Maintenanc

e Interval Description
Definition
Routine
Before departure, during driving and after off-work
maintenance
It is the necessary and prerequisite condition for the warranty to stay valid. The
Initial
initial maintenance should be performed at 5,000 km of mileage or vehicle in
maintenance
operation for 3 months.
Standard Comprehensive maintenance of the vehicle according to the scheduled
interval maintenance intervals.
Special Maintenance that does not match routine maintenance, initial maintenance and
maintenance vehicle maintenance intervals.

Note: For road transport vehicles operating mainly under special operating environment such as
mountains, deserts, hot areas, cold areas, areas with high humidity, areas with high salinity and
highland, shorten the maintenance intervals appropriately.

Type Description
For at least 2 months in a year, the average temperature exceeds 25°C;
Hot
For at least 7 continuous days in a year, the average temperature exceeds 40°C.
High
humidity, Areas with high humidity such as coastal areas
high salinity
Cold The area where the lowest temperature is ≤ -25°C
Desert Deserts and windy or dusty areas
Mountain The area with one slope or more whose gradient exceeds 9% (5°) and length
area exceeds 200 m
Highland The area with the average altitude greater than 2,500 m
Note: Mileage or time, whichever comes first. For the same interval, maintenance items corresponding to either drivin

Classification Assembly Operation Items

Check the central electric box

Electric box
and the rear sealed electric box

Anti-freezing liquid Replace the anti-freezing liquid

Air dryer Replace the air drying can

Check the level of expansion
Expansion tank
tank

Battery Check the battery

Vehicle Check the vehicle chassis

Inspect the disc-type brake

Brake
assembly
Moving parts of the Check the moving parts of the
steering system steering system

Replace the steering oil and the

Steering gear
filter element

Check the fluid level in the

Steering oil tank
steering oil tank

Replace the conductive contact

Charging socket
parts of the charging socket

Battery coolant Replace the battery coolant

Check/replace the air

Electric air compressor mount insulator
compressor
Replace the air filter element of
the air compressor
 Check the motor controller
grounding wire, low-voltage
wiring harness fixing point,
Motor controller high-voltage wiring cover plate,
integrated control unit high-
voltage connector, check the
controller fastening bolts

Inspect the battery pack

airtightness
 Traction battery balance

New energy part

Traction battery
New energy part

Traction battery

Check the appearance of the

battery pack, high-voltage
distribution box, battery control
box, as well as the battery
compartment

Check the fixing bolts of battery

pack, high-voltage distribution
box and battery control box and
high-voltage connectors
 Fasten the high-voltage
connectors, wiring harness
terminals and fixing bolts of the
battery pack and high-voltage
distribution box

Replace the traction motor oil

seal

Inspect the front and rear

bearings of the traction motor

Check and clean the traction

motor junction box; clean and
replace the vent valve

Traction motor

Check the three-phase

connecting wire terminals,
locking head and three-phase
wire through-hole connector of
the traction motor

Clean the strainer of the

Defroster
defroster
 Clean the A/C evaporator core
strainer and the grille strainer at
the A/C return air inlet

A/C Clean the inside of the A/C

evaporator core and housing

Clean the A/C condenser fan

and condenser
same interval, maintenance items corresponding to either driving time or driving mileage are the same. Check: ○; Add, fasten or

Initial
Technical Requirements and Operation Precautions Action
maintenance

The electric box is firmly fixed, the connector, relay and binding post and
Check ○
so on are firmly fixed without water intrusion and corrosion.

The level should be within the specified scale range. It can not be mixed
Replace
with other brands of anti-freezing liquid
It is firmly fixed and works normally Replace
The anti-freezing liquid level should be between the upper and lower
Check
marks.
1. The battery is fixed reliably, the battery cable and the battery pole are
fixed reliably, there is no short circuit problem, the battery surface is not
damaged or leaks fluid; Check
2. Observe the battery water level, if low so filled we battery water with in
the mentioned range.
There should be no oil stain or water stain on the ground where the vehicle
Check
is parked;

1. When small cracks of brake disc extend radially on the surface (cracks
with length, width and depth smaller than 1.5 mm), it can still be used;
2. When cracks of the brake disc with the depth smaller than 1.0 mm
extend peripherally, it can still be used;
3. Sheet cracks of brake disc cannot exist, or the brake disc assembly
should be replaced;
4. When the thickness of the brake disc is smaller than the thickness limit,
replace the brake disc;
Check
5. The total rotational clearance of the brake disc (the sum of clearance at
two sides) should be 0.6 to 1.2 mm;
6. The brake clearance adjusting mechanism should function properly
without being stuck. When brake is released, the brake pad should retract
rapidly without being stuck;
7. Check that the brake thrust disc rubber sleeve, adjuster cap, guide
bushing and rubber sealing part are not aged or damaged;
1. Each part of steering mechanism (steering drive shaft, angle steering
gear, angle steering gear bracket, steering gear, steering gear bracket,
pitman arm, steering drag link) is not corroded, but connected and fixed
firmly. The steering gear does not crack or leak oil; Check ○
2. The dust cover of the drag link ball joint should not be damaged; the
lock pins should be complete and fastened firmly; and the steering
connecting arm, drag link should not get deformed or cracked.

The gas in the high- and low-pressure steering pipes should be completely
discharged. The liquid level should be maintained between the highest
Replace
(MAX) and the lowest level (MIN). Do not mix power steering fluid with
products from other brands.

The fluid level should be within the specified scale range. Check

1. Power contact parts are installed in place; O-rings are free from damage;
2. Insulator surface is intact, with no cracks, melting, or deformation;
3. Screw O-rings are fitted at the screw root and free from damage; Replace
4. Insulator screws are tightened to the specified position; recommended
torque: 0.5 N·m.

1. The anti-freezing liquid to be replaced must be the same brand and

model as the original anti-freezing liquid of the vehicle;
2. Discharge the original vehicle coolant, turn on the battery water pump,
add replacement anti-freezing liquid until the coolant level in the expansion
tank does not drop, and flush the battery thermal management system
pipeline with replacement anti-freezing liquid;
3. Discharge the coolant, turn on the battery water pump, and add Replace
replacement anti-freezing liquid until the coolant level in the expansion
tank stops dropping rapidly. Keep the battery water pump on for ≥ 30
minutes to exhaust the system, until the water pump sounds normally
during operation and the liquid level in the expansion tank stops dropping.
Add the liquid level in the expansion tank to the MAX mark and the
coolant replacement is completed.

The mount insulator should not get cracked or damaged, the tightening
marks do not mismatch and the tightening torque of the bolt should be Check
45±5N·m.
The filter element is replaced in place, and the rear end cover is free of
Replace
looseness.
1. The tightening marks of the ground wire bolts do not mismatch.
Tightening torque: (15±2) N·m for M8 bolts; (25±2) N·m for M10 bolts;
2. The tightening marks of the first fixing point bolt of low-voltage wiring
harness do not mismatch. Tightening torque: (10±1) N·m for M6 bolts;
3. The tightening marks of the high-voltage wiring cover plate bolts do not
mismatch. Tightening torque: (2.8±0.3) N·m for M5 bolts and (4.8±0.5)
N·m for M6 bolts;
4. For locking head: The screw nut end face of the locking head should Check
cling to the hexagon flange end face of the substrate; for integral IPT
connector: The connector should cling to the housing. Tightening marks of
the high-voltage wiring harness IPT connector threaded fasteners do not
mismatch. Tightening torque: (4.8±0.5) N·m for M6 bolts;
5. Tightening marks of the bolts connecting the controller bracket and the
vehicle body do not mismatch, and the tightening torque for M10 bolts
should be (30±3) N·m;

1. Power on the vehicle, check if there is the insulation fault alarm on the
instrument; turn off all power switches, the main power supply of the
vehicle, and remove the vehicle key.
2. Check that the appearance of the battery pack is not abnormal, and the
battery pack MSD, connectors, and wiring harness are installed and
fastened in place. Check that the vent valve of the battery pack is free of
foreign matter such as muddy water or dust.
3. Check that the air tightness inspection connector is not damaged and the
rubber ring does not fall off; connect the air-tightness tester to the air
source and power supply, connect the tester’s test connector and the
balance valve of the battery pack together, and turn on the tester’s power Inspect
supply.
4. Set the parameters and inflation pressure (kPa): pre-inflation stage 3.5,
normal inflation 3.2; inflation time (s): pre-inflation stage 100, normal
inflation 200; stabilization pressure (kPa): 2.6-3.6; stabilization time (s):
60; test time (s): 60.
5. Start the test, and the required leakage rate (Pa/min) is: -60 to 60. If it
exceeds the leakage rate range, please contact Yutong after-sales service in
time, and never use the vehicle again before the after-sales service gives
the safety judgment result.
Balance maintenance method:
1. Drive the vehicle to discharge the battery for the SOC to be 25%～30%;
2. Stop the vehicle stably, turn off the power supply (turn the key to OFF
position), all the electrical switches and master power switch, then turn on
the master power switch and power supply (turn the key to ON position).
Check all electrical equipment switches on the vehicle to ensure that they
are off. Keep the vehicle charged for 12 to 15 h (If the period cannot be
met due to operating time, perform this maintenance in 2 to 3 times within
one month. Ensure that the accumulated standing time meets the
requirements); Balance
3. Fully charge it once after the maintenance;
4. To continue to store the vehicle, drive the vehicle to discharge the
battery for the SOC to be 40% to 70%;
5. For normal operating vehicles and stand-by operating vehicles: Conduct
maintenance once every 12 months;
6. For vehicles stored for a long period of time (exceeding 15 consecutive
days): Conduct maintenance once before operation;
7. For vehicles not used for a long time: Conduct maintenance once every 3
months.
1. The housing of the service disconnect in the high-voltage distribution
box should be complete and connected in place, free of looseness. The
plugging handle should be complete without breakage. The fuse should be
in good condition. The pin should be intact without any damage, ablation
or corrosion, and no foreign matters should remain in the base; the sealing
ring should not fall off or be misplaced;
2. The appearance of the battery pack, high-voltage distribution box and
battery control box should not get deformed, damaged, or unpleasant odor;
3. No muddy water or dust should be attached to the surface of the battery
pack, high-voltage distribution box and battery control box; the battery
pack protective cover is not damaged; the high-voltage warning
identifications of the battery pack, battery pack protective cover and high- Check ○
voltage distribution box are not blocked, stained, damaged or missing;
4. The external surface of the battery pack, high-voltage distribution box,
battery control box pressure relief valve or balance valve should not be
cracked or damaged, and should not be covered by soil or dust;
5. The drain hole of the battery compartment is not blocked. Its grille is not
blocked. And there is no foreign matter in the battery compartment.
6. The rubber gasket at the roof-mounted battery pack should not get
cracked or damaged (only for vehicle models with the roof-mounted
battery pack);
7. The appearance of the nitrogen inlet of the battery pack should not get
deformed or damaged; no mud is attached.

1. Check the tightening bolts connecting the battery pack, high-voltage

distribution box, and battery control box to the vehicle frame, ground wire
tightening bolts/nuts, high-voltage connector protective cover bolts, and
battery pack MSD fixing bolts. The spring washer of all bolts should be
Check ○
flattened without cracking. The red paint marking identification should be
intact and positioned properly. The bolts are free of fractures and cracks;
2. The high-voltage connector gland should be tightened in place and
high/low-voltage connectors should not be loose, damaged or cracked.
High-voltage terminals and bolts of battery pack and high-voltage
distribution box:
1. No rust, high-temperature oxidation or ablation should occur to the
wiring harness terminals and connectors; the tightening torque of high-
voltage terminals bolts: (30±2) N·m for M10 bolts;
Fasten
2. The sealing rubber ring of the high-voltage wiring cover plate should be
installed in place without exposure or torsion; the bolt tightening torque of
the high-voltage wiring cover plate: (2±0.5) N·m for M4 bolts, (4±0.5)
N·m for M5 bolts;
3. Battery pack air inlet adapter torque: 15±1 N·m.

Replace the oil seal on the output end of the traction motor
1. The groove of the oil seal of the motor should be filled fully with grease
during replacement;
2. The oil seal of the motor should be pressed into the oil seal chamber Replace
with tooling to avoid damage to frame sealing ring;
3. After the oil seal of the motor is pressed in, apply evenly a layer of
CAM2 high-temperature grease onto the lip of oil seal.

Criterion: When the root-mean-square of the vibration velocity is > 5 mm/s

and that of the vibration acceleration is > 30 mm/s2, the bearing should be Inspect
replaced; otherwise, the bearing needn't be replaced.

1. The high-voltage warning identifications of the traction motor are clear,

complete and undamaged;
Check, clean,
2. Check whether the motor vent valve is blocked. If it is blocked, clean
replace
with cloth. If there is damage or crack, replace it (Junction box side/non-
output end resolver assembly position).

1. The fastener bolt and the locking head of the terminal should be free of
rust or looseness. The tightening torque is 22±2 N·m for M8 bolts and
35±3 N·m for M10 bolts;
2. Distance between lock nut end face and flange end face is below 1 mm.
The rubber ring inside the lock head completely holds the wiring harness
(waterproof connector structure);
3. The tightening torque of the three-phase wire through-hole connector
installation bolts is (6±1) N·m for M5 bolts and (8±1) N·m for M6 (three-
phase wire through-hole connector structure). Check
4. For the high-voltage wiring cover plate, the tightening torque is (6±1)
N·m for M5 bolts and (8±1) N·m for M6 bolts;
5. Wiring harness terminals and connector are free from corrosion, high-
temperature oxidation and ablation.
Note: Depending on the actual status of the motor, it is only necessary to
perform one of the 2nd and 3rd items. If it is a waterproof connector
structure, perform the 2nd item. If it is an integrated through-hole
connector, perform the 3rd item.

It is clean without dust; if the strainer is damaged, it needs to be replaced Clean

It is clean without dust; if the strainer is damaged, it needs to be replaced Clean

Clean with cleaning fluid, clean without dirt Clean

The condenser fan is not covered by debris. The condenser runs properly
Clean
and is clean. If the blade of the condenser fan is damaged, replace it
me. Check: ○; Add, fasten or replace: ●. Operating procedures: √

Interval: *10,000 km/* months

Routine
3/6 6/12 9/18 12/24 15/30 18/36 21/42 24/48 27/54 30/60

○ ○

● ● ● ● ●

○ ○

○ ○ ○ ○ ○ ○ ○ ○ ○ ○
 ○ ○ ○ ○ ○

● ●

○ ○ ○ ○ ○

● ● ● ● ●
○

○
● ● ● ● ●
○ ○

○
 ●

60 months for the first time, and afterwards, once every 12 months

● ● ● ● ● ● ● ● ● ●
● ● ● ● ● ● ● ● ● ●

● ● ● ● ● ● ● ● ● ●

● ● ● ● ●
* months
33/66 36/72 39/78 42/84 45/90 48/96

○ ○

● ● ●

○ ○

○ ○ ○ ○ ○ ○
○ ○ ○

● ●

○ ○ ○

● ● ●
○

○
● ● ●
○ ○

○
 ●

rds, once every 12 months

● ● ● ● ● ●
● ● ● ● ● ●

● ● ● ● ● ●

● ● ●