Volare Euro III Owner's Manual

OWNER’S MANUAL

Euro III

VOLARE G3

General Information

Fuel and lubricants

The correct operation and durability of your Volare bus depend essentially on the quality of the products you use.

Fill up the tank of your vehicle only in gas stations you trust and require quality fuel free from contaminants. The use of low quality fuel or with a high rate of contaminants saturates prematurely the fuel filters, causing loss of engine power and requiring the replacement of the filter elements before the time scheduled in the maintenance plan.

Parts and Accessories

Use only genuine parts and accessories.

The use of parts and accessories that are not recognized by Marcopolo S.A – Volare Division may compromise the durability and safety of your Volare bus.

IMPORTANT

• All information contained herein is important for the safe operation

of your vehicle and must be followed to ensure the durability of its components and the physical integrity of passengers. However, we point out some information that, if not strictly observed, could result in damage to components of the vehicle, or cause bodily injury to passengers.

• This manual is intended to guide users of Volare vehicles on the correct operation and maintenance procedures, It also contains some items related to maintenance that could help you in any emergency repairs. The preparation of this manual was based on the most complete models of the line and includes the installation of optional items. Therefore, your vehicle may not be equipped with some of the items mentioned herein. If you would like to know about components and optional accessories that are available for your vehicle, please contact a Volare representative.

• At the discretion of the Sales Department, certain special requirements may be considered as compulsory equipment required for some bus models in order to meet market demands.

• Marcopolo SA - Volare Division reserves the right to change specifications or make improvements in vehicles at any time, without incurring any obligation to make the same changes on vehicles previously sold.

IMPORTANT NOTES

General Information

CAUTION: Indicates a situation of imminent risk, whose consequences, if not avoided, can result in death or serious

injury.

WARNING: Indicates a particular situation that can cause damage toyour vehicle or change its proper functioning.

IMPORTANT: These are used to alert the user on an operating or maintenance procedure, practice or condition which, if not

strictly observed, could result in damage or destruction of equipment.

NOTE or REMARK: these are used to alert the user on important information relating to a topic, application or procedure.

Information concerning environmental protection.

“Warning” Simbology

Throughout this manual, you will find different symbols indicating situations that will require your full attention:

General Information

Congratulations! You have just acquired a top quality product designed and built especially to serve you.

This manual has been prepared to provide you with information and instructions that are necessary for the proper utilization and maintenance of your vehicle, in addition to containing data related to technical characteristics of your Volare W Fly.

Read it carefully and find out how to operate your vehicle correctly and how to take proper care of it so as to prolong the useful life of your Volare.

Before operating your vehicle for the first time, read the information contained in this manual.

The durability of your Volare largely depends on how you operate it. The satisfactory performance of your vehicle is the result of your careful operation and regularity of maintenance.

Whenever you need technical assistance to your Volare, contact a Volare Representative. He will be pleased to help you service and preserve your Volare and is ready to offer you all technical assistance you may need.

Finally, we take the opportunity to congratulate you on your choice of a Volare product, and assure you that we are committed to keeping you

satisfied.

INTRODUCTION

General Information

GENERAL INSTRUCTIONS

GENERAL INSTRUCTIONS ............................................................ 01

IMPORTANT NOTES ................................................................. 01

INTRODUCTION ....................................................................... 03

CONTENTS .............................................................................. 04

WARRANTY TERM ................................................................... 07

ISSUE ..................................................................................... 188

OVERHAULS/INSPECTIONS AND MAINTENANCE SERVICES

INSPECTION AT DELIVERY ............................................................ 15

DELIVERY INSPECTION ........................................................... 15

MAINTENANCE PLAN ................................................................... 19

INSTRUCTIONS TO CUSTOMER DELIVERY .............................. 19

FREE-OF-CHARGE LABOR INSPECTIONS ................................ 22

LUBRIFICANTS AND FLUIDS .................................................... 23

MAINTENANCE OF YOUR VOLARE ........................................... 25

PERIODIC PREVENTIVE MAINTENANCE ................................... 28

Preventive Periodic Maintenance Plan ................................. 28

Severe or Special Conditions of Use ................................... 30

LUBRICATION AND RE-TIGHTENING PLAN PREVENTIVE PERIODIC MAINTENANCE

........................................................ 49

CONTROLS

CONTROL OF SCHEDULED INSPECTIONS .................................... 53

IDENTIFICATION CARD AND RECORD OF DELIVERY

................. 53

10,000 KM INSPECTION ......................................................... 57

20,000 KM INSPECTION ......................................................... 59

30,000 KM INSPECTION ......................................................... 61

CONTROL OF INSPECTIONS/OVERHAULS SERVICES ................... 63

REGISTRATION OF INSPECTIONS/ OVERHAULS ...................... 63

CONTROL OF REPAIR SERVICES .................................................. 65

CONTROL OF REPAIR SERVICES ............................................ 65

VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION ............................................................ 70

SPECIFICATIONS .................................................................... 70

Volare Identification Points ................................................. 70

VOLARE OPERATIONS AND MAINTENANCE

VOLARE OPERATIONS AND MAINTENANCE ................................. 73

COMMANDS, CONTROLS AND MAINTENANCE ....................... 73

Volare`s Dashboard ........................................................... 73

CONTENTS

General Information

Dashboard / Panel Indicators .............................................. 74

Panel Switches ................................................................... 84

Switches ............................................................................ 85

Starting Switch .................................................................. 86

Master Switch ................................................................... 86

Anti-Fog Command ............................................................ 87

Air Conditioner Command .................................................. 88

Sound System .................................................................... 90

Electric Switchboard .......................................................... 91

Multifunctional Switch ........................................................ 93

Speed Selector Lever – Gearbox ......................................... 94

DRIVER`S STATION ................................................................ 94

Engine hood ....................................................................... 94

Route Plate ........................................................................ 94

Parking Brake ..................................................................... 95

Commands and Controls .................................................... 95

Driver`s Seat ..................................................................... 96

PASSENGERS` COMPARTMENT ............................................. 98

Seats ................................................................................. 98

Seat Belts ........................................................................... 99

Individual Reading Lights/ Air Diffusers(Holder) ................... 100

Natural Air Inlet ................................................................... 100

Emergency Exit ................................................................... 102

Heating System ................................................................. 103

VOLARE EXTERNAL PART ....................................................... 104

Rear-View Mirrors ............................................................... 104

Doors ................................................................................. 104

External Covers and Hatches ............................................. 105

Bus Body Painting .............................................................. 106

Towing Hook ...................................................................... 107

CONSERVATION OF YOUR VOLARE ......................................... 108

Internal conservation .......................................................... 108

External conservation ......................................................... 111

Volare`s Colors ................................................................. 114

Cleanliness and conservation of your Volare ....................... 116

GENERAL INSTRUCTIONS ....................................................... 118

General Safety Regulations ................................................ 118

Conama Important Precautions .......................................... 119

Important Recommendations to the Driver .......................... 121

Economical Driving ............................................................. 123

Instructions for Breaking-In ................................................ 124

Engine Starting and Stoppage ............................................. 125

Precautions to be Taken When Starting the Engine

................ 126

Precations for Removal the Vehicle from Service (Until 12 Months)

.. 127

General Information

INSTRUCTIONS, CHECKS AND MAINTENANCE ....................... 128

Special Precautions for Lubricating Oils Change ................. 128

Weights and Capacities ...................................................... 128

Electric System .................................................................. 128

Battery ............................................................................... 129

Engine ............................................................................... 132

Feed System ...................................................................... 135

Fuel System ....................................................................... 137

Cooling system .................................................................. 142

Hydraulic Clutch System .................................................... 144

Gearbox ............................................................................. 146

Crankcase ......................................................................... 152

Hydraulic Steering System .................................................. 154

Wheels and Tires ................................................................ 154

Brake System ..................................................................... 159

TECHNICAL SPECITICATIONS

TECHNICAL SPECIFICATIONS ....................................................... 163

TECHNICAL SPECIFICATIONS .................................................. 163

LUBRICANT SPECIFICATIONS

LUBRIFICANTS ........................................................................... 173

LUBRICANT OILS SPECIFICATIONS ......................................... 173

Lubricant Table – Table 1 .................................................... 173

Lubricant Table – Table 2 .................................................... 174

Re-tightening – Table 3 ....................................................... 174

ENVIRONMENT AND ECONOMICAL DRIVING

ENVIRONMENT AND ECONOMICAL DRIVING ................................ 175

ECONOMICAL DRIVING AND ENVIRONMENTAL RESPONSIBILITY * .

.. 175

Putting Into Practice Economical Driving ............................ 176

Vehicles Maintenace ........................................................... 183

VOLARE CUSTOMER ASSISTANCE

VOLARE CUSTOMER .................................................................. 186

VOLARE`S CUSTOMER SERVICE ............................................ 186

NOTES .................................................................................... 187

General Information

1. VOLARE WARRANTY SYSTEM

1.1. MARCOPOLO S.A - Volare Division warrants its products which, during normal service or operation, show defects in material, workmanship or assembly for the periods and mileage specified in this Warranty Term.

2. VALIDITY TERM

2.1. The Warranty of Volare Product is 12 (twelve) months with no mileage restrictions, except for the components described in items 2.2. to 2.10 and itens 5.1. to 5.16 in which case the period in months or mileage prevails, whichever occurs first;

2.2. Specifically for the Powertrain (engine, gearbox and rear differential) and body items which do not undergo natural wear and tear, warranty will be extended to 24 (twenty four) months or 200,000 (Two hundred thousand) km, whichever occurs first;

2.2.1. The power train components having this extended warranty coverage, are:

Engine: Engine block, cylinder heads, crankshaft, connecting rods, bushings, pistons, cylinders and rings, camshafts, water pump, oil pump, valves, crankcase, rods and tappets, engine electronic unit (ECU),

injection system (nozzle injectors holder, high-pressure pump and pipe), air compressor and turbocharger,

Gearbox: The entire gearbox except for the clutch system (disk, clutch plate, bearing etc.),

Rear differential: Differential housing, crown and pinion set, differential case, axle shafts , differential case bearings and pinion bearings.

2.2.2. 4x4 Volare Vehicles: warranty extension does not apply to the front axle differential and transfer case.

2.3. For vehicles equipped with Allison automatic transmission, Warranty for this set (transmission) is valid for a period of 24 (twenty four) months without mileage limit.

2.4. Painting is warranted for a period of 24 (twenty four) months against possible defects in adhesion, brightness and resistance, provided that cleaning has been performed with the products recommended by the manufacturer.

2.5. Windshield, sight hole, fixed or mobile window panes, mirrors, headlights and taillights are warranted against workmanship and/or assembly defects for 180 (one hundred and eighty) days from the sales invoice/trade note date of issuance to the first buyer.

2.6. Lights, fuses, ballasts, control buttons, coils/solenoids, diodes and micro keys are pieces with a limited time of use. These items have a warranty coverage of 180 (one hundred and eighty) days from the sales invoice/ trade note date of issuance to the first buyer.

WARRANTY TERM

General Information

2.7. Repairs of pneumatic cylinders, pneumatic valves in general, electric motors, windshield wiper blades, ceiling exhaust fans, heating blowers/ defroster/ air conditioning blowers in the overhead luggage rack, windshield washer spray nozzle motor, door bushings, door guiding pieces, doors brushes, pivots and door terminals are pieces subject to natural wear and tear. Therefore, warranty coverage is limited to 6 (six) months from the sales invoice/trade note date of issuance to the first buyer.

2.8. The wood floor (plywood) is warranted for a period of 24 (twenty four) months, unless misuse has been detected;

2.8.1. “Misuse” can be understood as the use of jets of current water and/or plenty water jets in the interior of the vehicle. Operating the bus in locations where there is accumulated water, floods, streams, rivers and the like is also considered as “misuse”.

2.8.2. Likewise, it is expressly prohibited to make any change in the original characteristics of the vehicle, including but not limited to: changes in the way seats are arranged, new holes made in the floor and excess weight on it.

2.8.3. Any other event that is not provided for in item 2.9. of this Warranty Term will be subject to the analysis and decision of the manufacturer.

2.9. Warranty for sanitation system is 12 (twelve) months, without mileage limit.

2.10. The Warranty of Volare product is valid from the issue of the Invoice/ Trade Note to the first buyer.

2.11. The Warranty Certificate provides data on the first buyer. The Certificate is included in the back of Volare Owner’s Manual.

3. SCOPE

3.1. The warranty covers parts and components mounted on Volare product against defects or flaws, in accordance with item 2 (two), except for those detailed in itens 5.1. to 5.20.

3.2. The warranty covers workmanship, on a free of charge basis, for services outside the regular overhauls, performed within the period specified in clause 2 (two), including any eventual defects in material, manufacturing or assembly.

3.3. The warranty covers workmanship, free of charge, for services performed at 10,000 (ten thousand), 20,000 (twenty thousand) and 30,000 (thirty thousand) km overlauls, respectively.

3.4. The warranty covers necessary repairs or replacement of components proven to be defective due to failure of material, assembly or workmanship. IN NO EVENT THERE WILL BE PRODUCT REPLACEMENT.

3.5. Any event that is not foreseen in this term will be subject to Manufacturer`s analysis and decision ;

3.6. The replacement of assemblies/sets /or mechanical, electrical and electronic equipment will be considered only if their repair proves to be impossible.

General Information

4. WARRANTY CONDITIONS

4.1. Perform the preventive overhauls established by MARCOPOLO S.A

- Volare Division (overhauls`record item) at Volare`s Service Dealers;

4.2. Use this product properly according to its technical specifications and intended purpose.

4.3. Follow the operation and maintenance instructions established by MARCOPOLO S.A - Volare Division in the Owner’s Manual.

4.4. Keep the original structure of this product intact.

4.5. Use passenger /cargo capacity within the limits specified by MARCOPOLO S.A. - Volare Division.

4.6. Allow bus driving only to persons qualified under the law.

4.7. Use only fuel and lubricants recommended by MARCOPOLO S.A – Volare Division.

4.8. Request and perform overhauls only at Volare Representatives/ Service Dealers.

4.9. Not violate/temper with tachograph seals and / or in gearbox.

4.10. Follow the mileage limits established for the implementation of

foreseen overhauls/revisions.

• Inspection at product’s delivery.

• 10,000 (ten thousand) km: between 9,000 (nine thousand) to 11,000

(eleven thousand) km.

• 20,000 (twenty thousand) km: between 19,000 (nineteen thousand)

and 21,000 (twenty one thousand) km.

• 30,000 (thir ty thousand) km: between 29, 000 (twenty-nine thousand)

and 31,000 (thirty thousand) km.

4.11. Following the 30,000 (thirty thousand) km overhaul/inspection, preventive inspections shall be performed from 40,000 (forty thousand) km, at intervals of 10,000 (ten thousand) km. These inspections will be at owner`s cost.

NOTE

Tolerance in making overhauls/inspections, as indicated above, shall be of about 1,000 km.

NOT PERFORMING ANY FORESEEN OVERHAUL WILL AUTOMATICALLY VOID THIS PRODUCT WARRANTY.

General Information

4.12. Any maintenance procedure performed during overhauls/ inspections, whether they are free-of-charge or not, at mileage different from those specified in the maintenance and lubrication plan, shall be performed at Volare`s Service Dealers.

4.13. This warranty does not cover labor cost regarding services performed on non-free-of-charge periodical overhauls, according to Overhauls Record item.

5. LIMITATIONS OF WARRANTY

Defective parts or components replaced under warranty will become property of MARCOPLO S.A. – Volare Division.

5.2. Warranty covers possible defects in material, workmanship or assembly resulting from the product construction process, being the responsibility of the manufacturer to repair it, through a Volare`s Representative/Service Dealer, by either replacing the original parts and/ or components, or repairing/correcting the defect.

5.3. Any failure in the electronic system (electronic module, sensors and actuators) resulting from the non-compliance with the precautions mentioned in Volare Manual, and/or from the replacement of the electronic module due to an incorrect diagnosis, is not covered by the warranty. The use of non-original tools/ or tools other than MWM/ BOSCH to check for failures in the electronic module will not be covered by warranty as well (Applicable for buses equipped with Electronic Engine).

5.4. Windshield, windscreen, mobile or fixed side window panes, mirrors, headlights and taillights are warranted against manufacturing and/or assembly defects for 90 (ninety) days from the date of issue of the invoice/ trade note to the first buyer.

5.5. Bulbs, fuses, ballasts, control buttons, coils / solenoids, valves and mcro-switches are parts with a specified time of use, with warranty coverage limited to 90 (ninety) days from the date of issue of Invoice/ Trade Note to the first buyer.

5.6. Repair of pneumatic cylinders, pneumatic valve repair kits, pneumatic valves in general, electric motors, windshield wiper blades, ceiling exhaust fans, heating/defroster blowers, air conditioning blower in the overhead luggage rack, windshield washer motor, door bushings, door guide pieces, door brushes, door pivots and terminals, are subject to normal wear and tear and will have a limited warranty coverage of 6 (six) months from the date of issue of the invoice/trade note to the first buyer.

5.7. Parts or components subject to normal wear and tear shall be replaced depending on vehicle’s use, with cost to be borne by the owner, unless these parts are found to be defective in material, manufacturing or assembly within the warranty period specified in clause 2 (two).

5.8. The parts specified below are considered of normal wear and tear and shall, therefore, be paid by the customer. The replacement of these parts, proved to be necessary due to the end of their useful life, are the

General Information

Body: Floor coating, door mechanism, windshield wiper

mechanism, windshield wiper blades, defroster, windows and route sign felts.

Ar Conditioner: Filters, belts, gas loads, fans, controls and seals

in general .

sole responsibility of the customer. Wear is visible on such parts, whose durability is closely related to driving conditions, mileage, manner in which they are used, and manner in which the bus is driven.

Normal wear and tear parts are considered to be: bumpers, suspension bushings, clutch system (plate, disc and bearing), gaskets, brake linings and brake drums, tires, belts, seals in general, bushing of front axle spindle, alternator and starting engine brushes, exhaust pipes, bearings and seals of the wheel hub

5.9. Excluded from this warranty are the expenses related to the maintenance items listed below:

• Steering alignment and wheels balancing;

• Gaskets in general, radiator water additives, and fan belts;

• Air filter elements, lubricants and air conditioning;

• Oils, greases and solvents;

• Tests and Adjustments;

• Replacement of brake linings and pads;

• Brake and adjustments, and retightenings in general;

• Gas Load (Air Conditioning).

5.10. This warranty applies only to vehicles, its parts and components, and does not cover expenses related to towing, transport, vehicle parking or personal expenses such as telephone calls, accommodation and others, as well as damages and lost profits, direct, indirect or from third parties, and is limited to vehicle repair, replacement or repair of its parts or components.

5.11. The travel expenses of Volare`s Representative, or from Service Station to the vehicle, and from vehicle to Volare`s Representative or Service Station are not covered by warranty;

5.12. Excluded from the warranty are parts showing defects arising from the installation of other non-original parts and/or components that do not maintain the technical characteristics specified by MARCOPOLO S.A.- Volare Division;

5.13. This warranty does not cover equipment applied by, or changes made by third parties that are not accredited by MARCOPOLO S.A Volare Division .

General Information

5.14. The replacement of defective parts or components for brand new ones, or services performed within the warranty period of the product do not imply the extension of the original warranty validity period of the product, as described in clause 2 (two).

5.15. This warranty does not cover defects caused by prolonged disuse, accidents of any nature, acts of God or force majeure.

5.16. The following components: tires, tubes, battery, alternator, injection pump, starting engine, turbocharger, power steering, tachograph, radio, CD, air conditioning, video and monitor, are warranted by their respective manufacturers. These itens shall be sent to Volare`s Representative/ Service Dealer, who will forward them to the respective Authorized Representative of the component`s manufacturer, who will provide the warranty, provided that the validity terms under item 2 (two) are followed. This applies especially to the itens below:

5.16.1. Injection pump and nozzles (for mechanical engines), highpressure pump and eletro injectors (for electronic engines), starter engine and alternator, which are limited to a warranty of 12 (twelve) months or 50,000 (fifty thousand) km, whichever occurs first;

5.16.2. Power steering, which is limited to a warranty of 12 (twelve) months or 100,000 (hundred thousand) km, whichever occurs first;

5.16.3. Air-conditioning compressor and support, which is limited to a warranty of 12 (twelve) months or 100,000 (hundred thousand) km.

5.17. Excluded from this warranty are paint discolouration or alteration caused by improper use or by normal wear and tear, or by product accident;

5.18. Only Volare representatives are qualified to provide warranty service.

5.19. The parts replaced under warranty, within the period specified in clause 2 (two), will have the same validity as the current term of the vehicle`s warranty.

5.20. After the expiration of the vehicle warranty period, the parts purchased at Volare Representative/Service Dealer and replaced at the same premises, will have a validity of 6 (six) months, except for the parts mentioned in items 5.4 and 5.5.

6. WARRANTY CANCELLATION

6.1. The validity term specified in item 2.1. expires;

6.2. Within the periods of time specified in items 2.1., evidence is found that the conditions set out in this warranty have not been complied with, especially with provisions in Sections 4.1. to 4.13.

6.3. The warranty of the product structure ceases:

6.3.1. If there is evidence that there have been alterations in the original suspension system of the chassis;

General Information

6.3.2. If there are damaged suspension components, and / or components

have been removed (buffers, stabilizers, springs, etc. ...);

6.3.3. If there are bumps on underbody;

6.3.4. If the vehicle suffers an accident or collision;

6.3.5. If the vehicle structure has been repaired or altered outside a Volare Representative/Service Dealer;

6.3.6. If the vehicle has carried loads over the stipulated weight limit;

6.3.7. If non-genuine parts have been installed in the vehicle;

6.3.8. If manufacturer’s instructions have not been followed;

6.3.9. If the overhauls/ inspections specified in the Owner’s Manual have not been performed in a Volare Representative/Service Dealer.

7. GENERAL CONDITIONS

7.1. MARCOPOLO S.A. – Volare Division reserves the right to make changes and/or improvements in its designs without incurring the obligation of making the same changes or improvements in the products that have been previously manufactured;

7.2. Some optional items shall be requested at THE time of purchase of

the vehicle and MARCOPOLO S.A.- Volare Division, reserves the right to change, at any time, prices, offers, specifications, standard equipment and/ or other optional equipment without prior notice. Some items mentioned in this manual vary according to the model and version of the chosen vehicle.

7.3. This WARRANTY TERM applies only to Volare products. Commitments made by third parts that are not in accordance with this WARRANTY TERM are not the responsibility of MARCOPOLO S.A - Volare Division.

7.4. MARCOPOLO S.A - Volare Division recommends that buyers of their products consult with Volare`Representatives (and the Owner`s Manual) regarding the correct and proper use of this product. This is necessary so that warranty can be fully effective;

7.5. The drawings contained herein are merely illustrative. MARCOPOLO S.A. - Volare Division, reserves the right to demonstrate, at the owner’s manual, illustrative optional items without incurring any obligation to apply them in products sold without proper specification at time of purchase.

GENERAL INFORMATION

• Do not operate this product without first reading carefully your Volare

Owner’s Manual. The Manual contains important information regarding the proper use and maintenance of your product.

• Your Volare Owner’s Manual should always accompany the product.

General Information

Included in the Manual are: OVERHALS/INSPECTIONS CONTROL, WARRANTY CERTIFICATE, IDENTIFICATION CARD AND REGISTRY OF PRODUCT COMMISSIONING, OVERHAULS/INSPECTIONS SLIPS, AND THE MANUAL itself;

• The OVERHAULS/INSPECTIONS CONTROL CHART is intended to

record the inspections made in your product to ensure your right to the WARRANTY, as well as for your own control of product maintenance;

• The WARRANTY CERTIFICATE, duly completed and authenticated by

the Valores Representative, in addition to identifying your product, has the primary function of granting you the right to the WARRANTY;

Demand from your Volare Representative the correct completion of the TECHNICAL REGISTRATION OF DELIVERY, a document that ensures your right to WARRANTY when it is signed by you and registered by the manufacturer.

The WARRANTY TERM records the contractual information that will give you access to any Volare Representative with regard to the maintenance of parts and services within the WARRANTY PERIOD established therein.

• The Overhauls/ Inspection slips contain information on the maintenance

procedures to be performed within the periods indicated by them. Its correct completion assures you the Right to Warranty, as per the Warranty Term;

• At Delivery Inspection, require the verification and clarification of the

items mentioned in the item “ Delivery Instructions and Delivery Check List”;

• It is your responsibility to forward your vehicle to a Volare Representative/

Service Dealer for inspections at a Volare Representative/ Service Dealer;

• Always look for a Volare Representative to perform warranty services.

• The Volare Representative is qualified to provide technical assistance

to customers. Visit him/ it whenever you deem it necessary to clarify your doubts regarding the handling, maintenance, technical features, application and other aspects involving your Volare product;

• Carefully follow the instructions contained in the maintenance plan

attached to this Manual. The useful life of your product depends on how often you check/perform the described items within the periods established by it.

When any problems occur in your product, regardless of the inspection period, visit immediately a Volare representative to solve it

Inspection at Delivery

Overhauls/Inspections and Maintenance Services

DELIVERY INSPECTION

Before delivering the vehicle to customer, the Volare Representative shall make a Delivery |Inspection by checking the items listed below. The Volare Representative in charge of it must record in this Manual , in the respective confirmation box/field, the performance of an inspection of the vehicle at delivery.

Check and complete the level (if necessary) of: engine oil, gearbox lubricating oil, differential lubricating oil, power steering fluid, coolant in the radiator surge tank, clutch and brake fluid.

Check and correct (if necessary): the tension and alignment of engine belts and air conditioning, possible damage to the pipes and fastening of clamps in the cooling system (radiator, expansion tank) / air intake (turbocharger, aftercooler) gear shifting cables routing, and shifting efforts at gear shifting.

Checking (1): the functioning and performance of the engine, radiator fan coupling, brake operation (service, parking brake and motor (if fitted)), functioning of the gear shifting, operation and performance of air conditioning and/ or heating, internal and external noise (suspension, transmission, differential, driveshafts, etc. ..), and play on clutch pedal, suspension and driving behavior (geometry and balancing).

NOTE

After checking (1), check also for possible leakage of oil, coolant, fuel and air. Check fault codes and erase them from failure memory.

Fuel filters: check for leaks / crashes.

Cable and harness of starter motor: check mounting / fastening

/ damage.

Alternator cables and harnesses: check mounting / fastening /

damage.

Battery: Tighten terminals / check cables rubbing against parts

of the body and chassis / damage (cuts, burns, crushes, etc. ....) in

the cables.

General switchboard: Fasteninf of electric cables/ cables rubbing against parts of the body and chassis / damage (cuts, burns, crushes,

etc. ....) in cables.

Master Switch: Fastening of relays and fuses on the plate / fastening of electronic modules / coupling of electrical connectors.

Inspection at Delivery

Overhauls/Inspections and Maintenance Services

Chassis electric harness: grounding conditions, (engine and chassis cables and mesh), positioning / fixing / damage (cuts, burns,

crushes, etc. ....) in the cables.

Panel: Operation of instruments / optical warning indicators / cooling sound indicator/ dial indicator / lighting / electronic tachograph, horn.

Multifunctional lever: Operation.

Clutch and brake pipes (if any): Check fastening / folding / routing.

Muffler / Brackets / Tubes: fastening / positioning / leaks / abnormal

noise.

Fuel line: position / folding / fastening / tank breather.

Air tanks, brake valves and pipes: leaks in connections.

Rear axle breather: obstruction / dirt/debris.

Gearbox breather: obstruction / dirt/debris.

Points of lubrication: grease lubrication.

Tires: Calibrate tires and check for damage (cuts, blisters, ingrown

objects) – including spare tire.

Fuel filters and air tanks: Drain.

Conventional or air suspension: check and re-tighten screws.

Wheel hubs: check clearances and leakage.

Wheels: check tightness of wheel bolts;

Check: Manuals, set of keys, triangle, fire extinguisher and tools.

Cladding and external fillets: Check fixation, shrinkage and

buckling.

Cladding and internal fillets: Check fixation, shrinkage and

buckling.

Seats: Check operation, seat belts, slacks, and cleaning.

External rear-view mirrors: Check fastening and adjustment.

Front grille: Check alignment and mechanism, as well as functional

part.

Inspection at Delivery

Overhauls/Inspections and Maintenance Services

Hatches: Check for alignment, sealing, clearances in the mechanism,

locks, rubber parts, sealing and functionality.

Driver`s station: Check for functionality of components, noise,

fibers finish and noise.

Internal lining (overhead luggage rack, side pannels and floor):

Check for cleanliness, and if they are in perfect conditions.

Air Conditioning system: Check for functionality.

Audio and video system: Check for functionality of the switch, sound

quality, radio reception and functionality of the microphone.

Heating system: Check for functionality of components.

Windshield wipers: Check for clearances, alignments, oxidation,

spraying nozzle and blades.

Engine hood: Check for sealing and operation.

External lighting (headlights, taillights, reflective, roof markers,

back light, brake, lights): Check for infiltration of water and dust,

scratches, brightness, general features and functionality.

Internal lighting: Check for general functionality.

Windows: Check functionality.

External logotipy: Check for gluing and fastening.

Loose material: Check List and Invoice.

Other accessories: Check features and overall functionality.

Windshield: Check for ruptures and sealing.

Paint: Check gloss, adhesion, roughness, conservation and

appearance.

Service door (s): Check for alignment, clearances, operation

mechanism, guide, shafts, rubber seals.

Fuel tank hatches, side pannels, battery, spare tire holder: Check for

oxidation, operation of locks, articulation, handles and latches.

Inspection at Delivery

Overhauls/Inspections and Maintenance Services

Date: / /

Volare Representantive’s Stamp

Maintenance Plan

Overhauls/Inspections and Maintenance Services

INSTRUCTIONS TO CUSTOMER DELIVERY

The following instructions must be given to customer at the delivery of vehicle:

1 General Basic Instructions

1.1 Warranty Term (warranty term, term of validity, coverage, warranty conditions, warranty limitations, warranty void and generalities);

1.2 Periodic Inspections (intervals, benefits, importance and consequences of not performing inspections – free-of-charge or not);

1.3 Periodic Preventive Maintenance Plan (engine, cooling, air intake, power supply , start up, power supply, gear box, traction/driving, brakes, suspension, steering, front axle, clutch, tires);

1.4 Re-tightening and lubrication plan;

1.5 Operation of Vehicle;

1.6 Cares with seals (e.g. tachograph gearbox ....);

1.7 Passenger/ Cargo Limit;

1.8 Driver`s Manual;

1.9 Representatives` Manual;

1.10 Use of Owner’s Manual;

1.11 Cares to be taken with the electronics, sensors and

actuators);

2 Instructions on Preventive Periodic Maintenance Plan

2.1

Engine (care and maintenance intervals – engine and its peripherals: crankcase, lubricant oil filter, air compressor, turbo

compressor, belts, high pressure pump, eletroinjetores etc. .....);

2.2 Cooling System (compensation vessel and sensor);

2.3 Air Intake (air filter - primary and secondary element);

2.4 Power System (fuel tank, primary and secondary filters);

2.5 Starting engine (starter)

;

2.6 Power Supply (battery);

Maintenance Plan

Overhauls/Inspections and Maintenance Services

IMPORTANT

Mixture of water and lubricants recommended by the factory.

4 Instructions on Instrument Panel

4.1 Panel Indicators;

4.2 Panel Keys and Switches;

4.3 Start key and Master Switch;

4.4 Sound System - functions of switch;

4.5 Electric Switchboard (location and care);

4.6 Multifunction Lever and Gear Lever;

4.7 Engine Hood;

48.Route sign - mechanical or electronic;

4.9 Parking Brake, commands and controls;

2.7 Gear shifting (gearbox, oil change and filters);

2.8 Traction (differential - oil change and bearings);

2.9 Brakes (compressor, brake linings and / or pads, air tank and

air drying filter);

2.10 Suspension (springs and stabilizer bars);

2.11 Steering (hydraulic oil reservoir, steering bar and toe-in);

2:12 Front Axle (kingpin and front wheels bearings);

2.13 Clutch (clutch hydraulic reservoir and clutch fluid);

2:14 Tires (calibration and rotation);

3 Supply Levels Instructions

3.1 Windshield washer water, expansion and mixing vessel;

3.2 Clutch and brake reservoir fluid;

3.3 Engine oil sump, gearbox, differential and hydraulic system;

3.4 Fuel tank oil

Maintenance Plan

Overhauls/Inspections and Maintenance Services

4.10 Indicator lamp and instructive table;

4.11 Cooling system – indicator of water shortage;

5 Performance Instructions

5.1 Driver`s seat, second driver`s seat and passengers` seat

(adjustment and seatbelts);

5.2 Internal and external lighting;

5.3 Air fitting and emergency exit;

5.4 Heat system and air conditioning;

5.5 Rear view mirrors;

5.6 Door (s) – Activation and emergency mechanism;

5.7 Fire extinguisher (location and directions on how to use it);

5.8 External Covers and hatches;

5.9 Body Painting;

5:10 Bell;

5:11 Spare tire, jack, wheel spanner and triangle;

5:12 Towing pin;

5:13 Emergency hammers;

5:14 Internal and external conservation;

6 General Safety Rules;

7 Daily Inspection

– before starting the engine (eg, drain the water and impurities accumulated in the pre-filter, drain the brake air reservoirs, check oil level and fuel level, coolant, clutch fluid, tire pressure).

8 Important Tips to Driver;

9 Economical Driving

- factors that increase and decrease fuel

consumption;

10 Instructions for breaking in engine;

11 Engine Start and stop system;

12 Instructions, Checks and Maintenance;

13 Technical Specifications;

Maintenance Plan

Overhauls/Inspections and Maintenance Services

FREE-OF-CHARGE LABOR INSPECTIONS

The Volare maintenance plan provides the following services at no labor cost, to be performed at the mileage listed below.

At receipt of vehicle Inspection at Delivery

Vehicle delivery to customer

Vehicle commissionng

1st Inspection

At 10,000 Km (between 9,000 ande 11,000 Km)

2nd Inspection

At 20,000 Km (between 19,000 and 21,000 Km)

3rd Inspection

At 30,000 Km (between 29,000 and 31.000 Km)

INSPECTION/ Intervals

SERVICE

IMPORTANT

To ensure free-of-charge labor for services above, the vehicle must be within the 24-month period from the date of purchase of the vehicle. Inspections must be carried out by a Volare Representative.

RISK OF INJURY!

Before performing maintenance work, always read the owner’s manual and perform it at a Volare Representative.

Always have these inspections made at the indicated periods of time, otherwise breakdowns or failures in safety systems may occur. Accidents can also happen, causing injury to you or to others.

Maintenance Plan

Overhauls/Inspections and Maintenance Services

Lubrificants and fluids are:

• fuel;

• lubricants (eg, engine oils, gear oils, hydraulic oils, grease, etc.);

• antifreeze, coolants;

• brake fluid;

DANGER OF POISONING

RISK OF INJURY

Lubricants and fluids are harmful to the health, as they contain toxic and corrosive substances.

Lubricants and fluids are highly flammable. Therefore, observe the following instructions to prevent possible injury to yourself and others:

• Do not inhale the fumes. Indoors, make sure that there is always sufficient ventilation to prevent poisonings.

LUBRIFICANTS AND FLUIDS

• Lubricants and fluids must not come into contact with skin, eyes or clothing. In case of contact, wash the affected parts of the skin with soap and water to avoid cauterization and other injuries.

• In case of contact with eyes, rinse thoroughly with plenty of clean running water for 15 minutes.

• In case of ingestion of a lubricant or fluid, see a doctor immediately.

• Change contaminated clothing immediately lubricants and fluids to avoid a fire hazard and possible injury.

• When handling with fluids and lubricants, do not approach open flames, have unprotected lamps lit and smoke, since there is the risk of ignition.

• Keep all lubricants and fluids out of reach of children.

• Change lubricant and fluid-contaminated clothing immediately lto avoid a fire hazard and possible injury.

• Keep all lubricants and fluids out of reach of children.

• Always observe the signs of danger on toxicity, the danger of cauterization and fire hazard which are indicated on the packaging of lubricants and fluids.

Maintenance Plan

Overhauls/Inspections and Maintenance Services

In case of improper handling, lubricants and fluids are harmful to the environment and health.

Lubricants and fluids should not reach the:

• soil;

• sewerage network;

• surface water;

Observe the rules and norms of environmental protection.

Lubricants and fluids, their packaging, and parts which are dirty with lubricants and fluids, such as filters or cleaning cloths, must be disposed of in accordance with envir onmental protection standards.

Fuel

Fill up the tank of your vehicle only in gas stations you trust and require quality fuel free from contaminants.

The use of low quality fuel or with a high rate of contaminants saturates prematurely the fuel filters, causing loss of engine power and requiring the replacement of the filter elements before the time scheduled in the

maintenance plan, in addition to damaging the injection system.

Oil Change Services

Change oil at the recommended period of time to ensure maximum durability of the household.

Chassis components should be lubricated more frequently when railfall is heavy or when there is too much or dust.

Chassis components should also be lubricated whenever you wash the vehicle underside or when running through wetlands.

Vehicles expected to be predominantly used under off-road conditions, we recommend that the universal joints of the shafts/trees be lubricated at least once a week.

NOTE

“Off road” means unpaved roads, sidewalks or of difficult access.

Maintenance Plan

Overhauls/Inspections and Maintenance Services

Cargo Customer Services

Daily and weekly checks are the responsibility of the Customer/Driver, and, therefore, are not included in the periodic services of vehicle maintenance.

The daily check must be performed on a daily basis before the driver begins his/her work day.

If any irregularity is found during the daily inspection that cannot be remedied by the Customer/ Driver, go to a Volare Representative for repair.

Corrective Maintenance - Repairs

All corrective maintenance services performed on the vehicle within the Warranty Term must be recorded in the Repair Procedures Control

provided herein, with the part number causing the anomaly.

Control of emissions of exhaust gases

To meet legal provisions on emissions of exhaust gases, note that the maintenance of engines and their ancillary systems should be conducted in accordance with certain specifications and may need special measuring equipment. No change in components or interventions must be done that

MAINTENANCE OF YOUR VOLARE

For a safe operation of your vehicle, the maintenance procedures (see Maintenance Plan) must be carried out regularly and periodically at recommended intervals.

Have these services performed by a qualified repair shop with the expertise and the right tools to perform the necessary work. For this purpose, Marcopolo S.A – Volare Division recommends that you go to a Volare Representative/ Service Dealer.

The tasks included in the maintenance plan do not include repairs. Repairs, when required, should be performed under a separate service order.

Confirmation of maintenance services

The Volare Representative must record in this Manual, at the respective box/field, the maintenance services performed by it.

Marcopolo Genuine Parts & Accessories – Volare Division

To ensure maximum durability and safe operation of your Volare, use only gMarcopolo enuine parts and accessories (Volare Division).

Maintenance Plan

Overhauls/Inspections and Maintenance Services

could change the emissions of exhaust gases.

Tire rotation

Tires rotation is a recommended procedure to ensure uniform wear on the tread.

In general, tire rotation should be performed at least every 10,000 km. However, as tire wear is influenced by a number of factors that vary according to operating conditions, this interval may be reassessed by the Customer along with a representative from the tire manufacturer, and adapted to the type of vehicle application.

DAILY INSPECTION – Before starting the Engine

The daily inspection is the responsibility of the Customer/ Driver and must be systematically performed before starting the daily operation of the vehicle to ensure its safe operation and movement.

ATTENTION

When performing the daily inspection, the procedures described in this manual must be strictly observed to avoid any damage or injury.

The maintenance of the vehicle does not include the daily inspection of the vehicle:

• Check the engine oil.

• Check the coolant level.

• Drain water and impurities accumulated in the pre-filter.

IMPORTANT

This procedure is vitally important to prevent water penetration in highpressure pump and eletroinjectors.

• Check condition and tension (s) of engine belt (s) and hoses.

Maintenance Plan

Overhauls/Inspections and Maintenance Services

WEEKLY INSPECTION

•Clean THE windshield, window panes and rear-view mirrors.

• Clean the headlights and taillights.

• Check the operation of door latches and locks;

• Check the fluid level of the clutch driving system.

• Check the supply of the windshield washer reservoir.

• Check the operation of the windshield wiper and the condition of the

wiper arms and blades.

• Check tightness of wheel nuts.

• Calibrate the tires including the spare wheel.

• For vehicles mostly used on off-road conditions, lubricate the universal

joints of the transmission tree.

• Air filter (actuate the dust discharge valve to release accumulated dust).

• Conditions and fastening of safety belts.

• Inspect suspension and steering components under the vehicle, taking

immediate action if necessary.

• Check clutch fluid level;

• Check tire pressure.

• Check fuel level; this procedure should be followed at the end of each day to prevent that moisture and water vapor from the tank empty volume condenses to form water.

• Inspect the mechanical assemblies for leaks of oil, clutch fluid, fuel and water.

IMPORTANT

Check the electrical connections of the engine sensors in relation to their tightening and condition.

• Check the operation of all vehicle instruments and controls.

• Check the operation of lights, headlights, brake lights and back light, blinkers, etc ...

• Drain the water from brake air reservoirs, pulling the drain valves down.

• When starting the vehicle, check the performance of the brakes.

Maintenance Plan

Overhauls/Inspections and Maintenance Services

PERIODIC PREVENTIVE MAINTENANCE

Regular maintenance is essential to ensure longer useful life to the vehicle, better operating conditions, efficiency and safety.

The preventive maintenance plan presented herein indicates service points and their intervals, which were based on normal conditions of use.

ATTENTION

The vehicles subject to more severe service conditions should have their maintenance periods shortened by 50%.

The warranty is only valid if all the inspections have been made, showing the signature and stamp of the Volare Representative which has performed the service.

PREVENTIVE PERIODIC MAINTENANCE PLAN

NOTES - VOLARE V8, V8L, W8 and W9

IMPORTANT

For severe or special applications, perform maintenance at half of the periods indicated in the Maintenance Plan. (As per Severe or Special Conditions of Use - p.30).

Enginer

If the engine remains out of use for a long time, perform an idling test every two weeks, until reaching the respective operating temperatures.

Never bleed the electro injectors while the engine is running. (Operating risk).

BOSCH electronic Items (phase sensors and actuators) are maintenance free and are checked via the specified diagnosis tool with errors stored in the failure memory.

Regardless of the indicated intervals between changes of engine oil, this should be changed every 06 (six) months at the latest.

Maintenance Plan

Overhauls/Inspections and Maintenance Services

Lubrication

Volume (Sump with oil filter)

SAE 15W40 API CH/CI - 4 9,2 liters

The product listed below shall be used, where winter is severe, in the ratio of 50% of the total cooling system volume: > HAVOLINE XLC Change every 80,000 Km or 1 (one) year. For the other cases, the product bellow shall be used in the ratio of 10% of the total cooling system volume: > HAVOLINE XLI GREEN Change every 80,000 Km or 1 (one) year.

Coolant Volume

WATER AND ADDITIVE 22 liters

The product must be diluted in the ratio above before supplying/ fueling it.

For sealed batteries of 100 Ah, remove the battery cover and the vessel cover, check electrolyte level every 20,000 km or 06 months and fill up with distilled water if necessary.

Lubrication

TEXACO STARPLEX MOLY MPGM 2

Fluid Volume DOT 4/5 1,7 liters

The components should be lubricated every 10,000 km and / or every time you wash the vehicle. Make sure that grease purges out of ends.

Lubrication TEXACO STARPLEX MOLY MPGM 2

Oil Volume SAE 80W90 API GL3 ou GL4

FS 4505 4,6 liters

Oil Volume CASTROL TRANSYND Or MOBIL

DELVAC SYNTHETIC ATF

Crankcase 2”

17 liters

Crankcase 4”

19 liters

Fluid Volume DOT 4/5 1,25 liters Follow bleeding procedures.

Every time you replace the brake linings, replace the spring kits as well.

Lubrication TEXACO STARPLEX MOLY MPGM 2

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Volare Euro III Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual