Foton BJ491EQ1, BJ483ZQB, BJ486ZQ, YC4F90-21, 2RZ-E Service Manual

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OPERATION AND MAINTENANCE MANUAL

FOR FOTON VIEW SERIES LIGHT BUS

BEIQI FOTON MOTOR CO.,LTD.

BRIEF INTRODUCTION

BJ491EQ1 BJ483ZQB BJ486ZQ YC4F90-21 2RZ-E 4G64S4

FOTON VIEW series light bus is the leading product of Beiqi Foton Motor Corporation. This Operation and Maintenance Manual for FOTON VIEW Series Light Bus introduces in details the technical maintenance of VIEW series light bus; structure, operation, maintenance and troubleshooting of BJ491EQ1, BJ483ZQB, BJ486ZQ YC4F90-21 2RZ-E 4G64S4 engines; main technical parameters for structure, maintenance and troubleshooting of automobile chassis, electricals and instruments etc.

This manual offers a reference for user and service personnel of VIEW series light bus.

BEIQI FOTON MOTOR CO., LTD.

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW

SERIES LIGHT BUS

COMPIlED BY BEIQI FOTON MOTOR CO., LTD.

Printed by Chengshun Paper and Plastic Printing House of Langfang City:889mm×1194mm( 16 ) 22 76.89 Format: 889mm×1194mm (big 16 format) Printing Papers Words Kiloword


2006 8	2006 8
August , 2006 First Edition, Beijing		August, 2006 First Print
0 1000

Impression 0~1000 copies

PREFACE

BJ491EQ1 BJ483ZQB

BJ486ZQ YC4F90-21 2RZ-E 4G64S4

CD/ VCD

VIEW series light bus has been developed to meet the demands of our customers based on the technology introduced from Japan. The light buses adopts BJ491EQ1,BJ483ZQB BJ486ZQ, YC4F90-21 2RZ-E 4G64S4 gasoline and diesel engines; the buses among the series adopts flat/half high/ high roof bodies, they equip with peach wood imitated luxury interior trim, power steering, power window, remote lock, power rear view mirrors, rear floor lamps, rear combination tail lamps, diamond headlamps, interior and exterior temperature display, high mount brake lamp, rear warm wind, combination of CD/FM, VCD player, central lock, high back adjustable seat and individual A/C etc. The vehicles complies with emission regulations, they are ideal vehicles for city and rural areas.

VIEW series light bus features safety, strong power, economy and comfortability. They also have good performances such as stable operation and environment friendship. They have been very popular since the day they were put into market.

Maintaining and implementation of vehicle performance and service life / reliability depend on its orignal quality during design and manufacturing, as well as correct operation and careful

maintenance or repair by the user and service garage. This Operation and Maintenance Manual for VIEW Series Light Bus tends to make the operation and maintenance of VIEW series light bus known to the users and service stations, so that they could master vehicles’ operation, maintenance and repair methods to prolong service life of the vehicle. This manual introduces systmatically VIEW series light bus’s technical performance. It includes the structure, operation, maintenance, repair and troubleshooting of several engine models; also in this manual are maintenance and repair of chassis and electrical equipment as well as maintenance system of the vehicle.

This manual offers a reference for user and service personnel of VIEW series light bus.

Any comment to this manual is highly appreciated.

Author

2006 8

August, 2006

TABLE OF CONTENTS

·1·

TABLE OF CONTENTS

Chapter1 Main data and specification of View series light-bus…………………………………1

1.1

1.1Main data and specification of VIEW series light-bus……………………………………………………… 1

1.2BJ491EQ1

1.2Technical data of BJ491EQ1 gasoline engine……………………………………………………………… 23

1.3BJ486ZQ

1.3Technical specification of BJ486ZQ diesel engine………………………………………………………… 29

1.4YC4F90-21

1.4Technical specification of YC4F90-21 diesel engine……………………………………………………… 31

1.52RZ-E

1.5Model 2RZ-E Engine Technical specification………………………………………………………………33

1.64G64S4

1.6 Technical data of 4G64S4 engine……………………………………………………………………………43

Chapter 2 Vehicle Technical Maintenance………………………………………………………51

2.1

2.1Routine Maintenance………………………………………………………………………………………… 51

2.2First level maintenance……………………………………………………………………………………… 52

2.3Second level maintenance…………………………………………………………………………………… 54

2.4Run-in maintenance……………………………………………………………………………………………60

2.5Seasonal Maintenance…………………………………………………………………………………………60

2.6 Vehicle lubrication…………………………………………………………………………………………… 61

BJ491EQ1

Chapter 3 Structure, Adjustment and Service of BJ491EQ1 Gasoline Engine…………… 63

3.1

3.1Cylinder head parts ………………………………………………………………………………………… 63

3.2Cylinder block parts ………………………………………………………………………………………… 71

3.3Crank-connecting rod mechanism ……………………………………………………………………………76

3.4Valve train …………………………………………………………………………………………………… 79

·2·	FOTON OPERATION AND MAINTENANCE MANUAL FOR VIEW SERIES LIGHT BUS

3.5Lubrication system ……………………………………………………………………………………………84

3.6Cooling system ……………………………………………………………………………………………… 85

3.7Starting system ……………………………………………………………………………………………… 88

3.8Charging system ………………………………………………………………………………………………90

3.9Crankcase ventilator ………………………………………………………………………………………… 91

3.10 Clutch ……………………………………………………………………………………………………… 91

BJ491EQ1

Chapter 4 BJ491EQ1 Gasoline Engine Fuel Injection System …………………………… 94

4.1
4.1	Introduction of Delphi Electronic Control Fuel Injection (EFI) System………………………………………94
4.2
4.2	Parts and Components of Delphi EFI System ……………………………………………………………… 96

BJ491EQ1

Chapter 5 Application of BJ491EQ1 Gasoline Engine ……………………………………112

5.1

5.1Regulations for safe operating………………………………………………………………………………112

5.2Fuel, oil and cooling fluids …………………………………………………………………………………112

5.3Preparations before Startup …………………………………………………………………………………114

5.4Startup Proedures ……………………………………………………………………………………………114

5.5Idle Speed & Warm-up ………………………………………………………………………………………115

5.6Check during Running ………………………………………………………………………………………115

5.7Shutdown ……………………………………………………………………………………………………115

5.8Component Protection ………………………………………………………………………………………115

5.9Limp in ………………………………………………………………………………………………………116

5.10 Precautions during Operation ………………………………………………………………………………116

BJ491EQ1

Chapter 6 Technical Maintenance of BJ491EQ1 Gasoline Engine ……………………… 117

6.1

6.1Technical maintenance interval …………………………………………………………………………… 117

TABLE OF CONTENTS

·3·

6.2Content of technical maintenance ………………………………………………………………………… 117

6.3Technical maintenance for lubrication system …………………………………………………………… 118

6.4Technical maintenance for cooling system …………………………………………………………………119

6.5Technical maintenance for fuel system………………………………………………………………………119

6.6 Technical maintenance for air intake system ……………………………………………………………… 120

BJ491EQ1

Chapter 7 BJ491EQ1 Gasoline Engine Faults and Troubleshooting …………………… 121

7.1

7.1Gasoline engine troubleshooting summary …………………………………………………………………121

7.2Diagnosis basics -- gasoline engine electronic fuel injection system…………………………………………121

7.3Notes to diagnosis - gasoline engine electronic fuel injection system ………………………………………121

7.4 Gasoline engine troubleshooting procedures ……………………………………………………………… 122

BJ486ZQ

Chapter 8 Structure, Adjustment and Service of BJ483ZQB Diesel Engine …………… 131

8.1
8.1	Precautions on Service and Adjustment of Diesel Engine ………………………………………………… 131
8.2
8.2	Service and Adjustment of Diesel Engine ………………………………………………………………… 131

Chapter 9 Diesel Engine Faults and Troubleshooting………………………………………145

9.1

9.1Hard start-up…………………………………………………………………………………………………145

9.2Hard start-up at low temperature…………………………………………………………………………… 146

9.3Insufficient power……………………………………………………………………………………………146

9.4Abnormal noise during operation……………………………………………………………………………147

9.5Abnormal exhaust gas color…………………………………………………………………………………148

9.6Lower oil pressure……………………………………………………………………………………………148

9.7.

9.7Abnormal coolant temperature or coolant short…………………………………………………………… 149

9.8Supercharging system fault …………………………………………………………………………………150

9.9. .

·4·	FOTON OPERATION AND MAINTENANCE MANUAL FOR VIEW SERIES LIGHT BUS

9.9Starter does not run, weak start up or noise…………………………………………………………………151

9.10.

9.10Alternator does not work, lower or higher charging current………………………………………………151

9.11.

9.11Lower battery volume, higher self-discharging……………………………………………………………152

9.12Cold-start preheating system faults…………………………………………………………………………152

9.13 Water pump electro-magnetic fan clutch fault………………………………………………………………153

Chapter 10 Chassis Structure and Service …………………………………………………156

10.1

10.1Clutch ………………………………………………………………………………………………………156

10.2Transmission ……………………………………………………………………………………………… 163

10.3Propeller shaft ………………………………………………………………………………………………179

10.4Rear Axle ………………………………………………………………………………………………… 182

10.5Front Axle ………………………………………………………………………………………………… 190

10.6Steering Mechanism ……………………………………………………………………………………… 199

10.7Suspension …………………………………………………………………………………………………208

10.8. Brake System ………………………………………………………………………………………………214 10.9

10.9 Wheel ………………………………………………………………………………………………………225

Chapter 11 Structure, Application and Serice of Electrical Devices & Instruments …… 232

11.1

11.1Electrical System Overview ……………………………………………………………………………… 232

11.2Fuse Box ……………………………………………………………………………………………………232

11.3Troubleshooting ……………………………………………………………………………………………232

11.4Electrical Devices ………………………………………………………………………………………… 235

11.5Complex Instrument and Auxiliary Electrical Devices ……………………………………………………259

11.6 Air Conditioner ……………………………………………………………………………………………262

TABLE OF CONTENTS

·5·

Appendices

1 BJ491EQ1

Appendix 1 Vehicle (Luxury type) Circuit Diagram, with Delphi III BJ491EQ1 engine

2 BJ483ZQB

Appendix 2: Vehicle (Economy type) Circuit Diagram, with BJ486ZQs engine

3 2RZ-E

Appendix3 Vehicle Circuit Diagram, with 2RZ-E engine

4 BJ483ZQB

Appendix4 Vehicle Circuit Diagram, with BJ483ZQB engine

5 BJ491EQ1

Appendix5 Vehicle (new EFI) Circuit Diagram, with Delphi III BJ491EQ1 engine

6 BJ486ZQ

Appendix6 Vehicle Circuit Diagram, with BJ486ZQ engine

7 4YC4F90-21

Appendix7 Vehicle Circuit Diagram, with 4YC4F90-21engine

8 4G64S4

Appendix8 Vehicle Circuit Diagram, with 4G64S4 engine

9 4G64S4

Appendix 9 Vehicle (Economy type) Circuit Dirgram, with 4G64S4 engine

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·1·

Chapter 1 Main data and specification of VIEW series light-bus

1.1Main data and specification of VIEW series light-bus

1.1.1 Main data and specification of VIEW BJ6486 BJ6516

Table 1-1

General data

Model

BJ6486

HFB

J1F1B

H2F1

J1F2B

H2F2

HJ1F2B

B1DWA

J1FB

H1F

Drive type

4×2 rear axle drive

Seats (include

9~12

←

6~15

←

9~12

driver)

Overall

length

4900

←

4970

←

4900

(mm)

Overall

width

1690

←

(mm)

Overall

hight

1935

2205

1935

1995

1935

1995

2225

1935/19

1935

1995

(mm)

Wheel

track

1450/14

←

1460/14

←

1450/14

←

(front

/rear)(mm)

Min

ground

clearance

165

←

(mm)

Wheel

base

2590

←

(mm)

Front

extension

1200

←

1270

←

1200

(mm)

Rear extension

1110

←

1110

←

(mm)

Min

turning

≤11.5

←

diameter (m)

Approach

←

angle (°)

Departure

←

angle(°)

·2·	OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Table 1-2

General data

BJ648

BJ648J

BJ648

Model

HJ1FB

H2F

H2FB

1FC

HJ1FC

B1DW

B1DX

H1FB

A-8

A-6

A-1

A-2

Drive type

4×2 rear axle drive

Seats (include

6~15

9~12

←

6~15

6~12

6~15

←

9~12

driver)

Overall

length

4970

←

4900

4970

←

4900

(mm)

Overall

width

1690

←

(mm)

Overall

hight

2205

1995

1935

2225

1935

2050

2225

1995

(mm)

Wheel

track

1450/1

←

1460/1

←

(front/rear)

430

440

(mm)

Min Ground

165

←

clearance(mm)

Wheel

base

2590

←

1200

(mm)

Front

extension

1270

←

(mm)

Rear extension

1110

←

(mm)

Min Turning

≤11.5

←

diameter(m)

Approach

←

angle (°)

Departure

←

angle (°)

Note “←”same as indicated value

Table1-3 General data

BJ648

Model

B1DW

A-1

A-2

A-3

A-4

A-5

A-7

A-9

A-1

Drive type

4×2rear axle drive

Seats

(included

6~15

6~12

←

6~15

6~9

6~15

10~15

←

driver )

Overall

length

4970

←

5085

←

(mm)

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·3·

BJ648

Model

B1DW

A-1

A-2

A-3

A-4

A-5

A-7

A-9

A-1

Overall

width

1690

←

(mm)

Overall

hight

2225

1935

1995

2225

1995

2050

1935

2050

(mm)

Wheel

track

1460/14

←

front/rear) (mm)

Min

grond

165

←

clearance(mm)

Wheel base (mm)

2590

←

Front

1270

←

1320

←

extension(mm)

Rear

1110

←

1175

1110

extension(mm)

Min

Turning

≤11.5

←

diameter(m)

Approach

angle

←

(°)

Departure

←

angle(°)

Table 1-4 General data

BJ6516

Model

B1DW

B1DXA

A-2

A-3

A-4

-1

-2

-3

-4

-5

-6

Drive type

4×2rer axle dtive

Seats

(included

←

6~9

10~15

←

6~9

10~15

6~9

driver )

Overall

length

←

5085

←

(mm)

Overall

width

←

(mm)

Overall

hight

1935

←

1935

←

2050

←

1995

←

(mm)

Wheel

track

(front/rear)

←

(mm)

Min

Ground

←

clearance(mm)

·4·	OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

BJ6516

Model

B1DW

B1DXA

A-2

A-3

A-4

-1

-2

-3

-4

-5

-6

Wheel

base

←

(mm)

Front

←

extension(mm)

Rear

←

1175

1110

←

extension(mm)

Min

turning

←

dismeter(m)

Approach angle

←

°)

Departure

←

angle(°)

Table 1-5

Mass data

Model

BJ6486

HFB

J1F1B

H1F1

J1F2B

H2F2

HJ1F2B

B1DWA

J1FB

H1F

Curb

weight

1640

1700

1665

1710

1660

1715

1720

1660/1690

1670

1660

(kg)

Front

axle

890

940

903

950

960

950

960/975

965

960

(kg)

Rear axle (kg)

750

760

762

760

700

765

770

700/715

705

700

Max

total

2516

2576

2541

2586

2536

2591

2596

2635/2665

2450

2440

mass (kg)

Front

axle

1270

1300

1283

1310

1280

1310

1105/1115

1025

1020

(kg)

Rear axle (kg)

1246

1276

1258

1276

1256

1281

1286

1530/1550

1425

1420

Table 1-6 Operation data

Max speed

≥120

←

≥130

←

≥125

←

≥120

←

Min stable speed in D gear

≤20

←

Max climbing slope (%)

≥30

←

Brake distance (full load at

≤22

←

50km/h) (m)

Fuel consumption

(L/100km)

≤9.5

←

(average speed 50km/h)

							Chapter 1 Main Data and Specification of VIEW Series Light-bus																														·5·
														Table 1-7						Mass data
		BJ6486				BJ6486			BJ6486				BJ6486						BJ6486			BJ6486			BJ6486			BJ6486				BJ6486			BJ6486		BJ6486
Model		HJ1FB				H2F			H2FB					1FC					HJ1FC			B1DW			B1DW			B1DX					B1DX		B1DX			H1FB
																						A-8			A-6			A					A-1		A-12
Curb			1670			1680			1700				1680					1700				1660			1670			1660					1665		1740		1660
weight (kg)			1670			1680			1700				1680					1700				1660			1670			1660					1665		1740		1660
Front			965			980			990				980					990				960			965			960					938		1000		960
axle(kg)			965			980			990				980					990				960			965			960					938		1000		960
axle(kg)

Rear	axle		705			700			710				700					710				700			705			700					727		740		700
(kg)
Max	total		2405			2556			2576				2556					2576				2635			2450			3635					2640		2715		2440
mass (kg)
Front	axle		1025			1086			1096				1086					1096				1150			1070			1335					1300		1315		1020
(kg)
Rear	xale		1425			1470			1480				1470					1480				1530			1380			1300					1340		1400		1420
(kg)
														Table 1-8 Operation data
	Max speed						≥120			←				←					←			←			←		←		≥125					≥130		←		≥120

Min stable speed in D							≤20			←				←					←			←			←		←			←				←		←		←
gear
Max climbing slope (%)							≥30			←				←					←			←			←		←			←				←		≥38		≥30
Brake distance (m) (full							≤22			←				←					←			←			←		←			←				←		≤19		≤22
load at speed 50km/h)
Fuel cansumption
(L/100km)							≤9.5			←				←					←			←			←		←			←				←		←		←
(average speed 50km/h)

Note	“←” same as indicated value
														Table 1-9						Mass data
				BJ6486			BJ6486			BJ6486					BJ6486					BJ6486			BJ6486			BJ6486					BJ6486				BJ6516		BJ6516
Model				B1DW			B1DW			B1DW						B1DW				B1DW			B1DW				B1DW				B1DW				B1DW		B1DW
					A-1		A-2			A-3							A-4					A-5			A-7			A-9					C			A		A-1
Curb	weight				1740		1660			1670						1740					1670			1670			1660				1740				1690		1690
(kg)
Front axle (kg)					1110		960				965						985				965			965			960						985		975		970
Rear axle (kg)					730		700				705						755				705			705			700						755		715		720
Max tatal mass					2715		2050~2			2060~2					2130~2					2050~2				2615			2227				2715				2665			←
(kg)							440				450						520				645
Front axle (kg)					1145		860~11			865~11					895~11					865~11				1110									1140		1120		1135
Front axle (kg)					1145			05				10					40				10			1110									1140		1120		1135
								05				10					40				10
Rear axle (kg)					1570		1190~1			1195~1					1235~1					1195~1				1505							1575				1545		1530
Rear axle (kg)					1570		530				535						575				535			1505							1575				1545		1530
							530				535						575				535

·6·	OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Table 1-10 Operation data

Max Speed

≥120

←

Min stable speed in D

≤20

←

gear

Max

climbing

slope

≥30

←

≥38

←

Brake distance full

≤22

←

load at 50km/h m

Fuel

consuption

L/100km (average

≤9.5

←

speed 50km/ h)

Table 1-11

Mass data

BJ6516

Modle

B1DW

B1DXA

A-2

A-3

A-4

-1

-2

-3

-4

-5

-6

Curb

weight

1700

1730

1690

1695

1700

1705

1735

1730

(kg)

Front axle (kg)

980

900

980

978

980

905

Rear axle kg)

720

830

720

717

720

725

830

Max total mass

2675

2297

2675

2665

2670

2645

2650

2302

2680

2297

(kg)

Front axle (kg)

1140

1200

1405

1120

1123

1115

1110

1102

1280

1097

Rear axle (kg)

1530

1097

1270

1545

1547

1530

1540

1200

1400

1200

Table 1-12 Operation data

Max speed

←

≥125

≥130

≥125

≥130

←

Min stable speed in

←

≤22

←

D gear km/h

Max climbing slope

←

≥38

←

Brake distance full

←

≤19

←

load at 50km/h (m)

Fuel

consumption

L/100km

←

average speed

50km/h

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·7·

Table 1-13

Volume data

BJ64

BJ65

BJ64

BJ65

Model

B1D

J1F1

BDX

J1F2

HJ1F

B1D

H2F1

H2F2

XA-1

XA-2

A-1

A-3

XA-2

XA-4

XA-5

XA-6

Fuel tank L

Used fuel

Better than 93# non-lead gasoline

Engine

lubricating

4.3

5.2

system L

Oil

SF class 10W/30 or 15W/40

Engine

cooling

10.1

system L

Anti -freezer

Ethy lene anti –frezer or anti –corrosive anti freezer do not use alcoholic anti freezer

Transmission L

2.0

Transmission

oil

Gear oil GL-5 80W/90 in north cold China

85W/90 for other regions

type

Rear axle L

1.6

Table 1-14

Volume data

Model

BJ6486

HFB

H1F

H2F

H2FB

HFB

HJ1FB

J1FB

J1FC

HJ1FC

Fuel tank L

Used fuel

Better than 93#non-lead gasoline

Engine

lubricating

4.2

system L

Oil

SE class 10W/30 or 15W/40

Engine

cooling

10.1

system L

Anti -freezer

Ethylene anti-freezer or anticorrosive anti-freezer do not use alcoholic anti-freezer

Transmission

2.0

Transmission

Gear oil GL-5 80W/90 in north cold China 85W/90 for other area

oil type

Rear axle L

2.2

·8·

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Table 1-15

Volume data

BJ64

BJ65

BJ64

Model

B1D

WA-

Fuel tank L

Fuel #

Better than 93# non lead gasoline

Engine

lubrication

4.2

system L

Oil

SE class 10W/30or 15W/40

Engine

cooling

10.1

system L

Coolant

Ethylene anti-freezer or anti corrosive anti frezer do notuse alcoholic anti freezer area

Transmission

2.0

6.5

Transmission

Gear oil GL-5 80W/90 in north cold china 85W/90for other area

oil type

Rear axle L

2.2

Table 1-16

Volume data

BJ6

BJ64

BJ65

486

86B1

BJ64

BJ65

BJ64

16B1

Model

B1D

DXA

86J1F

86H2

16BD

86J1F

86HJ

86H2

86B1

DXA

XA-

-2

XA-1

XA-3

1F2B

DXA

-2

-4

-5

-6

Rear

axle

Gera GL-5 80W/90in north cold china ,85W/90for other area

oil

Brake

system (L)

Brake fluid

V -3 –QC/T670 – 2000

Battery

At 20 : concentration 1.28 full charged 1.16 charged 50% 1.06 discharged, max current

15A during quick charging; 5A during slow charging

Refrigerant

1400

1150

(g)

Refrigerant

R134a

type

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·9·

Table 1-17

Volume data

Model

BJ6486

H1F

H2F

H2FB

HJ1FB

J1FB

J1FC

HJ1FC

Gear oil

Gear oil GL-5 80W/90in north cold china,85W/90 for other aera

Brake

system (L)

Brake fluid

JG3# composed brake fluid

Battery

At 20 : concentration 1.28 full charged 1.16 charged 50% 1.06 discharged, max

current

15A during quick charging; 5A during slow charging

Refrigerant

1500

(g)

Refrigerant

R134a

type

Table 1-18

Volume data

BJ648

BJ651

BJ648

Model

B1D

WA-1

WA-2

WA-3

WA-4

WA-5

WA-6

WA-7

WA-8

WA-9

WA-2

WA-3

WA-4

Rear

axle

Rear oil GL-5 80W/90,innorth (cold )china

85W/90 other area

oil

Brake

system L

Brake fluid

V-3-QC/T670-2000

Battery

At 20 : concentration 1.28 full charged 1.16 charged 50% 1.06 discharged, max

current

15A during quick charging,5A during slow charging

Refrigerant

1500

(g)

Refrigerant

R134a

type

Table 1-19 Adjustment data

BJ648

BJ64

BJ65

BJ651

BJ64

BJ65

BJ651

Model

B1DX

B1D

J1F1

BDX

J1F2

HJ1F

B1D

H2F1

H2F2

A-1

XA-2

A-1

A-3

A-5

A-4

Spark

plug

0.7~0.8

1.1

clearance (mm)

Belt

deflection

5~7

←

(mm)

·10·

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

BJ648

BJ64

BJ65

BJ651

BJ64

BJ65

BJ651

Model

B1DX

B1D

J1F1

BDX

J1F2

HJ1F

B1D

H2F1

H2F2

A-1

XA-2

A-1

A-3

A-5

A-4

Free

travel

5~15

←

clutch pedal (mm)

Free travel-- brake

1~3

←

pedal (mm)

Free

angle

≤20(from center to left)

←

steering wheel (°)

Toe-in (mm)

3±1

←

Camber (°)

-0°20’

±30’

←

Kingpin

10°50’ ±30’

←

inclination

Caster (°)

1°15’ ±30’

←

Engine

Model

4G64S4M

2RZ-E

Type

In-line, water cooling ,four cylinders,four strokes, electronic control multi-point injection

gasoline engine

Bore×stroke(mm

86.5×100

95×86

×mm)

Displacement

2.350

2.438

Table 1-20 Adjustment data

Model

BJ6486

HFB

H1F

H2F

H2FB

HFB

HJ1FB

J1FB

J1FC

HJ1FC

Spark plug clearance

0.8~1.0

mm)

Belt deflection(mm)

5~7

Free travel of clutch

5~15

pedal (mm)

Free

travel of

brake

1~3

pedal (mm)

Steering wheel

free

≤20(From center to left)

angle (°)

Toe-in (mm)

3±1

Camber(°)

-0°20’ ±30′

Kingpin inclination

10°50’ ±30′

Caster(°)

1°15’ ±30′

Engine

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·11·

Model

BJ6486

HFB

H1F

H2F

H2FB

HFB

HJ1FB

J1FB

J1FC

HJ1FC

Model

491EQ

Type

Vertical ,in-line water cooling .four cylinder ,four strokes, electronic control one-point

injection gasoline engine

Bore×stroke(mm×

91×86

mm)

Displacement L

2.237

Note :“←” same as indicated value

Table1-21 Adjustment data

Model

BJ6486

B1DWA

B1DWA-1

B1DWA-2

B1DWA-3

B1DWA-4

B1DWA-5

B1DWA-6

B1DWA-7

Spark plug clearance

0.8~1.0

(mm)

Belt deflection (mm)

5~7

Free travel

of clutch

5~15

pedal (mm)

Free travel

brake

1~3

pedal(mm)

Steering wheel

free

≤20(from center to lift)

angle (°)

Toe in (mm)

3±1

Camber (°)

-0°20’ ±30′

Kingpin incliniation

10°50’ ±30′

(°)

Caster (°)

1°15’ ±30′

Engine

Model

491EQ1

Type

In-line, water cooling, four cylinders, four strokes, electronic control multi –point Injection

gasoline engine

Bore×stroke

91×86

(mm×mm)

Displacement L

2.237

Table1-22 Adjustment data

Model

BJ6486 BJ6486 BJ6516 BJ6516 BJ6516 BJ6516 BJ6516 BJ6486 B1DWA-8 B1DWA-9 B1DWA B1DWA-1 B1DWA-2 B1DWA-3 B1DWA-4 B1DWC

	Spark plug clearance	0.8~1.0
	(mm)	0.8~1.0
	(mm)
	Belt deflection (mm)	5~7

·12·	OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Model

BJ6486

BJ6516

BJ6486

B1DWA-8

B1DWA-9

B1DWA

B1DWA-1

B1DWA-2

B1DWA-3

B1DWA-4

B1DWC

Free travel of clutch

5~15

pedal (mm)

Free travel of brake

1~3

pedal (mm)

Steering wheel

free

≤20(from center to left)

angle (°)

Toein (mm)

3±1

Camber (°)

-0°20’ ±30′

Kingpin inclination

10°50’ ±30′

Caster (°)

1°15’ ±30′

Engine

Model

491EQ1

Type

In-line, water cooling, four cylinders, four strokes, electronic control multi –point Injection

gasoline engine

Bore

×strok

91×86

(mm×mm)

Dispencement L

2.237

Note :“←” same as indicated value

Table1-23

Adjustment data

BJ64

BJ65

BJ648

BJ64

BJ65

Model

16B1

B1D

J1F1

H2F1

BDX

J1F2

HJ1F

H2F2

B1D

DXA

XA-1

XA-2

A-1

A-3

A-4

A-5

-2

-6

Compression

9.5

9.0

ratio

Rated

power

95/5250

88/5000

(kW)(r/min)

Max

torque

196/2750

198/2600

(N.m)(r/min)

Idle

speed

750±50

800/±50

(r/min)

Lubri

During

≥20.4

Idle

catin

speed

g oil

press

During

ure

runnin

≥170

(kPa)

Drive system

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·13·

BJ64

BJ65

BJ648

BJ64

BJ65

Model

16B1

B1D

J1F1

H2F1

BDX

J1F2

HJ1F

H2F2

B1D

DXA

XA-1

XA-2

A-1

A-3

A-4

A-5

-2

-6

Clutch

Single disc, dry diaphram spring hydraulic operation

Transmission

Mechanic 5+1,gears with synchronizers

Drive

gear

3.967

4.452

gear

2.136

2.619

ratio

gear

1.36

1.517

Table 1-24 Adjustment data

Model

BJ6486

HFB

H1F

H2F

H2FB

HFB

HJ1FB

J1FB

J1FC

HJ1FC

Compression ratio

8.8

Rated power

70/4600

[kw r/min ]

Max torque

178/3200

[N.m(r/min)]

Idle speed(r/min)

780±50

Lubricati

During

≥20.4

oil

Idle

speed

pressure

During

(kPa)

≥170

running

Drive system

Clutch

Single disc dry disphram spring hydraulic operation

Transmission

Mechanic 5+1 gears with synchronizer

Drive

gear

4.452

gear

2.619

ratio

gear

1.517

Note :“←” same as indicated value

Table 1-25 Adjustment data

Model

BJ6486B1

DWA

DWA-1

DWA-2

DWA-3

DWA-4

DWA-5

DWA-6

DWA-7

Compression ratio

8.8

Rated power /rpm

76/4300~4600

kw(r/min)

Max roque

193/3200

·14·	OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Model

BJ6486B1

DWA

DWA-1

DWA-2

DWA-3

DWA-4

DWA-5

DWA-6

DWA-7

[N.m(r/min)]

Idle speed (r/min)

800±50≥

Lubrica

During

≥20.4

tion oil

Idle speed

pressur

During

≥170

e kPa running

Drive system

Torque converter

2.3

ratio

Clutch

Single disc dry diaphram spring hydraulic operation

Transmission

Mechanic 5+1 gears with synchronizer

Torque converter Planet gears

gear

4.452

gear

2.450

Drive

Planet

gear

1.450

gear

2.619

Gears

gear

ratio

O/Dgear

0.688

gear

1.517

Rgear

2.222

Table 1-26 Adjustment data

Modle

BJ6486B1

BJ6516B1

BJ6516B1D

BJ6516B

BJ6486B1

DWA-8

DWA-9

DWA

DWA-1

DWA-2

WA-3

1DWA-4

DWC

Compression ratio

8.8

Rated

power

Rpm

76/4300~4600

(kW(r/min)

Max torque

193/3200

(N.m(r/min))

Idle speed(r/min)

800±50

Lubrica

During

≥20.4

ting oil

Idle speed

pressur

During

≥170

e kPa running

Drive system

Torque converter

2.3

ratio

Clutch

Single disc dry diaphram spring

hydraulic operation

Transmission

Mechanic 5+1 gears with synchronizers

Torque converter Planet gears

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·15·

Modle

BJ6486B1

BJ6516B1

BJ6516B1D

BJ6516B

BJ6486B1

DWA-8

DWA-9

DWA

DWA-1

DWA-2

WA-3

1DWA-4

DWC

gear

4.452

gear

2.450

Drive

Planet gears

gear

1.450

gear

2.619

gear

ratio

O/Dgear

0.688

gear

1.517

Rgear

2.222

Table 1-27 Adjustment data

BJ648

BJ64

BJ65

BJ64

BJ65

Model

6B1D

XA-1o

J1F1

BDX

DXA-

J1F2

1DX

B1D

2F1

1F2B

2F2

r -2

A-1

A-3

XA-2

XA-6

Driv

gear

1.000

0.856

0.854

gear

ratio

R gear

3.578

4.473

Propeller shaft

Tubular exposed needle bearing, universal joint

type

Rear axle

Integrated banjo type or tubular type

Final drive

Single hyperbolic bevel gear

Final drive

4.1

4.27

ratio

Differntial

Symmetric bevel gear type

Half shaft

Semi-floating

Running system

Suspen

front

Torsion bar spring double cross arm independent suspention

tion

rear

Longitudinal leaf spring; non-independent suspension

Tire

195/70R15C

195/70R15C or 205/70R15

Tire

Front

325

325/250

pressur

rear

450

450/250

e (kPa)

Table 1-28 Adjustment data

Model

BJ6486H

BJ6486J

BJ6486H

FBor FB

2FB

J1FB

1FB

1FC

J1FC

Drive

gear

1.000

gear

0.854

ratio

R gear

4.473

·16·	OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Model

BJ6486H

BJ6486J

BJ6486H

FBor FB

2FB

J1FB

1FB

1FC

J1FC

Prepoller shaft

Tubular exposed needle bearing, universal joint

type

Rear axle

Integrate bonjo type or tubular type

Final drive

Single hyperholic bevel rear

Final drive ratio

4.556

Differential

Symmetric bevel gear type

Half shaft

Semi-floating

Running system

Suspens

Front

Torsion bar spring double cross arm independent suspension

ion

Rear

Longitudinal leaf spring; non-independent suspension

Tire

185R14

Tire

Front

325

pressure

Rear

450

(kPa)

Table 1-29 Adjustment data

BJ64

BJ65

BJ6516

BJ64

Model

86B

86B1

16B1

B1DWA

86B1

1DW

DWA

-4

DWC

-1

-3

-4

-5

-6

-7

-8

-9

-1

-2

-3

Drive

gear

1.000

gear

0.854

ratio

R gear

4.473

Propeller

Tubular exposed needle bearing universal joint

shaft

type

Rear axle

Whole banjo type of tubular type

Final drive

Single hyperbolic bevel gear

Final drive

4.556

ratio

Differential

Symmetric bevel gear type

Half shaft

Semi -floating

Running system

Susp

Front

Torsion bar spring, double cross arm independent suspension

ension

Rrear

Longtudinal leaf spring non-independent suspension

Tire

185R14

195/70R15C

185R14

Tire

Front

325

press

ure(k

Rear

450

Pa)

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·17·

Table 1-30 Steering gear and brake

BJ648

BJ651

BJ648

BJ651

BJ65

Model

6B1D

6J1F1

6H2F

6XA-

6J1F2

6HJ1

6H2F

6B1D

16B1

XA-1o

1or -2

F2B

XA-4

DXA

DXA-

r-2

-5

Steering gear

Rack and pinion

Drive ratio

36.42

Max Wheel

Left

37°±0.3°

turning

Right

34°±0.3°

angle

Steering Wheel

Left

position

Service brake

Hydraulic vacuum boosting dual circuits brake front disk/rear drum brake

Vehicle body

Unibody

Vehi

Wire hauness

Negative ground

cle

Rated voltage

body

and

Battery

N50Z

elect

model

ric

Alternator

90A

Japanese

devi

model

Starter model

Japanese

QDY1218 Japanese

Compressor

10PC15

10PA17C

Table 1-31 Steering gear and brake

Model

BJ6486

HFB0rFB

H1F

H2F

2FB

HFB

HJ1FB

J1FB

J1FC

HJ1FC

Steering gear

Rack and pinion

Drive ratio

36.42

Max wheel

Left

37°±0.3°

truning

Right

34°± 0.3°

angle

Steering wheel position

Left

Running brake

Hydraulic, vacuum boosting dual circuits brake, front disc/rear drum brake

Vehicle

Vehecle

Unibody

body and

body

electric

Wire harness

Negative ground

device

Ratded

voltage (V)

·18·	OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Model

BJ6486

HFB0rFB

H1F

H2F

2FB

HFB

HJ1FB

J1FB

J1FC

HJ1FC

Battery

N50Z

model

Alternator

65A

model

Starter

QD121

model

Compressor

V50

Table 1-32

Steering gear

and brake

BJ6486B

BJ6486B1

BJ6516

BJ651

BJ6516

BJ6486

Model

1DWA

1DWA-1

1DWA-4

DWA-7or-8

B1DWA

6B1DWA

B1DWA-

B1DWC

or-2or-3

or –5or-6

or-9

-10r-2

30r-4

Steering gear

Rear and rack

Transmission

36.42

ratio

Max

Lifut

37°±0.3°

Wheel

turning

Right

34°± 0.3°

angle

Steering wheel

Left

position

Running brake

Hydraulic vacuum booating daul circuits brake

front disc rear drum brake

Vehicle

All load –brearing metal body

body

Harness

Negative prond

Rated

Vehicl

voltage

e body

(V)

and

Battry

N50Z

electri

model

Alternator

65A

device

model

Stater

QD121

model

compress

V50

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·19·

1.1.2 Main data and specification of VIEW BJ6536

Table1-33

Vehicle model				BJ6536B1DBA-2	BJ6536B1DBA-4	BJ6536B1DDA-4	BJ6536B1DW	BJ6536B1DW
							A-2	A-1
Drive Type					4×2	rear axle drive

Persons in cab				6 9	7-9	7-9	6-9	10-12

Overall		L		5320	5320 5385	5320 5385	5320	5320
Overall
dimensions		W		1690	1690	1690	1690	1690
mm
mm		H		2050	2050 2225	2050 2225	2050	2050
		H		2050	2050 2225	2050 2225	2050	2050

Wheel base mm				2590	2890	2890	2890	2890

Wheel	Front			1460	1460	1460	1460	1460
track
track	Rear			1440	1440	1440	1440	1440
mm	Rear			1440	1440	1440	1440	1440
Max Speed				≥95	≥100	≥110	≥110	≥120
km/h				≥95	≥100	≥110	≥110	≥120
km/h
Max Climbing slope				≥22	≥22	≥30	≥30	≥38
%				≥22	≥22	≥30	≥30	≥38
%
Min ground				≥160	≥160	≥160	≥165	≥160
clearance mm				≥160	≥160	≥160	≥165	≥160
clearance mm
Curb weight kg				1785	1785 1825	1840 1865		1695

Total weight kg				2484	2484	2425 2450		2628

Engine				BJ483ZQB	BJ486ZQ	YC4F90-21	BJ491EQ1	BJ491EQ1

				Four cylinders in-line water		Four cylinders	In-line water cooling four
				Four cylinders in-line water		in-line water	cylinders four strokes
Type			cooling direct injection turbocharger			cooling Turbo	cylinders four strokes
Type			cooling direct injection turbocharger			cooling Turbo	electronic control multi-point
				diesel engine		charger diesel	electronic control multi-point
				diesel engine		charger diesel	injection gasoline engine
						engine	injection gasoline engine
						engine
Bore×Stroke mm				83×100	86×100	92×100	91×86	91×86

Compression ratio				17 5	18.1	17 5	8.8	8.8

Reted power/Rpm				46/3300	52/3300	65/3400	76/4300-4600	76/4300-4600
kw/rpm				46/3300	52/3300	65/3400	76/4300-4600	76/4300-4600
kw/rpm
Max torque/Rpm				150/2200	175/1900-2300	215/1900-2200	193/2000-2600	193/2000-2600
N.m/rpm				150/2200	175/1900-2300	215/1900-2200	193/2000-2600	193/2000-2600
N.m/rpm
Diaplacement(L)				2.164	2.324	2.66	2.237	2.237

Engine Lubricating				4.5	4 5	7 5	4.2	4.2
system (L)				4.5	4 5	7 5	4.2	4.2
system (L)
Engine coolanting						10 1
system (L)						10 1
system (L)
Fuel tank volume(L)				65	65/70	65/70	65	65

·20·	OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

Vehicle model				BJ6536B1DBA-2		BJ6536B1DBA-4	BJ6536B1DDA-4	BJ6536B1DW	BJ6536B1DW
								A-2	A-1
Fuel consumption(at
50km/h,full				≤9		≤8.5	≤9.5	≤	≤9.5
payload,good road)				≤9		≤8.5	≤9.5	≤	≤9.5
payload,good road)
L/100km)
Transm			Model	ZSY08		ZSY08	035H	5RYA
ission			Type			Mechanic 5+1 gears with synchronizer

Clutch						Single plate, dry type diaphragm spring

			Type			Whole banjo type, punch axle housing

Rear	Final drive			4.1		4.556	4.1	Final drive	4 556
axle			ratio					ratio
axle		Rear axle				2 2 85W/90
		Rear axle
			(L)
			(L)
Steerin-			Type			Pinion and rack

	Transmissi
g gear	Transmissi						1
			on (L)
Sevice brake				Hydraulic,vacuum boosting , dual circuits front disk,rear drum brake

			King
			–pin	-10°50′±30′	-10°50′±30′		-10°50′±30′	-10°50′±	-10°50′±
			inclinati					30′	30′
Front			on
wheel			Caster	1°15′±30′		1°15′±30′	1°15′±30′	1°15′±30	1°15′±30
alignment			Caster	1°15′±30′		1°15′±30′	1°15′±30′	′	′
alignment								′	′
			Camber	0°20′±30′		0°20′±30′	0°20′±30′	0°20′±30	0°20′±30
								′	′
			Toe-in	1 5 mm		1 5 mm	1 5 mm	1 5 mm	3±1 mm

Max Wheel turning				34 37		34 37	34 37	34 37	34 37
angle°				34 37		34 37	34 37	34 37	34 37
angle°
Free travel of brake				1 3		1 3	1 3	1 3	1 3
pedal mm				1 3		1 3	1 3	1 3	1 3
pedal mm
Parking brake type						Steel cable Wheel brake

Suspenti			Front	Torsion bar spring double crose arm independent suspension hydraulic two –way
Suspenti			Front			telescopic shock absorber
on						telescopic shock absorber

				Longitudinal half –elliptic leaf spring non –independent suspension
system			Rear
system			Rear			Hydraulic two –way telescopic shock absorber
						Hydraulic two –way telescopic shock absorber
Electrica			Type			Negative ground

			Rated
l device			Rated				12V
l device			voltage				12V
			voltage
Type of Tire and				185R14: 325		185R14C:325	185R14C:325	185R14C:325	185R14C 325

Foton BJ491EQ1, BJ483ZQB, BJ486ZQ, YC4F90-21, 2RZ-E Service Manual

Chapter 1 Main Data and Specification of VIEW Series Light-bus

·21·

Vehicle model

BJ6536B1DBA-2

BJ6536B1DBA-4

BJ6536B1DDA-4

BJ6536B1DW

A-2

A-1

Tire pressure (kPa)

195/70R15:250

Type of Tire and

185R14:450

185R14C:450

185R14C 450

Tire pressure kPa

195/70R15:300

Type of Rim

7JJ×15

Table1-34

Vehicle model

BJ6536B1DBA-1

BJ6536B1DBA-5

BJ6536B1DDA

BJ6536B1DBA-4

BJ6536B1DDA

-5

-4

Drive Type

4×2 Rear axle drive

Persons in cab

10 12

10-14

10-15

6-9

Over all

5320

5320 5385

dimensions

1690

2050

2050 2225

Wheel base mm

2890

Wheel

front

1460

track

rear

1440

Max Speed km/h

≥95

≥100

≥110

≥100

≥110

Max Climbing slope

≥22

≥25

≥30

≥25

≥30

Min ground

≥160

clearance mm

Curb weight kg

1785

1785 1825

1865 1890

1785 1825

1840 1865

Gross weight kg

2718

2952

3032 3057

2484

2425 2450

Engine

BJ483ZQB

BJ486ZQ

YC4F90-21

BJ486ZQ

YC4F90-21

Four cylinders

Four ylinders

in-line water

Type

cooling

cooling direct

supercharging

injection diesel

diesel engine

engine

Bore×Stroke mm 83×100

86×100

92×100

86×100

92×100

Compression ratio

17 5

18.1

17 5

18.1

17 5

Reted power/Rpm

46/3300

52/3300

65/3400

52/3300

65/3400

kw/rpm

Max torque/Rpm

150/2200

175/1900-2300

215/1900-2200

175/1900-2300

215/1900-2200

N.m/rpm

Diaplacement

2.164 L

2.324 L

2.66 L

2.324 L

2.66 L

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