BCI Zero Emission City Bus User manual

October 2020 – issue 1 Page 1 of 29
bcibus.com.au
ZERO EMISSION CITY BUS Owner’s
Manual
BCI Zero Emission City Bus
OWNER’S MANUAL
Bus and Coach International Pty Ltd

October 2020 – issue 1 Page 2 of 29
Preface
ZERO EMISSION CITY BUS Owner’s
Manual
Dear Customer,
We would firstly like to thank you for selecting to purchase one of our Bus and Coach International vehicles and congratulate
you on your wise choice. We believe that you will be impressed by the excellent performance of our products.
The BCI ZERO EMISSION CITY BUS is well-known for good value, safety and comfortable performance, its advantages
are stable smooth handling, and quiet operation. All models of buses and coaches are produced to meet the needs of public
transport, touring and commercial use.
In this Owner’s Manual, we will be introducing you to all the features and tips on how to best operate and maintain your
new BCI vehicle. Please ensure you read the instructions carefully before putting the vehicle into operation. It is a
requirement for the driver of this vehicle to strictly observe all laws and regulations concerning the operation of vehicles.
We believe our product will provide you with a more comfortable and safe service which will add value to your business.
Please ensure you operate and maintain the vehicle with care and attention. BCI will not be responsible for any loss caused
by improper use of the product. Should you have any doubts about the operating or maintenance of the vehicle, please do
not hesitate to make contact with your Service Agent or Dealer in your area to discuss it.
BCI is always striving for excellence and continues to improve its products and services as a means of offering the best
value for our customers in a very competitive market place. Bus and Coach International Pty Ltd. Reserves the right to make
changes in design and specifications and / or to make additions to, or improvements to this product without obligation to
install them on products previously manufactured.
Bus and Coach International Pty Ltd
October 2020
All rights reserved by the Technical Center of Bus & Coach International Pty Ltd
Note: The content of this Owner’s Manual is to provide as much relevant information to the Driver as possible. It will also
contain information on factory optional equipment, which may or may not be included in your vehicle

October 2020 – issue 1 Page 3 of 29
ZERO EMISSION CITY BUS Owner’s
Manual
Table of Contents
Front Cover Page 1
Preface Page 2
Table of Contents Pages 3 - 4
Section 1 - Important Items：
A)
Name Plate Introduction - - Page 5
B)
Explanation of the Product Warranty - - - Page 5
C)
Technical Documents - - - - Page 5
Section 2 - Technical Specifications：
A) Main Technical Specifications of the Vehicle Page 6
B) Main Technical Specifications of the Chassis Assembly ----------------------------------------------------------------------- Pages 7 - 8
C) The Body Structure - Pages 8 - 9
Section 3 - Operating Guide：
A)
Driver Seat Adjustment - - - - - Page 10
B)
Steering Column Adjustment - - Page 10
C)
Driver Controls - - Pages 10 - 16
D)
Passenger Door Operating Instructions - - - -- Page 17
E)
Emergency exits - -Page 18
Section 4 - Startup and Driving：
A)
Routine Checks Before & After Driving Page 19
B)
Checks Before / After Every One-Week Driving Pages 19 - 20
C) Checks Before / After Every Two-Weeks Driving ------------------------------------------------------------------------------------ Page 20
D)
Vehicle Start-up Page 20
E)
Moving / Driving the Vehicle Page 21
F)
Shutting down the Vehicle Page 21
Section 5 - General Maintenance：
A)
General Knowledge - - - - -- - Page 22
B)
Cleaning the Vehicle - - Page 22
C)
Maintaining the Batteries - Page 22
D)
Cleaning the Radiator - - - - Page 22
E) Coolant -- - - - - - Page 22
F) Rotation of the Tyres - - --- - Page 22
Section 6 - Vehicle Maintenance：
Notice Page 23
A)
Zero Emission City Bus First Service Schedule 5000km Page 23
B)
Zero Emission City Bus Service Schedules Pages 24 - 26
C)
Recommendations for Lubricants Page 26

October 2020 – issue 1 Page 4 of 29
Table of Contents (continued)
ZERO EMISSION CITY BUS Owner’s
Manual
Section 7 - Trouble Shooting：
A)
Chassis Pages 27 – 28
B)
Body Page 28
C)
Electrical Equipment Page 29

October 2020 – issue 1 Page 5 of 29
ZERO EMISSION CITY BUS Owner’s
Manual
Section 1 - Important Items
1A - Name Plate Introduction:
1A.1 - Vehicle Name & Tyre Plates：
The vehicle name plate and the tyre plate are mounted on the left of the front passenger area (figure 1), the name plate
includes: bus model, the VIN, the date of manufacture and the manufacturer; the tyre plate includes: tyre type, rim type,
standard tyre pressure and the maximum load.
Figure 1
1.A.1
– Electric Motor Name Plate:
The motor name plate is attached to the rear of the motor, in addition,
the model number and serial number are engraved at the bottom of the
motor cover plate.
Figure 1a
1A.2 - Chassis VIN Number：
The Chassis Vehicle Identification Number (VIN) is located on the off-side surface of the chassis-structure, in front of the
offside front wheel. (see sample figure 2).
Figure 2
1B - Product Warranty: (Please refer to the BCI Warranty Guide Booklet for further details)
Please ensure all users STRICTLY follow the Operating Instructions of the vehicle so that it is used and maintained correctly.
The BCI body warranty is limited to 240,000km or three years whichever comes first. Other Supplier Warranties such as
electric drive motor, batteries, air conditioning etc. will be covered directly by the Supplier’s Warranty and can be taken to a
Supplier’s outlet for rectification.
Please ensure any warranty repairs required are communicated with your selling Dealer. Should a warranty repair not be
able to be carried out at an official BCI Dealership, please ensure an official order number is obtained for the repairs from
your selling Dealership, prior to them being carried out at another service center?
1C - Technical Documents:
Please use this Vehicle Owner’s Manual together with the any appropriate operator / maintenance
manuals: (For further vehicle technical reference documents please go to the BCI Dealer website:
bcibus.com.hk)

October 2020 – issue 1 Page 6 of 29
ZERO EMISSION CITY BUS Owner’s
Manual
Section 2 - Main Technical Specifications
2A - Main Technical Specifications of the Vehicle (All figures quoted are approximate):
2A.1 - Body Dimensions (mm):
Overall L × W × H 12490 * 2495 * 3400
Wheelbase 6450
Front overhang 2750
Rear overhang 3280
Approach angle / departure angle (full load）(°) 8°/8°
2A.2 - Vehicle Mass (kg):
Body Mass (approx)
(Vehicle with 45 seats)
12,700
Gross Vehicle Mass (GVM) 18000
Maximum axle laden mass（front / rear） 7,500 / 13,000
2A.3 - Performance Parameters:
Maximum Speed （km/h） ≥100 (electronically speed limited)
Maximum angle of grade ability (%) 18% at 18,000 kg laden mass
Maximum diameter of turning (m) 20.8 m (kerb to kerb)
24.4 m (wall to wall excl. mirrors)

October 2020 – issue 1 Page 7 of 29
Section 2 - Main Technical Specifications (continued)
2B - Main Technical Specifications of the Chassis:
2B.1 – Electric Drive Motor:
ZERO EMISSION CITY BUS Owner’s
Manual
Model DDM155A (WEM195)
Manufacturer Prestolite
Mode and type Electric PMSM
PMSM (Permanent Magnet Synchronous Motor)
Maximum net output power 350 kW
Maximum net output power (30 min) 195 kW
Maximum torque 3500 Nm
Nominal rated voltage 600 V DC
Ingress protection IP67
2B.2 - Tail Shaft Model: Exposed, two universal joints; Universal joint: Rigid cross-shaft needle bearing
2B.3 - Front Axle Model : ZF RL-82EC IFS with Knorr disc brakes 7,500 kg rating.
2B.4 - Rear Axle Model：
Type: ZF A132 with Knorr disc brakes, 13,000 kg rating.
Final gear ratio: 5.87
Brake type: Pneumatic control braking system; Knorr disc brakes.
2B.5 - Steering System Type : Bosch 8098 steering gear
Redirector type: Recirculation ball-type, power steering system
Steering wheel diameter: 450mm, adjustable height and rake
2B.6 - Suspension Type: Air suspension with 2 + 4 air bellows.
Front suspension: Equipped with two airbags, two telescopic shock absorbers and transversal stabilizer.
Rear suspension: Equipped with four airbags, four telescopic shock absorbers and transversal stabilizer.
2B.7 - Wheels and Tyres:
Wheel type: 8.25 × 22.5 standard steel rims (alloys optional)
Tyre specification (front / rear): Michelin X coach energy Z 295/80R22.5 tyre (rolling resistance 4.9).
Tyre inflation pressure (front / rear): 825 / 825Kpa (maximum – ADR limit)

October 2020 – issue 1 Page 8 of 29
ZERO EMISSION CITY BUS Owner’s
Manual
Section 2 - Main Technical Specifications (continued)
2B.8 - Braking:
Service braking type: Wabco series 3 electronic braking system (EBS3) including electronic stability control (ESC) and hill
start aid; Automatic slack adjusters.
Park brake type: Spring actuated on drive axle
2B.9 - Electric equipment (Low Voltage System):
Circuit system: Single wire system, Negative earth
Circuit voltage: 24V
Power supply: Solid state inverter 28V 140A
Low voltage batteries: sealed 12V 100Ah × 2
Instrument Panel: Instrument cluster with high resolution 12.3 inch color TFT display screen.
Lighting: LED type for all exterior and interior lighting
2B.10 – Batteries (High Voltage System):
Energy Storage System (ESS)
Type: Lithium Ferro Phosphate (LFP) Chemistry
Rated Capacity: 403 KWH
Nominal Voltage: 589V
Configuration: 12 packs in total, 6 located on the roof and 6 at the rear below floor level
2C - Body Structure:
2C.1 - Structure type: Monocoque Body Frame
2C.2 - Structure of the Vehicle Body:
The structure of the vehicle body is fully welded and made with Australian Standard high tensile stainless steel tube. The
main components of the framework have been treated after welding to ensure their antirust properties.
2C.3 - Interior finish:
The interior of the bus has a light airy feel with a glossy light grey formica for easy clean and durable finish for City Bus
applications. The sides are also a glossy light grey formica for easy clean and durable finish. The floor is covered with a
heavy duty vinyl.
2C.4 - Vehicle doors:
Front passenger door: Twin leaf inward gliding type, electrically powered
Centre passenger door: Twin leaf plug-slider type, electrically powered.
2C.5 - Vehicle windows:
The front windscreen is laminated glass; the side windows are 4mm thick toughened glass with a dark grey tint. All glass is
fully bonded to the body.

October 2020 – issue 1 Page 9 of 29
Section 2 - Main Technical Specifications (continued)
ZERO EMISSION CITY BUS Owner’s
Manual
2C.6 - Seats:
Driver seat: ISRI air suspension driver’s seat with air lumbar support + 3-point restraint
Passenger seats: Various options for up to 45 seated passengers. All seats are approved for public transportation and
2C.7 - Interior trim:
The following items can be found inside the vehicle:
Driver’s side sun visor, electric front windshield sun visor, interior rear view mirror
Electrical devices: Audiobus; USB points
2C.8 - Air Conditioning System:
Type： Thermoking E1200 reverse cycle air conditioner including PTC heating elements and ESS cooling system.
Demister：PTC type, 7 kW power rating at 600 V DC

October 2020 – issue 1 Page 10 of 29
Section 3 - Operating Guide
3A – ISRI 6860-875 Driver’s seat (figure 3):
(Extract from ISRI Seat Brochure)
ZERO EMISSION CITY BUS Owner’s
Manual
1)
Belt adjustment
2)
Armrest adjustment
3)
Backrest adjustment
4)
Shoulder adjustment
5)
Seat climate control
6)
Integrated pneumatic system (IPS)
7)
Height adjustment (+ memory)
8)
Vertical shock absorber (adjustable)
9)
Quick release
13
Attention: For safety reasons, NEVER attempt
to adjust the Driver’s Seat whilst the vehicle
is in motion. 12
3B-Steering wheel / column adjustment: Please refer to item 3C.6.7 page 15
With vehicle at normal pressure, momentarily press switch and adjust
steering wheel/column position to suit.
Note; there is a 3 second window to adjust the steering column, before
the steering lock engages automatically.
3C - Driver’s controls (figure 4)
5
6
1)
Steering wheel / horn buttons
2)
Headlight & direction indicator stalk
3)
Windscreen wiper & retarder stalk 4
4)
Nearside switches
5)
Combination instrument panel (CAN)
6)
Offside switches
7)
Transmission control
8)
Driver side console
Figure 4
3
7
2
8
1
1
Figure 3
2
3
4
5
6
7
8
11
10
9