any questions, comments or concerns arise in your operation or maintenance of your new HT 45 Motor Coach, pleas e contact our National Service Group at 800-216-6788 or access our dedicated support website at www.chtcusa.com.

We strive to provide optimal customer service as well as parts availability and maintenance support. CHTC (USA), INC. strives to continuously improve and adapt in order to provide you with the highest quality product, service and support.

•

Consider this manual a permanent part of this HT 45 Motor Coach. If the HT 45 Motor Coach is sold or traded, also include this manual to provide the next owner with important operating, safety, and maintenance information.

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FOREWORD

NOTES

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iii

TABLE OF CONTENTS

INTRODUCTION

SAFETY INSTRUCTIONS ........................................................... 1

HOW TO USE THIS MANUAL ..................................................... 2

VEHICLE IDENTIFICATION NUMBER (VIN) PLATES ............... 2

MOTOR COACH SPECIFICATIONS ........................................... 3

BODY STRUCTURE .................................................................... 3

ELECTRICAL SYST EM ............................................................... 3

ENGINE SPECIFICATION ........................................................... 4

TRANSMISSION SPECIFICATIONS ........................................... 5

SUSPENSION .............................................................................. 6

STEERING SYSYTEM ................................................................. 6

WHEELS AND TIRES .................................................................. 6

BRAKING SYSTEM ..................................................................... 6

SAFETY

OPERATOR PRECAUTIONS ...................................................... 7

PASSENGER SEATBELTS ......................................................... 8

WARNING LABELS ..................................................................... 8

ROAD SAFETY ............................................................................ 8

FIRE EXTINGUISHER ................................................................. 9

EMERGENCY EXITS ................................................................... 9

INTEGRATED BACKUP CAMERA ............................................ 10

CONTROLS

INSTRUMENT PANEL ............................................................... 11

SWITCH PANELS ...................................................................... 16

CLIMATE CONTROLLER .......................................................... 20

STEERING WHEEL AND COLUMN .......................................... 24

EXTERIOR MIRRORS SELECT/CONTROL KNOB .................. 24

PARKING BRAKE ...................................................................... 27

EMERGENCY BRAKE ............................................................... 28

DRIVER’S SEAT ........................................................................ 29

DELUXE TOUR GUIDE SEAT ................................................... 32

PASSENGER SEATS ................................................................ 33

GEAR SELECTOR ..................................................................... 34

PASSENGER INTERIOR CONTROLS ..................................... 36

OPERATING

GENERAL INSTRUCTIONS ..................................................... 37

ENGINE STARTUP ................................................................... 37

WINTER DRIVING TIPS ........................................................... 39

DPF REGENERATION .............................................................. 39

PARK REGENERATION ........................................................... 42

AUDIO/VISUAL SYSTEM.......................................................... 43

LAVATORY ............................................................................... 46

ELECTRIC DRIVER SUN SHADES .......................................... 49

ENTRANCE DOOR EMERGENCY RELEASE ......................... 49

LUGGAGE COMPARTMENT .................................................... 50

SPARE TIRE COMPARTMENT ................................................ 51

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TABLE OF CONTENTS

DAILY INSPECTIONS

ENGINE OIL LEVEL ................................................................. 52

ENGINE OIL PRESSURE ........................................................ 52

DRIVE BELTS AND BELT TENSION ....................................... 52

BATTERY ................................................................................. 53

WASHER FLUID ....................................................................... 53

WINDSHIELD WIPER ............................................................... 53

AIR CLEANER .......................................................................... 53

AIR STORAGE TANK PURGE ................................................. 53

RADIATOR COOLANT ............................................................. 53

FUEL TANK .............................................................................. 54

PRIMARY FILTER-WATER SEPARATOR ............................... 54

EXTERIOR LAMPS .................................................................. 54

ELECTRICAL SYSTEM ............................................................ 54

POWER STEERING .................................................................

BITZER COMPRESSOR .......................................................... 54

TIRES AND WHEELS ............................................................... 55

INSPECTION SHEET ............................................................... 56

MAINTENANCE

GENERAL INFORMATION....................................................... 58

MAINTENANCE RECORDS ..................................................... 59

SEAT BELT MAINTENANCE ................................................... 60

CLEANING MOTOR COACH ...................................................

ENGINE AND CHASSIS MAINTENANCE ............................... 61

REMOTE START SWITCH/MASTER DISCONNECT.............. 61

AIR FILTER ............................................................................... 62

RADIATOR ............................................................................... 63

ENGINE COOLANT .................................................................. 63

BRAKE PEDAL ......................................................................... 66

TIRE ROTATION ...................................................................... 66

WINDSHIELD WASHER RESERVOIR .................................... 66

NEW MOTOR COACH BREAK-IN ........................................... 67

ENGINE COMPARTMENT ....................................................... 69

ENGINE OIL .............................................................................. 71

GEAR LUBRICANT ................................................................... 72

POWER STEERING LUBRICANT ............................................ 72

FINAL DRIVE UNIT LUBRICANT ............................................. 72

CHASSIS LUBRICANT ............................................................. 72

DIESEL FUEL ........................................................................... 72

EMERGENCY STARTING USING JUMPER CABLES ............ 73

FUSE PANEL ............................................................................ 74

WARRANTY/ CUSTOMER ASSISTANCE

INTRODUCTION…………………………….............…....76

WARRANT Y REIMBURSEMENT LABO R RATE………………76 LIMITED WARRANTY………………………………………..….. 77 THIS LIMITED WARRANTY COV ERS………………………… 78 OWNER’S RESPONSIBILITY…………………………………… 79 ENGINE AND TRANSMISSION………………………………….80 LEGAL REM EDIES…………………………………….………….80 SUSPENSION O F LIMITED WARRAN TY OBLIGATION……..80 PERFORMING REPAIRS………………………………..……81 WARRANTY REPL ACEMENT PARTS……………………….81

PARTS………………………………………………………........81

OTHER LIMITATIONS………………………………………… 82

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INTRODUCTION

This manual contains information on systems operation, component location, and scheduled maintenance procedures, which pertain to standard and optional equipment on HT 45 Motor Coaches. The service procedures described and/or recommended in this manual are effective methods for performing scheduled service or replacement of components. Other information, which may be needed to supplement this manual is contained in separate component manufacturer’s manuals. Specific information about the engine and transmission can be found in the applicable manufacturer’s operator, service, and troubleshooting manuals.

SAFETY INSTRUCTIONS

Safety instructions are noted throughout this manual. Each safety instruction is given as a WARNING or a CAUTION and is accompanied by a safety symbol as shown below:

WARNING Failure to observe a safety instruction noted by WARNING could result in severe injury or death.

CAUTION

Failure to observe a safety instruction noted by CAUTION could result in injury or damage to the equipment.

NOTE: Used throughout this manual, NOTES provide useful data, but

are never used to communicate safety hazards.

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INTRODUCTION

HOW TO USE THIS MANUAL

This manual is divided into nine major sections: SECTION 1 - FOREWORD SECTION 2 - INTRODUCTION SECTION 3 - INSPECTION SECTION 4 - SAFETY SECTION 5 - CONTROLS SECTION 6 - OPERATING SECTION 7 - MAINTENANCE SECTION 8 - WARRANTY/CUSTOMER ASSISTANCE Some of these major sections may be divided into smaller subsections

dealing with specific components and/or operating systems. NOTE: Some illustrations in this manual were provided courtesy of the

appropriate vendor. Typical illustrations may be used; therefore, minor illustration differences may exist when compared to actual parts or other publications.

VEHICLE IDENTIFICATION NUMBER (VIN) PLATES Motor Coach VIN Plate

The motor coach VIN plate is mounted inside the motor coach to the driver’s right side at step-well wall. The motor coach plate has the following information on it: motor coach model, motor coach overall weight, motor coach code, rated passenger capacity, VIN, chassis code, manufacturing date and manufacturer.

Second Location for VIN Number

The second VIN number is located front right wheel well chassis frame of the coach. The VIN has been stam ped on the bod y understruc tur e . A third is located at passenger side 2

luggage bay at frame.

Engine Plate

The engine plate is located on the center of the engine and to the right side of the fuel filter. The engine plate has the following information on it: engine model, engine serial number, and arrangement numbers.

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INTRODUCTION

Motor Coach SPECIFICATIONS

Overall Length . . . . . . . . . . . . . . . . . . . . . . . 45 ft 6 in (13.9 m)

Overall Height . . . . . . . . . . . . . . . . . . . . . . . 12 ft 4 in (3.7 m)

Overall Width . . . . . . . . . . . . . . . . . . . . . . . . 8 ft 6 in (2.5 m)

Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . 24 ft (7.3 m)

Luggage Space Volume Without Lift . . . . . . 430 ft³ (12.2 m

³)

Luggage Space Volume With Lift . . . . . .. . . . 400 ft³ (11.3 m

³)

Overhead Storage Capacity . . . . . . . . . . . . . 117 ft³ (3.3 m

³)

Front Overhang . . . . . . . . . . . . . . . . . . . . . . 7 ft 6 in (2.3 m)

Rear Overhang . . . . . . . . . . . . . . . . . . . . . . . 9 ft 1 in (2.8 m)

Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . 45 ft 6 in (12.6 m)

Fuel Tank Capacity. . . . . . . . . . . . . . . . . . . . 210 gal (795 L)

Floor-to-Ceiling Height . . . . . . . . . . . . . . . . . 6 ft 5 in (2 m)

GVWR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54,000 lb (24,494 kg)

Front Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,500 lb (7,484 kg)

Drive Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . 26,000 lb (11,793 kg)

Tag Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,500 lb (7,484 kg)

BODY STRUCTURE

The semi-monocoque bod y truss structure is closed by U-shaped body assemblies. A skeleton is formed by welded rectangular galvanized square tubing, made from Australian dual-galva nize d s teel, gi ving rigidity, stiffness, and torsional resistance. Welded segments are anticorrosion treated before final assembly.

ELECTRICAL SYSTEM

Controller Area Network (CAN) system architecture with MultIC and four IOUs. TFT Multifunction display / instrument panel.

Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 24VDC

Alternator (dual) . . . . . . . . . . . . . . . . . . . . 24V 140A Prestolite

Batteries (OPTIMA) . . . . . . . . . . . . . . . . . 24V 975A

Combination instrument panel incl udes : odometer, tachometer, intelligent signal processor, voltage meter, water thermometer, oil pressure gauge, fuel-level gauge, air-pressure gauge together with the indicators such as steering indicator and high beam indicator.

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INTRODUCTION

ENGINE SPECIFICATION

Cummins ISX12 425 EPA2013

Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . 6 inline

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12 in (130 mm)

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18 in (157 mm)

Displacement . . . . . . . . . . . . . . . . . . . . . . 12.5 L (763 cu in)

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,880 lb (1,306 kg)

Horsepower . . . . . . . . . . . . . . . . . . . . . . . 425 @ 1800 rpm

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,450 lb-ft @ 1200 rpm

Standard Equipment

•

Diesel particulate filter

•

Electronic Control Module (ECM)

•

Electronic Data Link, SAE/ATA, SAE/J1939

•

Electronically Controlled Unit Injection Fuel System

•

Governor: full-range, electr onically controlled

•

Hydraulic steering pump drive, SAE A

•

Lubrication: gear-driven pump, front or rear sump pan, full flow spin-on filter, oil filler, oil level gauge (dipstick)

•

Open crankcase ventilation

•

Pad mount air conditioner compressor

•

Engine mount alternators

•

SAE No. 1 Flywheel Housing

•

Series-turbochargers

•

Vibration damper

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INTRODUCTION

TRANSMISSION SPECIFICATIONS Allison B 500R Transmission

•

Allison Transmission has built a reputation on their ability to build transmissions that last just about forever. That is why Allison Automatics are the preferred choice for many large, well-known transit and charter bus fleets.

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When you factor in all life cycle costs along with the increased productivity, an Allison Automatic-equipped vehicle costs less per mile to operate than a comparable competitively equipped vehicle.

•

On a vehicle with an automated manual transmission, the power interrupts that occur during shift changes result in lower average wheel horsepower. With an Allison Automatic, there is no power interrupt during shift changes so Allison Automatic’s can make full use of the engine’s horsepower. No power interrupts also contribute to a smoother ride.

Gear Ratios

1st gear .................................................. 3.51:1

2nd gear ................................................. 1.91:1

3rd gear .................................................. 1.43:1

4th gear .................................................. 1.00:1

5th gear .................................................. 0.74:1

6th gear .................................................. 0.64:1

Reverse gears . . . . . . . . . . . . . . . . . . . . -4.8:1

Transmission Continued

Allison B 500R Features and Benefits:

•

Six forward speeds, one reverse.

•

Its dynamic shift sensing automatically selects between lower and higher speed shift schedules based on the vehicle’s weight and the grade on which it’s operating.

•

It features a set of low and “super” low speed shift schedules designed to keep the engine speed at its optimum point, maintaining necessary performance without shift cycling.

•

The transmission moves neutral at stop to reduces or eliminates the load on the engine while the vehicle is stopped, reducing fuel usage and emissions.

•

Its acceleration rate management mitigates aggressive driving practices by automatically controlling engine torque. The intensity of control is determined by the vehicle’s weight and grade on which it’s operating.

•

To get the most out of every drop of fuel, Allison 5th Generation Electronic Controls offer an enhanced array of smart controls designed to increase fuel economy and fuel efficiency for the specific needs of buses.

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INTRODUCTION

SUSPENSION Front Axle

ZF RL75E (2016)

RL85E (2017)

Double A-shaped beam axle, airbag suspens ion, t wo leve ling va lves with two airbags, two telescopic shock absorbers and lateral stabilizer.

Front wheel orientation: Wheel camber 0.5º - 1º. Approaching 1º is recommended. The angle difference should not exceed 0.3º on both sides.

Kingpin inclination . . . . . . . . . . . . . . . . . . .7.5º+/- 0.5º

Castor . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30º

Toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . .0mm +/-1mm

Driving Axle

ZF A132

Integrated press-welding axle housing, full-floating axle shaft, single reduction final drive hyperbolic gear.

Final gear ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27/1

All airbag suspension, two leveling valves with four airbags, four telescopic shock absorbers and lateral stabilizer.

Tag Axle

ZF RL85A TAP

Integrated I-shaped beam, with adapted steering control. Airbag suspension, two airbags, two telescopic shock absorbers and air pressed control braking system disc brake.

STEERING SYSYTEM Power Steering

ZF8098

Recirculating ball-type power steering system.

WHEELS AND TIRES

Wheel type Hub Pilot Alcoa

wheels.

Tire specifications (front and rear) . . . . . Michelin 315/80R22.5

BRAKING SYSTEM

Dual-circuit air braking ABS and self-correcting adjusting arm. Air pressure servo assist with identical disc brakes at all w heels. Manual valve operated parking brake, energy storage spring works on rear brake. Emergency brake effected with parking brake.

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SAFETY

OPERATOR PRECAUTIONS

The following precaut ions have been prepare d f or your safety and the safety of your passengers and fellow motorists. Read and understand this information before operating the motor coach.

The safe and reliable operation of this vehicle includes a thorough working knowledge of all its components. When checking the vehicle over or driving it, you should be able to recognize problems when they exist and determine if your motor coach can be driven without affecting its safe operation or causing more serious mechanical problems. When work is required, you should be able to report accurately on the problem.

WARNING Before starting engine, ensure the transmiss ion is in neutral and the parking brake is engaged.

WARNING Prior to performing any checks, maintenance, or repair procedures, ensure that motor coach is disabled to avoid serious injury or death. When conducting checks, reme m ber to keep a safe distance away from moving parts.

WARNING Do not unnecessarily idle the engine. Do not operate the engine without an efficient exhaust removal system. Carbon monoxide gas is toxic. Breathing it can cause unco nsciousn ess and even death.

WARNING Use extreme caution while under motor coach, as motor coach can suddenly drop when air is intentionally or un intentionally removed from the suspension. Ensure parking brakes have been applied and the wheels remaining on the ground are secur ed with wheel chocks. Use properly sized jacks with the appropriate lifting power. Always use proper chassis stands under a jacked up motor coach.

WARNING Never open the engine cooling system or the interior heating system while the system is hot. Never add cold coolant to an overheated engine. Do not place unprotected hands on a hot engine, transmission, or exhaust.

WARNING Safely depressurize systems containing compressed air or liquid under pressure prior to opening system.

WARNING Refuel outdoors and use extreme caution while refue ling.

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SAFETY

PASSENGER SEATBELTS

Each passenger seat is equipped with a lap belt. Designed to comfortably keep each passenger safely in the seat.

Why wear seat belts

•

Seat belts are the single most effective safety device for adults and larger children (infants and smaller children must be properly restrained in child seats.

•

Not wearing a seat belt properly increases the chance of serious injury or death in a crash.

•

Keep you connected to the vehicle so you can take advantage of the motor coaches built-in safety features.

•

Help protect you in almost every type of crash; including side, rear impacts, and rollovers. In a rollover crash, an unbelted person is more likely to die than a person wearing a seat belt.

•

Help keep you from being thrown against the inside of the motor coach and against other passengers.

•

Keep you and your passengers from being thrown out of the motor coach.

Of course, seat belts cannot completely protect you or your passengers in every crash. But in most cases, seat belts can reduce your risk of serious injury.

What should you do:

•

Always wear your seat belt properly and make sure your passengers do as well.

WARNING If a seat belt does not seem to work as it should, it may not protect the occupant in a crash. No one should sit in a seat with an inoperative seat belt. Anyone using a seat belt that is not working properly can be seriously injured or killed.

Contact CHTC (USA), INC. 800-216-6788 as soon as possible for parts or repairs.

WARNING LABELS

Warning labels warn you of potential hazards that could cause serious injury. Read all warning labels carefully and follow instructions on them. Learn and watch for labels.

If a label comes off or becomes hard to read, contact CHTC (USA), INC. 800-216-6788 as soon as possible

ROAD SAFETY

The motor coach has been equipped with three reflective roadside emergency safety triangles that are to be deployed while motor coach is disabled. After opening the kit, unfold the triangle and ensure it locks into place.

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SAFETY

FIRE EXTINGUISHER

WARNING Inspect the fire extinguisher monthly to make sure it has a sufficient charge. Look at the gauge at the top of the extinguisher to verify proper charge.

WARNING Safely evacuate motor coach prior to fire exting uisher use.

Fire extinguishers are located under first isle passenger seat and at rear wall of lavatory compartment. To remove, release latch and lift. Follow instructions on fire extinguisher. Under 1

passenger seat.

EMERGENCY EXITS Emergency Roof Escape Hatch

There are two escape hatches located in the roof for emergency exit of the motor coach. The hatch is also used as a ventilation for passenger compartment.

In case of emergency, pull red handle and push hatch open fully. Proceed to exit the motor coach safely.

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SAFETY

Emergency Escape Windo w

The motor coach is equipped with three emergency exit windows on the left side and three on the right side. The emergency window can be opened by lifting the red handle and pushing the window out. Proceed to exit the motor coach safely. Instruction labels are on each escape window. Regularly inspec t all em er gency windows to ensure latch is secure.

Integrated Backup Camera

This backup camera and radar sees not only what is behind the motor coach, but also gives an estimated distance to the nearest object.

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SAFETY

CONTROLS

INSTRUMENT PANEL

The instrument panel and controls are designed to provide the driver with the ability to monitor and control the operation of the motor coach.

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CONTROLS

Table 1: Instrument Panel Face

Number Item

Brake Pad Wear Indicator

This light appears when the brake pad is worn and thin.

Battery Warning Indicator The light appears when battery failur e occurs and needs to be replaced.

Check Transmission

When transmission electronic control unit detects errors on the transmission, this light will appear.

ABS Fault Indicator

When an error occurs with ABS system, this light will appear.

Engine Coolant Hot

When engine coolant temperature is high, this li ght wi ll appear.

Park Brake Applied

When the vehicle has stopped and the driver applied parking brake, this light will appear.

Brake System Warning

When electronic system found air pressure is under 6 bars, this light will appear.

Number

Ite

Seatbelt Warning

If driver is not wearing seat belt, this light will appear.

Engine Oil Pressure

When the electronic system find engine oil pressure does not match calibration data, this light will appear.

Engine Fault Stop

Engine is not operating pr o per ly. Engine may derate, with reduced power or speed if problem is detected. Action: bring vehicle to safe stop as quickly as possible and have vehicle serviced before resuming. Note: if engine shuts down and vehicle is still on the road it may be possible to restart for brief period (approximately 30 seconds) after turning the ignition off to allow vehicle to be moved to safe location.

Engine Fault Warning

Engine is not operating properly. Engine may derated, with reduced power or speed if problem is detected. Action: seek a service facility to address the registered fault code at the earliest opportunity.

Engine Malfunction Indicator Lamp

The light indicates that the electronic system has detected malfunction related to emission control system and the after-treatment system should be diagnosed and serviced at your next available opportunity.

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CONTROLS

Table 1: Instrument Panel Face

Number Item

Water in Fuel

Water has been sensed in fuel filter assembly. This can cause the engine to run rough and be difficult to start. Action: water must be drained from fuel filter assembly. Have vehicle serviced as soon as possible.

Fog Lights

This light indicates that the fog lights are turned on.

Left Turn Indicator

This light indicates that the turn left signal is on.

Right Turn Indicator

This light indicates that the turn right signal is on.

Cruise Control

When the TFT screen is used for reverse monitor, this button is used to turn on the Brightness Function.

High Beam

This light indicates that the high beam is on.

MPH Indicator

km/h Indicator

Number Item

Glow plug

Wait to start engine preheat. Do not start engine until after light goes out.

High Exhaust System Temperature (HEST)

The light indicates that high exhaust temperatures may exist due to after treatment regeneration. This is normal and does not signify the need for any kind of vehicle service or engine service. When this lamp is illuminated, ensure that the exhaust pipe outlet is not directed at any combustible surface or material

DPF Status Indicator

This light indicates that DPF regeneration is required.

Exhaust After Treatment Warning

This light indicates that the after treatment DPF requires regeneration. This is accomplished by the following:

1. If the vehicle is equipped with regeneration inhibit switch, ensure that the switch is not in inhibit position.

2. Perform DPF regeneration by one of the following: a. Change to a more challenging duty cycle such as highway driving for at least 20 minutes.

Low DEF

This light indicates that the DEF level is low.

Low Fuel

When diesel fuel level is low, this light will appear.

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CONTROLS

Number Item

Washroom Emergency Label

This symbol appears when the emergency switch inside the WC was pressed.

Washroom Working Indicator

This symbol appears when the WC is being used.

Washroom Water Level Warning

This symbol indicates that the WC water tankard level is low.

Disabled Pedal Indicator

Passenger Service Indicator

Table 1: Instrument Panel Face

Normal TFT Screen

Table 2: Normal TFT Screen

WARNING

When the Stop Light is on, you must stop the motor coach and solve the problem.

CAUTION

When you are welding on the motor coach, you must disconnect the MultIC and IOUs from the power supply and disconnect the batteries. Do not directly spill or spray any liquid on the MultIC and IOUs. Do not allow objects to touch lens of MultIC.

Number Gauges

Engine RPM

Fuel Level

III

Speedometer

Air Pressure 1

Air Pressure 2

Page 20

CONTROLS

TFT Screen Indicator Symbols

Table 3: TFT Screen Indicator Symbols

Number Item

Disabled Service Requirement

Heater Working Indicator

ASR System Functional or Error Indicator

9 ECAS Warning Indicator

EACS Error Indicator

ECAS Kneeling Indicator

Body State Indicator

Fog Lamp Indicator

Letter Item

Retarder Functional Indicator

Transmission Gear Indicator

Cooling Water Level Warning Indicator

Air Filter Warning Indicator

Hydraulic Fan Warning Indicator

Transmission Oil Temperature Warning Indicator

Tag Axle Release Pressure Indicator

Kilometer/mileage Display

Emergency Door Indicator

Passenger Door Indicator

Engine Cabin Door Indicator

25 Time Display 26

Engine Temperature

27 Engine Lubrication System Pressure 28 Adblue Liquid Level Display 29 Accelerator Pedal Position Display 30 Current Fuel Consumption 31 Average Fuel Consumption

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CONTROLS

SWITCH PANELS Upper Left Switch Panel

Table 4: Upper Left Switch Panel

Number Item

1 Automatic Fire Suppression System Stand-by

(Only operate in case of engine fire)

WC Emergency Indicator and Level

Front Fog Lamp Switch

Rear Fog Lamp Switch

Number Item

Luggage Compartment Light Switch

Driver Light Switch

Step Light Switch

Docking Lights Switch

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CONTROLS

Table 5: Lower Left Side Switch Panel

LOWER LEFT SWITCH PANEL

Number Item

Window Switch

Yellow Daylight Switch

White Daylight Switch

Passenger Reading Light Switch

Blue Overhead L.E.D. Switch

Left Sun Visor Switch

Right Sun Visor Switch

Main Power Switch

Dash Light Dimmer 10 Rear View Mirror Defrost Switch 11 Wash Compartment Activation Switch 12 A/C Economy Switch 13 SPHERO Heater Activation Switch 14 Hydraulic Fan Drive Switch (Speed)

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CONTROLS

Right Side Upper Switch Panel

Table 10: Right Side Switch Panel Table 10: Right Side Switch Panel

Number Item

Engine Air Intake Stop Switch

Air Intake Close Test Switch

Outage Protection Cover Switch

Outage Protection Switch

DPF Inhibited Regeneration Switch

Cruise Control Speed/Resume/Set Switch

Number Item

Cruise Control Activation Switch

Page 24

CONTROLS

Right Side Lower Switch Panel

Table 10: Right Side Switch Panel Table 10: Right Side Switch Panel

Number Item

ABS Diagnosis Switch

ASR Shut Down Switch

ASR Switch

Tag Axle Bleed Valve Switch

Back to Normal Height Switch

Kneeling Switch

Body Lift/Lower Switch

Number Item

Diagnosis Trigger Switch

Limp Home Switch

Retarder On/Off Switch 11 TV Monitor Flip Down Switch 12 TV Monitor (Spare Switch) 13 Air Horn Switch 14 Passenger Entrance door switch

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CONTROLS

CLIMATE CONTROLLER

Driver Climate Controller

Table 6: Driver Climate Controller

Main Screen: When the MVC is powered on, it displays mode, set-

point and fan speed. Temperature set-point can be changed in this menu.

Fan Speed Screen: To change fan speed, enter the fan speed menu by press the SET knob once then turn knob to decrease or increase fan speed

Number Item

Set/Select Button

It is used for selecting between menus. In Test/Diagnostic mode, it is used to test and diagnose different components with in the HVAC system.

Power Button

Turn unit ON or OFF

Number Item

LCD Display

During normal operation, the set-point temperature, blower speed, operation mode and fresh/recirc air selection are displayed. In Test/Diagnostic menu, error messages will be displayed on screen for troubleshooting

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CONTROLS

Motor Coach Climate Controller During vehicle maintenance, service personnel can enter diagnostic

mode by pressing preset sequence of buttons or using optional MCC Coolview via CANBus connection. In this mode, errors stored in memory and real-time data of inputs and outputs are displayed for easy trouble shooting

Table 7: Motor Coach Climate Controller

Number

Item

1 Temperature Set-point

Adjust temperature for passenger compartment

2 On/Off Button

Turn HVAC system On or Off

3 Cursor

Cursor and mode selection

4 Information

Display system information

Page 27

CONTROLS

SPHEROS® Auxiliary HEATER

Table 8: Timer Controls

Number Item

7-Day Digital Timer Display

Day/Time Advance Button

Day/Time Reverse Button

Heater On/Off Button

Program Selection Button

Clock Button

WARNING Due to the danger of poisoning and suffocation, the heater must not be operated in enclosed areas, such as garages or workshops,

without an exhaust-venting system, not even if the start-up is activated by the timer or remote start device.

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CONTROLS

WARNING At filling stations and fuel depots, the heater must be switched off as there is a potential danger of explosions.

WARNING Where flammable fumes or dust may build up (e.g. in the vicinity of fuel, coal, wood, cereal grain deposits, or simi lar situations), the heater must be switched off to prevent explosions.

CAUTION

Before switching the Sphero heater on, open any shutoff valves and set vehicle heater controls to the HOT position.

The digital timer with three time settings permits the Sphero heater to be switched on and off instantly, or automatically at 3 programmable starting times.

The operating time of the heater can be pre-selected. It is possible to program three different heating times according to your individual needs.

Only one preset starting time can be activated at any one time. When the ignition is switched on, the current time of the day and the day of the week are displayed.

When the heater is in operation, the display and the buttons of the timer are illuminated.

Programmed Heater Operation

Three memory locations numbered 1 to 3 are available. Each memory location can be assigned a given time together with the day of the week.

Pre-selected Starting Times

The pre-selected starting time is the time at which the heater will be switched on automatically.

NOTE: Recommended that memory locations 1 and 2 be used for presetting starting times within a 24-hour period of setting the timer. Memory location 3 can be reserved for a starting time within the next seven days of setting the timer. Location 3 is useful for occasional weekend or field trip operations outside of the normal schedule. By repeatedly pressing the program selection button on the timer, starting time pro- gram 1, 2 or 3 can be viewed and preset.

Operating Time

The period of time during which the heater is in operation is referred to as the operating time. The heater remains in operation for as long as the operating time has been preset. Heater operation can be preselected for any time from a minimum of 1 minute (a minimum of 10 minutes is recommended) to a maximum of 120 minutes (factory preset is 60 minutes).

Page 29

CONTROLS

STEERING WHEEL AND COLUMN

The two levers on the steering column contain controls for driving features you use most often. The left lever controls the turn signals, headlights, and hazard warning lights. The right lever controls the windshield washer, wipers, and retarder lever.

Headlights

The rotating switch on the left lever controls the lights. Turning this switch to the first position turns on the parking lights, taillights, instrument panel lights, side marker lights, and rear license plate light. Turning the switch to the second position, turns on the headlights.

To change from low beams to high beams, lift the turn signal lever up until you hear a click. The blue high beam indicator will light on instrument panel.

To return to low beams, push the turn signal lever down.

Turn Signals

To signal a lane change, push lightly on the turn signal lever in the proper direction. The turn signal lever will return to the center position upon completion of turn.

Hazard Warning Flashers

The left lever controls the hazard warning flashers. Push the button on the end of the lever to turn on the hazard warning lights (four-way flashers). This causes all four exterior turn signals and both indicators in the instrument panel to flash.

Use the hazard warning lights if you need to park in a dangerous area near heavy traffic, or if your motor coach is disabled.

EXTERIOR MIRRORS SELECT/CONTROL MODULE

Exterior mirrors have separate upper and lower segments. The convex lower portion is for wide angle view. Adjust the exterior mirrors so that you can see the side of the coach in part of the mirror. This helps determine the relationship of the coach to objects seen in the mirror. The left side and right side mirror control is on the upper left hand console switch panel. Use the mirror select/control module to select which mirror is to be adjusted. Adjust the mirror using the same control module. Pass the buttons to the left to adjust the mirror to the left and to the right to adjust the mirror to the right. Defrost the mirrors using the mirror heat switch located below the mirror controls on the upper left switch panel.

Page 30

CONTROLS

Windshield Wiper Controls

Windshield Wipers

CAUTION

Do not operate wiper in dry conditions. Activate the washers for proper lubrication before wiper operation.

The rotating switch on the right lever controls the windshield wipers, including the intermittent wiper control. The rotating switch has four positions:

•

OFF-Wiper is off.

•

INT-Wiper on intermittent setting.

•

LO-Wiper on low speed setting.

•

HI-Wiper on high speed setting.

Turning this switch to the first position turns on the wiper intermittently, frequency of the wiper blades depends upon the setting of the delay switch. In intermittent, the wipers operate every few seconds.

Turning this switch to the second position turns the wiper on a low speed. In low speed, wipers run continuously.

Turning this switch to the third position turns the wiper on a high speed. In high speed, wipers run continuously.

Windshield Washer

The right lever controls the windshield washer. To clean the windshield, push the button on the end of the lever to turn on the windshield washer. The washer will spray until you release the button.

Steering Wheel Height Control

WARNING Adjusting the steering wheel position while driving may cause you to lose control of the motor coach, and to serious ly injure you and your passengers. Adjust the steering wheel only when the motor coach is stopped.

Turn lock-handle located on left side of steering column counterclockwise to adjust steering wheel height. Tighten by turning lock-handle clockwise.

WARNING Make sure you have securely locked the steering wheel in place by trying to move it.

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CONTROLS

Steering Wheel Angle Control

Turn lock-handle located on right side of steering column counterclockwise to adjust steering wheel angle, then tighten by turning lock-handle clockwise.

WARNING Make sure you have securely locked the steering wheel in place by trying to move it.

Page 32

CONTROLS

Ignition Switch

WARNING Do not turn the ignition key to the OFF position while the motor coach is moving.

NOTE: In the event of failed start, wait 2 minutes before attempting to

re-start. NOTE: If a re-start fails, check the fuel supply before any further

attempts. The ignition switch is located on the right side of steering column. The

ignition switch has five positions. The following is an explanation of those ignition switch positions:

•

LOCK - This pos iti on is us e d f or inser ti ng the key into the ignition and for withdrawing the key from the ignition. This position is also used for turning off the engine.

•

ACC - This position is used for powering only the radio and other accessories.

•

ON - This position is used for the continuous period of engine operation.

•

START - This position is used for engine startup only. Key will automatically return to the ON position when released.

Horn

To use the horn, press either horn button located on the top of the steering wheel center pad. The horn should sound while pressing down on either button. The horn can be an electric or air horn, the electric/air horn switch is located on the right switch panel.

PARKING BRAKE

The parking brake knob is located on the left console of the driver seat. When the vehicle is stopped, pull out knob to set the parking brake. When ready to start moving with engine running and primary air supply at 90 psi, beeper and low air pressure light off. Place foot on brake pedal and push in knob to release the brake.

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CONTROLS

EMERGENCY BRAKE

CAUTION

Motor coach must be stopped prior to activating emergency brake.

Pull the handle up to engage the emergency brake. Press the handle down to release emergency brake. In case of parking brake malfunction, the em ergenc y brak e wil l retur n to t he ori ginal positio n automatically.

Page 34

CONTROLS

ISRI® Driver’s Seat

The seat can be moved forward and backward. The backrest angle can be fully adjusted.

Table 11: ISRI Driver’s Seat

Number Item Number Item

Armrest Adjuster

Height Adjuster

Backrest

Adjuster

Shock Absorber

Adjuster

Horizontal Adjuster 10 Quick Release

Tilt Adjuster

Seat Cushion

Adjuster

Integrated 3 Points

Safety Belt

Pneumatic Lumbar

Adjuster

WARNING Do not adjust the driver’s seat while the motor coach is moving. The seat could suddenly and unexpectedly move, causing the driver to lose control of the vehicle.

CAUTION

After making a seat adjustment, always test to ensure that the adjusters have latched. An improperly latched mechanism could impair driver abilities.

Page 35

CONTROLS

General Information

WARNING No objects should be placed within the moving area of the driver’s seat to prevent injury.

WARNING Settings must be checked to ensure they are correctly engaged before the motor coach is driven. Adjustments must not be made while driving.

A correctly functioning and individually adjusted driver’s seat is essential to good health. Seat is maintenance free. Take adequate care of your seat to ensure that it functions properly.

CAUTION

Dirt can impair the function of the seat. Keep the seat clean.

Upholstery does not need to be removed from the seat frame for cleaning.

NOTE: Do not soak through upholstery during cleaning. Do not use pressure washer to clean seat.

CAUTION

Use standard commercially available upholstery or plastics cleaning agent. Test for compatibility on a small, concealed area.

Check seat frequently to ensure proper function. Regularly check that seat is tight. If seat wobbles, check for loose bolts or other faults. To ensure proper function of the driver’s seat and to prevent damage of pneumatic spring, adjust the loaded driver’s seat to the highest height position.

Seat Operation

Height Adjustment

The seat height can be adjusted continuously within a range of 3.9 in. (99 mm). Pull or press the handle for height adjustment to move the seat upwards or downwards.

NOTE: Always release the handle after reaching the upper or lower stop.

Lumbar Support

With front and back switch, the curvature in the upper and lower area of the backseat upholstery can be adjusted individually.

The air compartments will be filled by setting the respective switch to “+” and emptied by setting it to “-”.

Lateral Support Adjustment

By actuating the switch, the curvature of the lateral guide right and left of the backrest can be adjusted individually by means of compressed air.

By setting the switch to “+”, the air compartments will be filled. By setting it to “-”, they will be emptied.

Page 36

CONTROLS

Backrest Adjustment

Pull up the locking lever to release the backrest catch. The backrest is brought into the desired position by simultaneously exerting or relieving pressure. Release the locking lever to lock the backrest.

NOTE: It should not be possible to move the backrest into another position after it has been locked.

Seat Heater ( OPTIONAL )

By operating the seat heater switch, the heating mats in the backrest and seat cushion can be heated in two steps.

•

0 = Heater Off

•

1 = Heating step 1 ON

•

2 = Heating step 2 ON

Armrests

The armrests can be folded up if required.

Armrest Adjuster

The inclination of the armrests can be modified by turning the adjustment knob. When turning the knob to the outside “+”, the front part of the armrest will be tilted. When turning the knob to the inside “-”, it will be lowered.

Seat Pan Angle Adjustment

Adjust the angle of the seat pan by pulling the left handle upwards. The seat pan can be moved to the desired position by press ing or relie ving the seat to the front or to the rear.

NOTE: The adjustment range can be made between minus 6º and 10º.

Seat Depth Adjustment

Pull the right handle upwards to adjust the depth of the seat cushion. Move the seat cushion backwards or forwards so the desired seating position can be reached.

NOTE: Adjustment range of 2.3 in. (58 mm) is in six increments.

Fore/aft Adjustment

The forward/aft adjustment can be made by pulling the locking handle, while simultaneously sliding the seat forwards or backwards to the desired position.

WARNING The seat must lock into place with an audible click when the lever is released.

NOTE: The adjustment range can be made in ten steps of 0.78 in. (20

mm) each.

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CONTROLS

Quick Lowering

The seat can be lowered to lowest position by pressing the key and locking it.

Vertical Shock Absorber Adjustment

The vertical vibration behavior of the seat can be adjusted continuously from soft to hard by using the turning knob.

•

1 = Soft shock absorption

•

2 = Medium shock absorption

•

3 = Hard shock absorption

DELUXE TOUR GUIDE SEAT (OPTIONAL)

The deluxe tour guide seat is a folding seat located at the entrance door. The tour guide seat is conveniently located near the audio/video controls and next to the fire extinguisher for safety, guide seat is standard leather-covered. Seat is equipped with retracting armrests and a lap belt for safety.

Push the seat downwards and sit on the seat. When folding up the seat cushion, the seat automatically slides back as far as possible.

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CONTROLS

PASSENGER SEATS

Table 12: Passenger Seat Controls

The passenger seats are self-righting and adjustable recline seats. These seats are equipped with (optional) folding footrests. Passenger seats are outfitted with retractable armrests and reclining handles. Each seat is equipped with a convenient magazine holder and USB connections.

Fasten and position the seat belts

Insert the latch plate int o th e buc k le, the n t u g on the b elt t o ens ure belt is securely fastened. Also chec k that the belt is n ot twist ed, because a twisted belt can cause serious injuries in a crash.

WARNING Not wearing a seat belt properly increases the chance of serious injury or death in a crash. Be sure you and your passengers always wear seat belts and wear them properly.

CAUTION

In case of malfunction with parking brake, the emergency brake knob will return to original position automatically.

Number Item

Seat Recline Handle

Safety Belt

Retracting Armrest

Page 39

CONTROLS

GEAR SELECTOR

WARNING Before starting a vehicle always be seated in the driver's seat, select N on the shift control, and set the parking brakes.

WARNING If engine cranks in any gear other than neutral, service your vehicle immediately!

WARNING Before working on a vehicle, parking the vehicle , or leaving the cab with the engine running, place the transmission in neutral, set the parking brakes, and block the wheels.

WARNING For safety reasons, always engage the service brakes prior to selecting gear positions from neutral.

WARNING It is a requirement that the driver of a commercial vehicle specified under paragraph A sections 1-6 of FMCSA regulation 392.10 need only cross railroad grade crossings in a gear that permits the vehicle to complete the crossing without a change of gea rs.

CAUTION

Do not release the parking brake or attempt to select a gear until the air pressure is at the correct level.

CAUTION

Battery (+) and (-) must be disconnected prior to any ty pe of welding on any UltraShift™ equipped vehicle.

Gear selector lever has three positions operating panel.

•

R - Reverse. Selects reverse gear once vehicle is less than 2 Mph.

•

N - Neutral. Selects neutral.

•

D - Drive. Selects the default starting gear and automatically selects gears between the starting gear and the top gear.

Page 40

CONTROLS

Start-up

Turn the ignition key to ON and allow the “Allison shift pad” to powerup.

•

Engine cranking is delayed until the transmission power-up is complete.

Start the engine.

Apply service brake.

•

If the service brake is not applied while selecting a starting gear, the initial start gear will not be found and the driver will have to re-select Neutral and press the brake while re-selecting the desired mode.

Select the desired mode and starting gear on the shift console.

Release the vehicle parking brakes.

Release service brake and apply accelerator.

•

The transmission is not intended to provide hill-hold capability. The service brakes should be used to stop and hold the vehicle on an incline. To prevent the vehicle from rolling when starting on an incline, place both feet on the brake pedal before sliding the right foot to the throttle pedal. Gradually back off the brake while applying as little throttle as necessary to move along the incline.

Power Down

Select N on the shift control.

NOTE: Neutral should always be reached before UltraShift power down is performed except in cases of emergency.

Set the vehicle parking brakes.

Turn off the ignition key and allow the engine to shut down.

Driving Tips

Proper Starting Gear

Choose a starting gear appropriate for the load and grade conditions while at a stop in D mode by using the up/down buttons. Refer to D mode for detailed information.

Page 41

CONTROLS

PASSENGER INTERIOR CONTROLS

Table 13: Passenger Controls

Number Item

1 Speaker

Individual Reading Lamp Switches

Push button to turn On/Off

Omni-directional Individual Reading Lamps

Push in any direction to direct light

Omni-directional Individual Ventilation Ports

Push in any direction to direct air flow

Stop Switch

Press to let the driver know to stop the vehicle

Passenger Chime Switch

Page 42

OPERATING

GENERAL INSTRUCTIONS

After performing the daily inspection and safety checks, you are ready to operate the motor coach. Safety on the road also depends on you. Observe weather and road conditions, then drive accordingly. Be physically and mentally alert.

WARNING Do not run engine for long periods of time in a closed or p oo rly ventilated building, where exhaust gases can accumulate.

If, while driving the motor coach, any of the items below are noticed, correct condition immediately.

•

STEERING ACTION - Binding, wander, shimmy, excessive steering wheel play, and pulling to one side.

•

BRAKING ACTION - Increased pedal travel, slow response, chatter, grabbing, weak, pulling to one side, and excessive air pressure drop for brake application.

•

VIBRATION - From engine, driveline, accessories, and wheel imbalance. Scan the instrument panel frequently and be alert for any changes from normal gauge readings.

Refer to appropriate subject in troubleshooting section of this manual for detailed data.

ENGINE STARTUP

Engage parking brake. Put the gearshift in the neutral position, making sure that the rear compartment doors are closed (or engine is prevented from starting). Insert the key into the ignition start switch and turn clockwise to the start position. The engine should start within 30 seconds. If starting fails, wait 2 minutes for starter motor to cool down. Repeat start procedure until the engine starts.

Do not run a cold engine at high rpm. Idling too fast during warm-up will cause too rapid and uneven expansion, resulting in premature engine wear. The rpm should be increased gradually after starting a cold engine.

Do not operate the motorcoach at high rpm until the engine water temperature reaches 158°F (70°C).

CAUTION

Damage may occur if engine idles for more than 10 minutes at low rpm. Idling the engine too slowly does not allow suffici ent splash lubrication of cylinder walls and may result in excessive wearing of pistons and liners.

There must be a display of the oil pressure on the instrument panel within 15 seconds after starting the engine, otherwise stop the engine and correct problem immediately.

If the parking brake indicator on the instrument panel is illuminated, the parking break is engaged.

Page 43

OPERATING

Engine

After starting the engine, but before operation, be sure the indicator lights and gauges work. The braking system air pressure should read at least 81 psi (490 kPa) or above. Coolant temperature should be 158° F (70° C) or above, and the parking brake released. You can now operate the motor coach in a safe manner.

Normal Driving Conditions

Ensure the following are within their acceptable limits.

•

Oil pressure should be within the range of 33 to 52 psi (227 to 358 kPa ).

•

Water temperature should be within the range of 176 to 200° F (79 to 94° C).

•

The indicator of the air pressure gauge should be within the green range of 78 to 130 psi (538 to 896 kPa).

If you encounter any abnormal sounds or smells, stop and check the motor coach. Avoid any abrupt acceleration or braking if possible. Avoid engine over-speed.

Before Stopping Engine

CAUTION

Do not shut off the engine while vehicle is in motion. This will cause eventual brake and immediate power steering failure.

A hot engine has a great deal of heat stored up in its iron mass. Let the engine idle for no more than 10 minutes before shutting down the engine.

This will allow circulating c o ola nt an d lu bric at ing oi l to c ar ry heat away from cylinder head, val ves, pis tons, cylinder liners, and bear ings , th us preventing warping of valve stems or distortion of other parts resulting from uneven cooling.

NOTE: Refuel before final shutdown. The less air space in the fuel tank means that there is less op por tun ity there will be for water to condense in the tank.

Stopping The Engine

CAUTION

Do not shift into neutral until vehicle is stoppe d!

Perform the following procedures:

Bring the motor coach to a complete stop using the service brakes.

Shift transmission into neutral. The transmission should be set to the neutral position before shutting off the engine to prevent an error report display.

Set parking brake by pulling out control knob.

Allow the engine to cool below 194° F (90º C). Do so by letting the engine idle no more than 10 minutes.

Shut engine down by turning the ignition key to the ACC position. The accessory position cuts off the fuel supply and shuts down the engine.

Page 44

OPERATING

WINTER DRIVING TIPS

Perform the following winter driving tips for enhanced motor coach performance needed during cold weather

•

Add long life coolant into the cooling system.

•

Check the fluid level, specific gravity, and voltage output of the battery.

•

Use soft water in engine cooling system.

•

Do not operate the vehicle until the engine has had time to warm up.

•

Do not operate if any malfunctions are present.

DPF REGENERATION

A diesel particulate filter, sometimes called a DPF, is a device designed to remove diesel particulate matter or soot from the exhaust gas of a diesel engine.

In addition to collecting th e particulate, a method exists to c lean the filter. This is known as f il ter regeneration. Regener ation is the process of removing the accumulated soot from the filter.

WARNING To avoid serious personal injury or property damage, ensure that no persons or objects are at or within 2 feet of the exhaust outlet at any time during a regeneration.

WARNING Ensure that exhaust and outlet are clear of any trash, grasses, or other vegetation or debris.

WARNING Use extreme caution during a stationary regeneration, as exhaust gas tail pipe outlet temperatures can exceed 900° F (482° C).

WARNING Stationary regenerations are to be performed outdoors only.

WARNING DO NOT perform inside a garage or maintenance facility. DO NOT attach an exhaust extraction hose to the exhaust outlet.

Page 45

OPERATING

Page 46

OPERATING

Page 47

OPERATING

Park Regeneration Procedure

Park the vehicle safely off the road and away from flammable materials. Place vehicle in neutral and apply parking brake.

Press regen button ON then press engine diagnosis button . DPF Switch Diagnosis Switch The engine speed will automatically ramp up to a preset RPM which indicates the regen cycle has started. When regen cycle is complete engine speed(RPM) will return to normal operating status and return regen button to OFF position.

WARNING Failure to perform Parked Regeneration when the exhaust filter indicator is ON will cause the engine to lose power and eventually shutdown. When performing Parked Regeneration, make certain the vehicle is safely off the roadway and away from people or any flammable materials or structures, as the regeneration process will result in elevated exhaust temperatures. Failure to follow these instructions may result in a loss of engine power, vehicle speed, and may cause an accident or fire resulting in property damage, personal injury, or death.

Page 48

OPERATING

AUDIO/VISUAL SYSTEM Xiahua™ DVD/CD

Table 1: Xiahua™ Audio/Video Player Basic Controls

GSS DVD/VCD/CD/MP3/USB Receiver features:

•

DVD/VCD/CD/MP3 Player

•

GIGA MP3 multi-play MP3

•

WMA

•

WAV Files Burned on DVD

•

MOS-FET Power Amp

•

iPod™ Ready

•

Satellite Radio Ready

•

Optional Bluetooth with KS-BTA200

•

DivX™ Compatible.

Microphone

The HT 45 audio system comes with a state of the art wireless microphone. The microphone is located on motor coach next to driver side seat with a convenient holder. In conjunction with public address system, the wireless microphone will allow mobile announcing. Microphone requires a 9V battery.

Page 49

OPERATING

Remote Control

Operation

Page 50

OPERATING

Public Address System

The coach is equipped with one 19 inches strategically drop down LCD screen monitor that are controlled by switch at drivers dash and 6-10 inch stationary LCD monitors .

Operation

1. 24V power supply, while output voltage is 13.8V±0.2V (8Amax). Use the host unit with audio amplifier and connect as to system requires, check

cable connection.

2. Press power butt on and it s tarts to work .

3. When the driver or guide speaks, plug the microphone to MIC1, turn on the microphone, the background sound is mute, only comes the sound from

the microphone, adjust knob VOL1 to adjust volume of microphone.

4. MIC2 socket on the backside of the unit, you can connect to microphone with long cable to install it on anywhere on coach, plug the microphone and

the background sound is mute, only comes the sound from the microphone, adjust knob VOL2 to adjust volume of microphone.

5. Adjust the mix knob in the middle, you can adjust the mix sound volume, no matter the host unit is in DVD, Cassette or radio status, you can speak

to microphone after it is plugged in, the volume will not be influenced by the host unit volume.

6. When playing karaoke VCD, or dual language VCD, press L/R key to mute the voice or select audio channel, this is only valid for VCD.

7. Goos eneck microphone and wireless microphone is optio na l. Remark: Microphone mute function is optional.

Page 51

OPERATING

LAVATORY General Information

For safety and convenience, the toilet module has been installed with safety handles inside and out of the module.

The dashboard contains an indicator for the following:

•

When The module is vacant or occupied.

•

For The status of the wastewater holding tank.

•

To alert the driver that the alarm button in the toilet module has been activated.

•

Then The wastewater holding tank is full.

NOTE: If wastewater holding tank indicator is on, stop using toilet immediately and ensure door is properly locked.

The toilet module door has a seal strip which prevents odors from entering the motor coach. The toilet module is equipped with dual fans. Low fan speed will vent constantly when the module is vacant. The fan will change to high speed when the module is occupied. The outer fan works to keep fresh air moving automatically.

The power to the toilet is controlled by the driver at the dashboard. If the toilet is not functioning properly, the driver can turn off power and temporarily put the toilet out of order.

NOTE: If the toilet is to be out of service for an extended time, turn off the main power to the toilet.

Pre-Trip Procedures

Ensure that the freshwater tank is full.

Fresh water tank for lavatory is located at the rear driver side compartment on top of trailing axle. Fill freshwater tank by attaching water hose and opening valve. Fill full and close fill valve. Fold wheel skirt down and securely latch.

Check that wastewater tank is completely drained and drain valve closed prior to trip. Make certain trash bin is empty prior to trip.

Check that toilet paper, paper towels, and other supplies are fully stocked prior to trip. Toilet module needs to be cleaned and maintenance regularly.

Page 52

OPERATING

Toilet Module Operation

Ensure the toilet system is functioning properly by locking the door. The toilet has sensor inside and it turns on when toilet is in use. The occupied light will make other passengers aware of the toilet status. Toilet is unoccupied if the occupied light is off. If the toilet is occupied, the occupied light will be on.

The dome light inside the toilet module has a dual status. The low light level is on as long as the power to the module is on. The high light level is on whenever a passenger enters the toilet module, closes, and locks the door.

Sensor will automatically produce a flush that will go through the drain valve into the wastewater holding tank.

Post Trip Procedures

After motor coach arrives at wastewater evacuation area, flip switch of

evacuation valve to drain holding tank.

WARNING Do not spray water at the electrical junction box, fans, or other electrical equipment. Doing so could damage equipment and seriously injure personnel.

Remove all trash and restock supplies. Use a damp cloth to wipe the surfaces. Sliding valve on holding tank should be cleaned regularl y to ensure smooth operation.

Page 53

OPERATING

Wastewater Holding Tank

Wastewater holding tank is located in the right rear access panel of the motor coach.

Flip switch back after evacuation. When cleaning inside of toilet module, remove the cover of the floor

drain. The water then can be drained directly out of the motor coach through the floor drain.

Water tank capacity: 38.3 gallons

WARNING Refer to local health regulations for pr op er d isposal procedures and equipment.

CAUTION

Do not throw bottles or cans in toilet module can resul t in over flowing or damage.

Page 54

OPERATING

Cold Weather Procedures

Shut down toilet module for sub-freezing temperatures. Drain all water from freshwater and wastewater holding tanks. Ensure toilet flushes several times to drain water from bowl. Toilet module cannot be put back in service until sliding valve and all components are thawed.

CAUTION

Never try to open a frozen valve by force. Use warm water to defrost valve before use.

ELECTRIC DRIVER SUN SHADES

Sun shades have been installed at the left and right behind the windshield. Each shade has its own control switch on the lo wer left switch panel console.

CAUTION

Do not try to operate manually, this could cause gears to break.

ENTRANCE DOOR EMERGENCY RELEASE Interior Emergency Release

In case of emergency or door power failure, locate emergency release knob in entry way. Rotate handle clockwise and push door outwards.

Exterior Emergency Release

In case of emergency or door power failure, locate emergency air dump valve located on right side behind front bumper. Turn valve handle onequarter of a turn clockwise to release door. Two second delay will follow before door opens. Once door is open, turn the interior emergency release handle in entry way open before closing exterior emergency air dump valve. Passenger door will now stay open.

Page 55

OPERATING

LUGGAGE COMPARTMENT

The transverse luggage compartment may be accessed through seven aluminum doors. There are four luggage bay doors on curb side and 3 luggage bay doors on street side. Each luggage bay has an overhead light for safety and convenience. Luggage compartment overhead lights are controlled by the switch on the driver’s right switch panel.

The luggage compartment contains three emergency road reflectors for roadside emergencies. The compartment also includes a tool kit for minor repairs.

*Optional wheel chair lift information will be available upon request

Number Item

Radiator Compartment

Fresh Water Compartment

A/C Condenser Compartment

Fuel Tank Filler Door

Junction Box Compartment

Rear Side Service Compartment/DEF

Battery Compartment

Entrance Door

Lights

Directional Lights

Page 56

OPERATING

SPARE TIRE COMPARTMENT

Jacking points are located at front and rear axles marked in yellow

The HT 45 has an easily accessible spare tire compartment located behind the front motor coach body panel. The spare tire compartment latch can be released by lifting both spare tire compartment release handles.

The spare tire compartment release handles are located inside the motor coach dash and behind an access panel. The access panel is on the far-right side of dash. Push the two access panel release latches and remove panel.

To remove the spare tire, perform the following:

Fold bottom door completely down.

Loosen ratchet straps, allowing excessive slack for strap to be placed

above tire as it is being removed.

Pull the tire forward so it slides along the rollers, using caution as the

tire exits the support rollers.

To place the spare tire back, perform the following:

Place tire flat on first roller.

Lift straps over tire while lifting and pushing tire back into the

compartment.

Pull down ratchet straps to tire tread face.

Tighten ratchet straps against tire tread face.

Close spare tire compartment doors, closing the bottom door firs

Page 57

INSPECTION

DAILY INSPECTIONS

To make sure your motor coach is ready for service, make the following daily inspections.

NOTE: Inspection check sheet is available at the end of this section, and can be copied for reuse.

WARNING Before checking, park the motor coach on a flat roadway.

Before starting each day, check or inspect the following to ensure trouble-free performance:

•

Make visual inspection of entire unit.

•

Check under motor coach for signs of leaks. If any are noted, correct condition causing leaks.

•

Check all fluid levels on chassis: engine and transmission oil, coolant level, power steering fluid, and all other oil and liquid levels. Also check engine belts, hoses, and wiring for condition and adjust as needed.

NOTE: For more details, read the following:

ENGINE OIL LEVEL

CAUTION

Do not overfill the crankcase. NEVER operate the engine if oil quantity is below the add mark.

With the engine stopped, pull out the oil level dip stick and clean it with a clean cloth. Insert the dipstick into the crankcase completely, then pull it out again. The fluid level should be between the add and full marks. If engine had been running recently, allow at least ten minutes for oil to drain into crankcase. Use only recommended engine oil.

ENGINE OIL PRESSURE

The oil pressure will be high soon after cool-starting the motor coach; oil temperature will be increasing, and engine rotat ion speed will be normalizing. The oil pressure should be in the range of 33-55 psi. If the indicator is low or does not register within 15 seconds, stop and check oil level/condition and for any needed repair.

DRIVE BELTS AND BELT TENSION

Check condition and tension of the belts on the engine, fan, and compressor. If any relaxation, tighten belts. If there is any belt damage is present, replace belt.

Check for intersecting cracks on belts. Cracks are acceptable along the width of the belt, but if these transversal cracks intersect with longitudinal (belt length) cracks, replace belt. Also replace if the belt shows extensive wear.

CAUTION

Over-tight or excessive slack in belt tension can be harmful to the engine.

Page 58

INSPECTION

BATTERY

WARNING

Do not start the engine when working on the batteries.

Check battery post and terminals for looseness, and the batteries are acid free.

WASHER FLUID

Park on a flat, level surface. Open the outside hatch at left, front side of motor coach where the washer fluid reservoir is located. Add washer fluid if low.

NOTE: Washer fluid tank location may vary.

WINDSHIELD WIPER

Check that wiper arms and blades are secure, not damaged, and operate smoothly.

AIR CLEANER

Wipe away the dust that may have accumulated over the air intake and outlet once a weak. Check that all hose connections are tight to prevent dust from being sucked into the intake system and reducing engine life.

NOTE: Replace air cleaner filter when air filter warning light ind icates .

AIR STORAGE TANK PURGE

Open (LH) driver axle skirt for rear tank drain valve access, and front (LH) driver side access panel behind headlights for front air tank drain valves.

If too much water is in the tank, check the dryer and pre-dryer for proper operation and service if needed.

Air storage tanks are located on left side, inside the access panel and behind wheel skirts.

NOTE: The core of the air dryer must be replaced at least once a year.

RADIATOR COOLANT

Check Radiator fan inlet for debris. Check fan blade condition.

WARNING Scalding Hazard - Do Not Open Lid of Expansion Tank When Engine Coolant Is Hot!

CAUTION

Check the coolant level only when the engine is off and coo l.

Add coolant when below full. Be sure to check coolant temperature gauge.

Page 59

INSPECTION

FUEL TANK

CAUTION

Use recommended diesel only.

Check fuel gauge while ignition key is in “on” position or engine is running. Add clean diesel when needed. If the motor coach operates in a humid area, keep the fuel level full to prevent moisture on the inside surface of the fuel tank. Ensure filters are clear of water deposits. Ensure there are no leaks in the fuel line and the fuel cap remains tightly closed. Ensure fuel cap is clean before opening or closing.

PRIMARY FILTER-WATER SEPARATOR

Drain the primary filter-water separator system.

EXTERIOR LAMPS

Check that all external lights and reflective equipment are clean and functional.

ELECTRICAL SYSTEM

Check functioning of all instruments and indicators, including headlights, steering lamps, braking lamps, reversing lamps and emergency blinkers.

NOTE: Clean instrument panel cover to ensure indicators can be seen clearly.

POWER STEERING

With motor coach on level groun d, ope n the eng ine com par tment door and inspect the oil level from the viewable window on the power steering system reservoir. If low, add power steering fluid.

After adding power steering fluid, start the engine. The fluid will be driven throughout the entire system and some air may be present. Turn the steering wheel to the left and right limiting positions several times. This will extract the air from the system. Shut down engine to allow air to rise and escape the fluid in reservoir. Repeat bleed procedure if needed.

BITZER COMPRESSOR

WARNING Use extreme caution near compressor; hair, hands, or clothing can be caught in drive belt. Serious injurie s are possible.

Check oil level on sight glass. Oil level should be one-fourth to threefourths the height of sight glass.

Page 60

INSPECTION

TIRES AND WHEELS

WARNING Always maintain your tires in good condition. Frequently check and maintain correct inflation pressures as specified by the tire manufacturers. Inspect periodically for abnormal wear patterns and replace/repair cut or broken tire casing. Always use experienced, trained personnel with proper equipment an d correct procedures to mount or remove tires. Failure to adhere to these warnings could result in tire mal fun ction, damage to the motor coach, personal injury, and possibly death.

NOTE: Correct inflation pressure should be:

•

Front axle 120 psi.

•

Drive axle 110 psi.

•

Tag axle 120 psi.

•

Spare 120 psi.

Check and maintain the correct inflation pressure for each tire every morning or when tires are cool. Check tire pressures ONLY when the tires are cool. Warm or hot tires cause pressure buildup. Do not deflate a warm tire to specified pressure. Tire thumping during the walk around inspection will tell you if a tire is deflated, but the only way to check tire pressure is with an accurate gauge. If any tires are found to be considerably under inflated, the motor coach should not be driven until cause of the leak is determined and repairs have been made.

Regular and frequent inspection and proper care will give you the assurance of safe, reliable tire operation. Most tire wear problems are caused by under inflation such as a slow leak. Low pressure is a tire's worst enemy. It allows tires to flex badly and this causes high temperatures to build up. Heat causes early tire damage, such as flex breaks, radial cracks, and ply separation. Furthermore, low tire pressures can affect control of your motor coach, particularly at the front wheels.

Look for bumps, blisters, cuts, punctures, cracks, uneven wearing, and tread depth. Verify that lug nuts are tight. Adjust to specifications if loose.

NOTE: After driving a new motor coach approximately 31 miles (50 Km), an adjustment of the lug nuts should be performed according to torque specifications. The fastening sequence should be cross symmetrical. The fastening sequence and torque specifications can be found in the maintenance section.

*No regrooved tires on the front axle are allowed.

Page 61

INSPECTION

INSPECTION SHEET

 Check engine oil level.

 Check for fluid leaks. Engine oil, power steering,

transmission, axle oil, and coolant.

 Check power steering fluid.

 Check coolant system level.

 Inspect drive belts.

 Check belt tensions.

 Check cooling fan.

 Inspect coolant hose condition.

 Inspect condenser fan inlet for debris.

 Check transmission fluid level, if applicable.

 Visually check battery.

 Check washer fluid.

 Check windshield wipers.

 Check air cleaner restriction indicator.

 Check fuel tank.

 Check primary filter-water separator.

 Check mirrors.

 Check headlights (high and low beams).

 Check taillights.

 Check brake lights.

 Check turn signals.

 Check 4-way flashers.

 Check clearance lights (red on rear, amber elsewhere).

 Check red reflectors on rear and amber reflectors

elsewhere.

 Check wheel nuts.

 Check tire inflation.

 Check tire condition.

 Check A/C compressor oil level at sight glass.

 Check that all compartment doors are shut tight.

 Drain air tank.

Page 62

INSPECTION

 Check that all equipment is secured.

 Check steering system free play.

 Check all emergency equipment.

 Check driver’s and passenger seat belts.

 Check horn.

 Check foot and hand brakes (parking and emergency)

for proper operation.

 Visually inspect motor coach ride height.

 Check instrument lamps.

 Check voltmeter reading with engine running.

 Check brake air pressure.

Page 63

MAINTENANCE

WARNING To avoid property damage, personal injury, or dea th when servicing the motor coach, park on a flat level surface, set the parking brake, turn off the engine, and chock the wheels.

GENERAL INFORMATION

This manual contains information on systems operation, component location, and periodic maintenance procedures which pertain to standard and optional equipment on HT45 series motor coaches. Proper maintenance is important to the safe and reliable operation of all HT motor coaches. The service procedures described and/or recommended in this manual are effective methods for performing routine service or replacement of components. Other information, which may be needed to supplement this manual, is contained in separate parts of the operator’s manual.

Specific information about the engine and transmission can be found in the applicable manufacturer’s service and troubleshoot ing m anua ls .

WARNING Failure to perform proper maintenance and service could result in property damage, personal injury, or death.

Your motor coach has been engineered and manufactured to provide economical service. However, it is the responsibility of the owner to see that the motor coach receives proper care and maintenance to assure high performance.

WARNING To avoid property damage, personal injury, or death; take care when performing maintenance, making any inspections, or repair. Some of the materials in this motor coach may also be hazar do u s if used, serviced, or handled improperly. If you have any questions pertaining to service, have the work done by a skilled technician.

Check the motor coach periodically as recommended by this Operators Manual and by the component-specific Operation and Maintenance manuals. Perform function checks as well as a test run after performing maintenance.

Shorten maintenance intervals if motor coach use is severe or under severe conditions. Keep all fluid reservoirs full and clean as needed.

Page 64

MAINTENANCE

MAINTENANCE RECORDS

It is the responsibil ity of t he owner to k eep acc urat e m aintena nce and repair records; including receipts. Should the lack of required maintenance be the reas on for repair, the warranty claim may not be accepted. CHTC (USA), INC. reserve the right to request your maintenance and repair records for verification of compliance with required maintenance practices and intervals.

CHTC (USA), INC recommends that the maintenance and repair records/receipts be maintained as permanent records. All records must state the date service was performed, mileage, vehicle identification number, and service performed.

WARNING Always use floor stands to support the motor coach before working under it. Using only a jack c ould allow the motor coach to fall, resulting in property damage, personal injury, or death.

WARNING When welding on the motor coach is required, always disconnect the ground battery terminal first. Then disconnect the positive cable prior to electric welding. Attach the welder ground cable as close to the part being welded as possible. If welding close to an electronic component, temporarily remove tha t component. Failure to follow this warning will result in a fire or explosion hazard which could result in property damage, personal injury, or death.

When servicing your motor coach always perform the following:

Turn off the ignition switch unless the procedure calls for a running engine.

Set the parking brake and chock the wheels.

Use support stands, never a jack, whenever you must be under a raised vehicle.

Do not smoke.

Wear safety glasses for eye protection.

Operate engine in a well-ventilated area.

Do not work on brakes unless proper precautions are taken to avoid inhaling friction material dust.

Do not wear loose clothing, hanging jewelry, watches, or rings. Tie up long hair and avoid rotating components.

Avoid contact with hot surfaces. Allow hot components to cool before working near or working on components.

10.

Correct any problems that were revealed during inspection, prior to operating motor coach.

Page 65

MAINTENANCE

SEAT BELT MAINTENANCE

For safety, you should check the condition of your seat belts regularly. Pull each belt out fully and look for frays, cuts, bur ns, a nd wear. Check

that the latches work smoothly and that the belts retract easily. Any belt not in good condition or not working properly will not provide good protection and should be replaced as soon as possible.

CLEANING MOTOR COACH

The coach body should always be kept clean. Wash the coach at the end of every driving day. Do not use any type of harsh chemicals or utensils to prevent damage to the body and paint.

•

Keep the seal strips of the doors and windows in good condition. Inspect for damage and replace if needed.

•

Do not wash or rinse th e p aint ed s urf ac e of the bus with hot water, alkaline water, kerosene or any type of oil. These types of products could damage or ruin the paint.

•

Check the connecting portions between the chassis and the body and repair any abnormal conditions that may be discovered.

•

Check the fasteners within the interior components of the coach and tighten them as needed.

•

Check the condition of the passenger doors and make adjustments as needed.

•

Check the lights and lamp conditions of the coach. If any damage is discovered, replace it immediately.

Interior

Sweep or vacuum cabin daily. Clean up spills as soon as possible to prevent injury and to prevent permanent stains. If necessary, hand wash belts in warm water with neutral soap. Keep buckles dry! Rinse thoroughly and allow to dry.

Exterior

Please clean your motor coach at approved washing sites. Do not wash motor coach in direct sunlight. Use clean water to rinse motor coach from top to bottom. Ensure that water does not pass through the air filter into the engine. Do not spray water on the radiator grilles on the right or left sides of the motor coach.

Wash the motor coach as needed. To remove light dust, wipe off with a clean damp cotton towel or chamois. Always use a separate cloth or sponge when washing the painted surfaces. The other areas, such as steps, bumpers, and tread plate; could leave abrasive materials on the cloth or sponge that could scratch the painted surfaces. Never use shop rags.

Wash off all salts, highway deicers, petroleum, industrial fallout, and chemicals as soon as possible. All exterior surfaces should be washed (top, sides, and underbody).

To wash, use warm water and mild soap. Use caution when pressure washing. Always use a wide fan, and care must be taken not to get too close to the vehicle or any striping, lettering, labels, or vinyl overlay.

After washing, rinse the body thoroughly with water. Soap residues can damage the finish.

Page 66

MAINTENANCE

Number Item

Remote Engine Start Button

Transmission must be in “N”, parking brake applied, and ignition key must be in the “On” position to remote start the engine. If area is safe, push start button to start engine.

Remote Engine Stop Button

Push stop button to shut off engine.

ENGINE AND CHASSIS MAINTENANCE

WARNING NOTE: Engine will not start while engine compartment access panel is open. The engine access panel safety switch will disable the ignition switch to prevent serious injury or death.

Engine access panel safety switch.

Clean engine and trans m ission ever y 10,000 m iles. Af ter ever y 50,000 miles, the following items of the intake manifold and the exhaust manifold should be checked:

•

Check the nuts and bolts at various positions to determine if they are loose. The torque should be even and uniform while fastening the nuts and bolts. Otherwise, leakage may occur.

•

Check for cracks or holes on the intake manifold and the exhaust manifold. If there is any damage or washout at the washers, replace

the parts as needed. The main battery disconnect switch is located at rear curb side battery

Compartment shuts off all electrical supply. Turn handle right for power Left to shut off.

REMOTE START SWITCH/MASTER DISCONNECT

Table 1: Remote Start and Master Disconnect Switches

Page 67

MAINTENANCE

AIR FILTER

NOTE: Replace the filter if damaged.

When the filter indicator lamp is activated on the instrument panel, it means that the filter should be cleaned or replaced. A dirty filter will cause insufficient power and wear of the engine. In order to ensure the service life and normal operation of the engine, the air filter must be maintained carefully and periodically.

The air filter should be checked and maintained after each 5,000-mile increment. When the vehicle runs in a heavy dust environment, the replacement cycle of the filter should be shortened. The engine must be off when the intake system is being serviced. Do not start the engine once the filter has been removed. Restart only after the filter has been replaced.

To remove the cover, take off the 4 snap clips and remove the outer filter and lid. Remove the dust in the unloading valve. Clean the filter by tapping lightly with hand, wooden tool, or by blowing air into the filter with an air compressor. Remove the inner filter butterfly-nut. Clean th e filter by tapping l ightly with hand, wooden tool, or by blowing air into the filter with an air compressor.

CAUTION

Do not blow air on the outside surface of the filter core.

When using compress ed air, be sure the air pressure is lo wer than 7 2 psi (496 kPa). Blow the air from inside the filter to the outside, until the dust is no longer visible.

Clean the surface using a clean, dry cloth. The filter should be checked by using an examining lamp to make sure there is no damage before installing it. Check for damage or cracks on the sealing ring.

NOTE: Do not start the engine without the air filter in place.

Page 68

MAINTENANCE

Numbe

Item

Coolant Res er voir Le vel Window.

Coolant Reservoir Fill Cap.

RADIATOR

Keep the outside of the radi ator clea n by using compressed air or a water hose. This will ensur e pr oper a ir cir c ulatio n an d c ooli ng of the engine.

For the vehicles equipped with the inter-cooling device, keep the fins of the radiator clean at all times. Normally compressed air or water is used to clean the radiator. When there is hard scale on the radiator, steam should be used. In order to avoid damaging the radiator fins, the flow of air, water, or steam should be vertical to the surface of the radiator.

NOTE: It is essential to keep the radiator system clean and clear of any obstructions, so the engine will cool adequately.

In areas, where there may be numerous flying insects, clean the radiator fins more often.

CAUTION

Not abiding by this operating requirement could cause poor engine cooling, and possibly severe damage to en gine components.

ENGINE COOLANT

WARNING Never open filler cap if coolant is hot. When opening filler cap, first turn it carefully counterclockwise to the first stop and let the pressure escape. Then turn it to the second stop and remove the cap.

Coolant tank.

Table 2: Coolant Reservoir

Page 69

MAINTENANCE

Add the long-life anti-freeze and anti-rust liquid into the radiator. The coolant is all-purpose and need not be charged/discharged in the

winter. When selecting the freezing point of the coolant, it should be 5

C lower than the minimum ambient temperature. Different types of coolants should not be mixed.

NOTE: The coolant should be replaced every 2 years. An antifreeze and a rust inhibitant solution (a mixture of the glycol and

water) should be added to the cooling system to prevent settling, freezing, and oxidizing as well as to raise the boiling point.

CAUTION

Add the same type of coolant to prevent settling. If the coolant is substandard or the freezing point is too high, replace it immediately.

Long term operation of the engine may cause lime scale to build up in the cooling system. Cooling system must be cleaned by the following method:

•

Blend the causticity sodium of 24/28 oz. (700/800 gm) with kerosene of 5.25 oz. (150 gm)

•

Pour the liquid mixture into the radiator.

•

Let the engine run for 5 to 10 minutes at a middle rate.

•

Let the engine rest for 10 to 12 hours.

•

Restart and run the engine for 10 to 15 minutes.

•

Drain the solution.

•

Once this is complete, flush the radiator with clean water.

Page 70

MAINTENANCE

Table 3: Coolant Mixture Chart

Temperature Maximum Boiling Point Glycol Content Water Content Additive Content

-49º F (-45º C) 226.4º F (108º C)

58% 32% 10%

-40º F (-40º C) 225.5º F (107.5º C)

54% 36% 10%

-31º F (-35º C)

224.6

º F (107º C)

50% 40% 10%

-22º F (-30º C) 223.7º F (106.5º C)

46% 44% 10%

-13º F (-25º C) 222.8º F (106º C)

42% 48% 10%

-4º F (-20º C) 221.9º F (105.5º C)

38% 52% 10%

5º F (-15º C) 221º F (105º C)

34% 56% 10%

14º F (-10º C) 220.1º F (104.5º C)

30% 60% 10%

Page 71

MAINTENANCE

BRAKE PEDAL

Adjust brake pedal clearance by loosening the locking nut of the brake pedal and adjust the adjustable nut. Measure the vertical distance with a steel strip ruler. The distance between the pedal free play position and the position at which the pressing pressure wou ld dis tinc tl y incr ease sho ul d be 0.32 to 0.48 in. (8 to 12 mm). Tighten the locking nut securely after adjusting.

TIRE ROTATION

To extend the use and life of the tires, they should be rotated every 4,800 to 6,000 miles (8,000 to 10,000 km), depending on driving conditions. If there is unusual or irregular wear, the tires should be rotated immediately, as well as checking the orientation of the wheels and the dynamic balance.

The rear axles wheel skirt can be easily lifted out of the way, allowing for clear access to jack up the axles and wheel replacement.

•

To lift wheel skirt, pull on each bottom skirt corner to release skirt from latch. Lift wheel skirt out of the way.

•

To reposition wheel skirt, pull skirt all the way down. Push on each bottom skirt corner to secure into latch.

WINDSHIELD WASHER RESERVOIR

Maintain windshield washer reser vo ir level with a high qua lity washer fluid. Washer reservoir is located in the first left access panel under the driver’s window.

Page 72

MAINTENANCE

NEW MOTOR COACH BREAK-IN

CAUTION

The engine must not be run at its maximum output power during the break-in period.

In order to maintain the excellent performance and efficiency of the motor coach, as well as ensure an extended service life.

Pay attention to any unusual noises, vibrations, or handling characteristics, at all times during break-in period. The mileage for the break-in period is usually 1,500 miles (2,500 km).

New Motor Coach Preparations

It is advisable to perform the following procedures:

Clean the motor coach.

Check the connections and fasteners of various components.

Check the coolant storage of the cooling system and look for any leakage.

Check the fluid levels in the engine, the gearbox, the driving axle and the steering system. If fluids are low, add the appropriate fluid being careful to not overfill.

Check for any leakage in each system.

Check to see if the brake system is normal and look for any leakage among the valves and the various pipeline connections.

Check the steering system for loose or blocking parts.

Check tire pressure to ensure proper inflation

Page 73

MAINTENANCE

New Motor Coach Break-in Maintenance

Perform the following procedures. NOTE: The vehicle should be driven on well-maintained roadways

during this period.

•

Drive the motor coach appropriately for a new vehicle and accelerate smoothly. Do not place the motor coach in neutral when coasting. As much as possibl e; do not brake in an urg ent manner during the break-in period.

•

The speed limit during this time is less than 30 Mph. (50 Km/h). Drive the bus empty for the first 150 miles (250 km). Do not overload the bus after the 150 mile (250 km) break-in period.

•

Check the fluid levels in the engine, the gearbox, the driving axle, and the steering system. If fluids are low, add the appropriate fluid, but do not overfill. Check for any leakage in each system.

•

Check to see if the brake system is normal. Look for any leakage among the valves and the various pipeline connections.

•

Check the steering system for loose or blocking parts

•

Check the electric appliances, lamps, and instruments.

•

Pay attention to the temperatures on the gearbox, the driving axle, the wheel hubs, and the brake discs frequently. If there are any overheating problems, find the cause and correct immediately.

•

Pay special attention to the oil pressure and engine coolant temperature. They should remain in the normal range.

•

Replace the engine lubricant according to the engine manufacturer’s manual. The engine lubricant should be drained while the engine is hot.

WARNING

Take extreme precautions to drain engine oil while engine is hot. The hot components or hot oil can cause severe burns which can lead to permanent injury or death.

Post New Motor Coach Break-in Maintenance

Perform the following procedures.

•

Ensure proper nut and bolt torque on cylinder head, valve cover, manifold bolts, etc.

•

Check the valve lash.

•

Replace the lubricant in the engine, the gearbox, and the reduction final drive, as well as the filter core in the oil reservoir.

•

Check the connecting positions in the steering system for any loosening or damage.

•

Tighten the bolts and nuts in the front and rear suspension systems according to the specified torques.

•

Check the installation and fastening of the various components in the hydraulic system of the steering mechanism. Lubricate and maintain the motor coach according to this basic maintenance check list.

•

Check for any oil, water, or air leakage within the various portions of the motor coach.

Page 74

MAINTENANCE

ENGINE COMPARTMENT

Table 4: Engine Compartment Components

Number

Item 1 Air Filter

Alternator

Coolant Sight Glass

Coolant Fill Cap

Engine Oil Dipstick

Trans Oil Dipstick

Number

Item 7 Fuel/Water Separator

Power Steering Reservoir

Remote Start / Disconnect Switch

Bitzer AC Compressor

Engine Oil Fill Tube

Engine Plate

Page 75

MAINTENANCE

Page 76

MAINTENANCE

ENGINE OIL

The preferred engine oil is an equivalent of the American Petroleum Institute API CI-4 15W-40.

The engine oil will need to be replaced at specified intervals due to oil consumption, contamination of the oil as it flows through the engine, and the breakdown of chemical additives. The recommended frequency for changing the oil is approximately every 15,000 to 20,000 miles (24,000 to 32,000 km). Based on the driving conditions, quality of fuel and environmental conditions the frequency may increase or decrease based on the individual use of each motor coach.

Engine Oil level

CAUTION

Never operate the engine with oil level below the ADD mark or above the FULL mark on the dipstick.

Oil dipstick and oil filler tube.

Place motor coach on level surface. Pull out dipstick and wipe it clean with a clean cloth. Insert dipstick and pull out again. The oil level should be between the ADD and the FULL marks on the dipstick.

If the oil level is too low, add oil through the oil filler tube. Bring level up to FULL mark.

Engine Oil Viscosity

Since the viscosit y of t he e ngine oi l c hanges with the tem per ature, th e average ambient temperature at the operating site of the engine is very important for us to choose oil viscosity grade. Occasionally, if temperature drops below the lower limit, it may reduce the cold staring capability of the engine but not cause any damage to the engine.

The engine oil with an excessively high viscosity would cause engine starting difficultly. Therefore, the ambient temperature while the engine starts is the main basis on which to choose an engine oil. You may also avoid replacement of the engine oil due to the temperature changes provided the multi-functional engine oil is used.

NOTE: Adding any additive into above-mentioned engine is unnecessary. Avoid mixing and using different types of engine oil. Performing oil changes on time is crucial.

Page 77

MAINTENANCE

GEAR LUBRICANT

Always use synthetic gear lubricant that conforms to the API GL5 SAE 80W-90 grade. Using the recommended brands from ZF Axles is acceptable.

POWER STEERING LUBRICANT

Allison C-3, DEXRON-II hydraulic transmission oil should be chosen when the power steering mechanism operates under temperatures

lower than 50

° F (10° C); If above 50° F (10° C) then choose C-3/10W;

the C-3/10W grade oil is an all-season oil in freezing zones; The C-3/30 grade oil is all-season oil in non-freezing areas.

FINAL DRIVE UNIT LUBRICANT

The lubricant for reduction final drive should meet the applied conditions of the ECO FluidX (80w-90) grade of API for the heavy load, the hyperbolic surface gear as well as meet the applied ambient temperature conditions.

CHASSIS LUBRICANT

The #2 lithium-based lubricant grease (suitable for ambient temperature of -22

° to 248°F (-30° to 120°C)) should be appl ied to the various

components.

DEF TANK

The DEF tank is located rear curbside access door panel. Filled to max line. Max capacity 15 gallons. Never add diesel fuel into the DEF tank.

DIESEL FUEL

Fuel tank fill caps are located behind small locked panels. The small locked panels are located on both sides of motor coach. Use only high purity diesel, with a content of sulfur that is not more than 0.3 percent.

CAUTION

Avoid driving with an extremely low fuel level. Running extremely low or out of fuel could cause engine damage.

Page 78

MAINTENANCE

EMERGENCY STARTING USING JUMPE R CABLES

WARNING The following procedures must be performed exactly as outlined, otherwise a fire or a battery explosion could result in property damage, personal injury, or death.

Do not allow metal tools to contact positive terminal of battery to prevent shorting of the electrical system.

Place transmission in Neutral and set parking brake in both vehicles.

Shut off lights, heater, air conditioner and any other electrical loads in both vehicles.

Wear eye protection.

Make sure vehicle bodies are not touching.

Connect one of the first jumper cables to the positive terminal of the dead battery and then other end to the positive terminal of the booster

battery.

Connect one of the second jumper cables to the negative terminal of the booster battery and then other end to the chassis of the dead battery

vehicle.

Reverse above procedure when removing the jumper cables.

Page 79

MAINTENANCE

FUSE PANEL

Page 80

MAINTENANCE

First diagram’s fuse panel is installed in the luggage compartment, and second fuse panel is installed beside the battery cabin.

WARNING

Electrical circuits are designed with a particular wire gauge to meet the fuse and circuit breaker current rating. Do not increase the size of fuse or circuit breaker, or change type of breaker supplied with your motor coach. To do so could cause wiring to overheat and possibly burn, resulting in a fire which could cause property damage, personal injury or death.

CAUTION

No modification should be made to any motor coach control system without first contacting your HT dealer.

Fuse panel can be found on wall at the rear of the luggage bay. Refer to the schematic located on the fuse panel cover.

Page 81

HT 45 MOTOR COACH

12851 South Reservoir Street

Chino, CA 91710

Tel.: (909) 325-8588

Fax: (909) 993-0838

Page 82

CHTC HT SERIES MOTOR COACH

OWNER LIMITED WARRANTY MANUAL

INTRODUCTION

The information provided in this manual has been prepared by the Warranty Department of CHTC(USA), Inc. in order to assist you with any warranty questions or problems that may arise. This manual describes many features of your motor coach and provides a guide to operating procedures so that you can obtain the best performance possible.

Like all automotive equipment, your motor coach will require care and maintenance to retain its maximum performance. This manual, along with the specific instructions provided by the leading appliance manufacturers, is in your Owner’s Information Kit. The Chassis Operator’s Manual outlines important areas of service and provides a maintenance schedule. Please follow them carefully to ensure a safe, trouble-free service. Study these instructions carefully. A good working knowledge of your unit and how to care for it will help you enjoy many miles and years of use.

It is in the owner and operator’s best interests to review this document carefully and have a clear knowledge of the coverage and terms and conditions of CHTC’s Limited Warranty before submitting any claims. If you have any questions or problems in regards to the warranty coverage, please contact the CHTC Technical Support Center at 1-800-216-6788.

WARRANTY REIMBURSEMENT LABOR RATE

Before your warranty account can be set up, CHTC requires that you submit your current mechanical labor base rate for CHTC’s approval (and any changes in such rates that may occur in the future). You should submit your CHTC service account number along with the labor base rate to which credits are to be applied. In order for us to support your requested labor rate, please provide related documents such as pay stubs, payroll statements, direct deposit statements, or any other legal proof of your company’s labor cost for that category of employ ee. CHTC will make reasonable efforts to ensure all information that you send to us remains confidential and will not be used in any other manner except for approval of labor reimbursement. Please send the requested information to:

CHTC BUS GROUP

12851 S. Reservoir St.

Chino, CA 91710

ATTN: Warranty Service Department

[email protected]

Fax: 909-993-0838

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Labor Rate is effective from the Approval Date by CHTC

CHTC’s Limited Warranty states that CHTC will credit to Buyer’s CHTC service account for the labor cost on the removal and replacement of any defective part(s) that is covered by the Limited Warranty based on: (i) the number of hours determined by CHTC to complete the job (ii) times 125% of the mechanical labor base rate* the Buyer paid at their locale garage at the rate that’s previously approved by CHTC.

*mechanic labor base rate is the average base rate of labor paid to your local mechanics, excluding any benefit costs or overhead expenses.

Example:

Top Mechanic’s rate: $35.00

Times:

Warranty reimbursement labor rate: $43.75

Third Party Repairs:

The payment at any third party facilities will solely be Buyer’s responsibility. Afterwards please submit the applicable invoice(s) and any other required documentation to CHTC for review and approval. Upon approval, CHTC will credit Buyer’s CHTC service account.

125%

LIMITED WARRANTY

Applicable only to HT Series Motorcoaches Manufactured by Jianxi Kama Bus

Co.

This Limited Warranty applies only to new coaches (together with all accessories and equipment comprising such coach, collectively the “Coach”) manufactured and sold by CHTC for use in the territorial limits of Canada and the United States, including Hawaii and Alaska, excluding Puerto Rico, Guam and the Virgin Islands. This Limited Warranty is not assignable or otherwise transferable to subsequent owners of the Coach unless CHTC receives either a properly completed Sale Notification form or other documentation acceptable to CHTC.

Seller warrants for the Warranty Term herein specif ied that each new Coach, subject to certain exceptions, exclusions, and conditions noted below, will be free from defects in material and workmanship. This Limited Warranty applies only to de fects discovered during the Warranty Term, which shall be 24 months or 250,000 miles whichever comes first, from the date of delivery of the new Coach to Buyer.

The CHTC extended limited warranty applies only to contracts for future delivery of all new CHTC HT Series motor coaches.

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Buyer shall give Seller written notice of any defect occurring during the Warranty Term to which Buyer claims this Limited Warranty applies within thirty (30) days from the date such defect becomes apparent, specifying the nature of the claimed defect and the date it became apparent.

Seller’s obligation under this Limited Warranty is limited to (A) repairing or, at Seller’s option, replacing free of charge any parts that, in Seller’s reasonable opinion, have failed as a result of a defect in material or workmanship occurring during the Warranty Term under normal service conditions, provided that Buyer (i) has given Seller timely w ritten notice o f the de fect and (ii) upon Seller’s request, has returned the defective part(s) to Seller, transportation charges collect; and (B) crediting Buyer for the labor cost incurred in the removal and replacement of any such defective part(s) based on (i) the number of hours designated by Seller to be required for such work, times (ii) 125% of the base rate for mechanical labor prevailing at Buyer’s garage locale at the time of replacement, such base rate to have been previously approved by Seller.

This Limited Warrant y Covers

Warrantor’s Limited Warranty covers only defects in the workmanship performed and/or materials used to assemble those portions of your motor coach covered by the limited warranty. See also the section “What the Warranty Does Not Cover” that is de tailed bel ow. “Defect” means the failure of the workmanship performed and/or materials used to conform to Warrantor’s design and manufacturing specification and tolerances.

EXAMPLES OF ITEMS NOT COVERED BY THE LIMITED W ARRANTY

● Engine (covered by Cummins, please see section “Engine and Transmission” below)

● Transmission (covered by Allison, please see section “Engine and Transmission” below)

● Tires

● Flood, collision, f ir e, theft, freezing, vandalism, riot, explosion, or object striking the

vehicle

● Par t s or equipment that failed as the result of normal wear and tear, or damage due to accident, standard maintenance, or service adjustment.

● Road Service Calls and/or Towing charges (6 months and/or above $600 per occurrence). Any assistance initiated by CHTC (roadside or otherwise) does not constitute CHTC’s approval of, or agreement to pay, such charges

● Down time, rental of automobiles or other equipment, lodging, telephone, text messages, or other intangibles

● Lost profits or revenues

● O vert im e, premium labor, or labor hours in excess of Standard Repair Time (SRT). SRT

must be used where applicable or labor breakdown must be provided to properly process the request for warranty credits.

● Failure due t o improper installation or careless or negligent workmanship

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● Troubleshooting or diagnostic inspections (in excess of half an hour), phone calls for technical support, or no trouble found/no repairs made.

● Ser vice items or routine maintenance items including, but not limited to: oil, oil filters, fuel filters, air filter, tr a ns mission fluid, anti-freeze, coolant, belts, hoses, light bulbs, wiper blades, tune-ups, fuel, windshields, brake and clutch linings, exterior mirror glass, wheel studs, radius rod or king pin bushings, wheel balancing, wheel seals and bearings, and drive axle pinion seals

● Shop supplies ( shop rags, drill bits, solvents and other miscellaneous items)

● Tools purchased to repair or replace parts

● Failures r esult ing from or due to the lack of required preventive maintenance, improper

repair procedures, or otherwise not complying with CHTC Maintenance manuals and service bulletins.

● I ns t allation of non-OEM equipment

● Claims f iled after more than 30 days finding the defect

This warranty does not cover any economic loss, including without limitation, communication expenses, meals, lodging, loss of use of the coach, loss of revenue, coach replacement charges, towing, loss of time, inconvenience, cargo damage, overtime premium, mileage, shop supplies, hotels or any other cost or expense resulting from a defect covered by this warranty.

Notwithstanding the foregoing, towing and/or road service is limited to $600 per incident when a coach is inoperable or continued operation would result in additional component damage due to a defective component listed in the engine component coverage list included therein. Towing and/or road service charges due to a failure of a non-covered engine component or resulting from an accident are not covered. Towing coverage is limited to a single tow per incident for covered coaches that are accessible from a MAJOR paved highway and towed to the nearest authorized CHTC Service Center.

● Perform maintenance on the vehicle as described in in the applicable maintenance manual

● Perform routine adjustment services regularly, which includes but is not limited to: wheel alignment, wheel balance, headlight adjustment, and brake adjustment

● Keep all preventive, maintenance, and repair records. CHTC will require these records before performing any services.

OWNER’S RESPONSIBILITY

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ENGINE AND TRANSMISSIO N

The engine and transmission are warranted by their respective manufacturers (Cummins and Allison) and NOT by CHTC. Since CHTC does not warrant the engine or transmission, the preferred and suggested method is for you to request assistance from your local authorized engine or transmission dealer and obtain engine or transmission service under any such manufacturer’s warranty.

LEGAL REMEDIES

To the extent permitted by law, CHTC disclaims all implied warranties, including the implied warranties of merchantability or fitness for a particular pur pose. To the extent such a disclaimer is not enforceable, all implied warranties, including warranties of merchantability and fitness for a particular purpose, are limited in duration to the duration of this limited warranty. The performance of repairs is the exclusive remedy under this warranty. No person is authorized to modify this warranty or to assume any other liability on behalf of CHTC unless this modification is made in writing and signed by an authorized officer of CHTC. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

SUSPENSION OF LIMITED WARRANTY OBLIGATION

CHTC reserves the right to review and audit all warranty related records, including but not limited to the claims filed, maintenance records, and parts returned. Also, CHTC has the right to suspend its Limited Warranty obligations if Buyers are not following obligations, including but not limited to putting Buyer's warranty account aside and withdrawing or revoking Buyer’s access to Technical Support Center.

CONTACTING FOR ASSISTANCE OR REPORTING A FAILURE

When assistance is required related to warranty claims or other questions, please contact CHTC Technical Support Center:

CHTC BUS GROUP

12851 S. Reservoir St.

Chino, CA 91710

1-800-216-6788

INFORMATION REQUIRED TO REPORT A F AILURE

● Operator and Buyer’s name

● Coach VI N Number

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● Coach Delivery Date (optional)

● O perator’s Fleet Number

● Mileage and Dat e at Failure

● Det ailed Descript ion of Failure (Complaint, Cause, and Correction Needed)

● Cont act Pers on, Address, Phone and Fax Numbers, E-mail (If applicable)

A warranty claim must be filed within 30 days after a failure has been reported and should be processed through our Technical Support Center at 1-800-216-6788.

PERFORMING REPAIRS

As mentioned before, Based on this Limited Warranty, CHTC’s sole obligation is limited to: repairing or replacing parts that failed as a result o f a de fect in material or workmanship occurring during the Warranty Term under normal service conditions. Buyers have to provide CHTC with timely written notice of the defect as well as return defective part(s) to CHTC, transportation charges collect. Also, the labor cost incurred in the removal and replacement of any such de fective part(s) based on working hours designated by CHTC, times 125% of the base rate for mechanical labor at repair facility at the time of replacement, which have been previously approved by CHTC.

WARRANTY REPLACEMENT PARTS

Replacement part(s) may be available at CHTC Technical Support Center. Replacement part orders for covered warranty claims go to CHTC Technical Support Center directly. Warranty claims for defective parts should be filed and mailed to CHTC Technical Support Center. The filing of a warranty claim is not contingent upon ordering a replacement part from CHTC. Instruction will be provided when the warranty is filed. For example, the def ect ive par ts sh ould be returned within 30 days (if instructed), otherwise CHTC will deny the warranty claim. After the part(s) returned, CHTC will check if: (a) the part(s) is found not defective; or (b) the Buyer’s warranty claim with respect to the returned part is not otherwise in accordance with the terms and conditions of CHTC’s Limited War ranty ; or (c) the part was damaged during shipping (materials must be well packaged in a sturdy container to prevent damage). If any of these conditions are met, CHTC will deny the claim and return part(s) to Buyer with written explanation.

Parts purchased from CHTC Service Parts and used by Buyer on Coaches within the Coach Limited Warranty will be handled, in case of failure, by the appropriate CHTC Warranty Department. Warranty coverage for parts purchased and installed on a Buy er’s coach outside the terms of the Limited Warranty will be covered only by the part’s warranty, if any, that may be provided in connection with the part’s sale. Buyer should contact the appropriate Fleet Support parts center for warranty claim handling instruction.

PARTS

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OTHER LIMITATIONS

The obligations of CHTC shall not extend beyond the obligations expressly undertaken herein and CHTC shall have no liability of responsibility to the purchaser of the coach or any third party for any loss or damage, whether direct or indirect or for incidental or consequential damage. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STAT E.