Wrightbus NBFL 2013 User manual

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Customcare is the Customer Service Division of Wright Group, Galgorm, Fenaghy Road, Ballymena BT42 1PY, N. Ireland.
Telephone: [phone] Fax: [phone]
©Wright Customcare Ltd - 2013
NBFL
Operations Manual
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Table Of Contents

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Wrightbus reserve the right to change the procedures, materials, specification, dimensions or design
of the vehicle shown, described or referred to herein at any time and
without prior notice in accordance
with the Company’s policy of Continuous product improvement.
All rights reserved/ No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in
any form or by any means, electronic,
mechanical, photocopying, recording or otherwise without prior written permission
of Wrightbus Ltd.
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Introduction
It is recommended that this handbook is
kept with the vehicle.
This handbook is based on the vehicle
and original equipment fitted at the
factory. Whilst every effort is made to
ensure the information given in the
manual is correct at the time of going
to print, the Wrightbus policy is one
of continuous improvement and the
right to change specifications and
equipment without notice is reserved.
For this reason, you may find some
illustrations and/or certain parts of
the text in this handbook which do
not correspond exactly to the particular
situation on your own vehicle.
The purpose of this operation guide is
to provide drivers with information to
help them to operate their vehicles
safely and efficiently. It is
recommended
that it is kept
with the vehicle.
Care and attention given at the right
time will ensure efficient and
optimum
performance. Periodic attention is necessary,
and should help to avoid breakdowns.
Never run the vehicle in a doubtful
condition, always report back to the
garage for inspection and attention.
Vehicles manufactured by Wrightbus,
when delivered, comply with all
current
department of transport regulations and codes
of practise appertaining.
In all communications please quote
the relevant V.I.N and engine
number.
This will ensure prompt attention.
Gross vehicle weight and axle loadings
are based
upon the maximum seating
capacity of the vehicle, as delivered,
(including the driver).
Wrightbus
Galgorm Industrial Estate
Fenaghy Road
Ballymena
BT42 1PY
N. Ireland
Telephone: [phone]
Fax: [phone]
Wright Group Customcare
Galgorm Industrial Estate
Fenaghy Road
Ballymena
BT42 1PY
N. Ireland
Telephone: [phone]
Fax: [phone]
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Table of Contents
Description Page
Dash Layout - Lower L/H Side Console 23
Front Door Buttons 24
Mid Door Buttons 25
Rear Door Buttons 26
Rear Crew Controls 27
ICM Warning Indicators - Stop Warnings 28-29
ICM Warning Indicators - Caution Warnings 30-32
ICM Warning Indicators - Information 33
ICM Warning Indicators 34-36
DMUX Screen Instructions 37-41
Starting And Driving - Engine 42-43
Starting And Driving - Speed Control Humps 43
Starting And Driving - Engine Stop 44
Starting And Driving - General Driving 45-47
Description Page
Introduction 4
Warnings - Health and Safety 7-8
Environmental Warnings 8
Keys To Symbols 9
Options 9
Buyer’s Obligations 9
General Information 10
Vehicle Identification Plate 11
Vehicle Identification Sheet 12
Driver’s Seat Adjustment 13
Controls Layout 14
Dash Layout - Upper Console 15
Dash Layout - R/H Side 16-17
Dash Layout - L/H Steering Wheel Stalk 17
Dash Layout - R/H Side Console 18-22

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Table of Contents
Description Page
Vehicle Filler Locations 48-51
Battery Door Panel - Opening/Closing 52
Batteries - Jump Starting 53
Cleaning - Body Exterior 54
Cleaning - Body Interior 55-56
Cleaning - Treadmaster Flooring 57
Daily Checks 58
Maintenance - Service Schedule 59-63
Maintenance - Body Checks 64
Maintenance - Engine Oil Level 65
Maintenance - Fuel System 65
Maintenance - Electrical 66
Maintenance - Cooling Systems 67
Maintenance - Fluids And Lubricants 68-69
Emergency Repairs - Jacking Points / Prop Heights 70-71
Description Page
Emergency Repairs - Wheels And Tyres 72-75
Emergency Repairs - Battery Boost Socket 76
High Voltage Lock off And Isolation Procedure 77-81
Towing 82
Emergency Equipment 83-85
Electrical System Schedule 86-102

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Warnings
Health and Safety
Moving the vehicle
Before driving the vehicle, operators must
familiarise themselves with the vehicle’s
operation guide.
Working on the vehicle
Before commencing work on the vehicle,
take note of all the instructions relating to
safety and hazardous items. The following
potential hazards should be considered.
Stored Energy
Certain components and systems on the
vehicle contain stored energy which must
not be released in a non-approved manner.
Tyre air pressure.
Braking system spring compression, pressure in
the air lines, Hybrid electrical system
Cooling system pressure and temperature.
Coolant in the system will remain hot and
under pressure for some time after use.
Allow to cool before attempting to remove
the header tank cap.
Chassis lifting - adequate support required
during jacking or lifting. Eye protection
should be worn when working under the
vehicle
Diesel injection pumps supply fuel to the
engine at a very high pressure, care must
be taken when working on the injectors or
injection pipes, as fuel under high pressure
can penetrate the skin.
Brake discs will remain at an extremely
high temperature for a considerable
amount of time after use, caution must be
exercised when handling such items to
avoid burns.
Hazardous materials
Certain components on the vehicle contain, or
can produce, material which must be handled
with caution. Theses materials are as follows:
Those which must not be taken internally or
contact the eyes, skin or mouth.
Battery Acid
Diluted sulphuric acid can cause skin
burns, eye damage and internal damage if
ingested. Vapour from the solution can also irritate
the respiratory system and the eyes. Take care
carrying the battery. Hydrogen gas given off by the
battery is highly explosive.
Mineral Oil
This type of oil contains small quantities of
polycyclic aromatic hydrocarbons, which
can cause irritation, dermatitis and oil acne
if allowed persistent contact with the skin.
Toxicity through ingestion is of a low order,
however this should be avoided. If swallowed
or gets into eyes, seek medical advice.
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Warnings
Health and Safety
Hydraulic fluids
These can cause mild irritation of the skin
and eyes. The toxicity through ingestion is
generally regarded to be low order. If
swallowed or gets into the eyes, seek
medical advice.
Friction Material Dust
The OEM friction materials are asbestos free.
Handling and fitting lined brake pads or clutch
plates is not regarded as a health risk. The
dust produced by worn linings is degraded by
the brake or clutch and is not believed to
be hazardous. However it is prudent to
avoid generating airborne dust concentration,
therefore dust removal should be by the use of
an approved vacuum cleaner or by the use
of a damp cloth (for occasional exposure).
Insulation Material
Man made fibres which include glass, rock, slag
and metal oxides. Inhalation of dust from the
fibres should be kept below 1 fibre/ml.
Fuel
Contact with the skin can cause irritation
and dermatitis. Inhalation and ingestion
are serious risks and can cause chemical
pneumonitis. If swallowed or if it gets into
the eyes, seek medical advice.
Exhaust Emissions
Can be highly toxic if inhaled in sufficient
quantity. Emissions in enclosed spaces
should be minimised unless adequate
extraction facilities are available.
Points to Remember
Remove rings and watches before working
on the vehicle, particularly necessary when
working on the electrical system.
Wear eye protection when underneath the
vehicle.
Use barrier cream or wear gloves as necessary
to protect the hands.
Keep loose clothing and long hair away
from moving parts.
Used engine oil, hydraulic fluids, transmission
fluid, antifreeze, (and their containers) batteries
and tyres can be a hazard to health and the
environment.
Fluids and other substances (e.g. used oil)
and surplus parts must be disposed of in a
safe environmentally sound manner.
On no account must any of these items be
placed in household refuse bins, or the fluids
poured down drains.
Observe local regulations and laws on environmental
protection and disposal of hazardous materials.
These should be disposed of using authorised
waste disposal facilities.
Consult local authority for safe disposal
facilities.
Environmental Warnings
For further information, see the safety section
in the Parts or Service manual.
Warning
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General
Keys to Symbols Buyer’s Obligations
Options
Please take note of the following symbols
used throughout this manual, which identify
any health hazards or instructions to prevent
any personal injuries or damage to the vehicle.
Items marked with this sign are
fitted as options.
Operational
 The maximum permitted laden
weight is identified on the VIN plate.
 The maximum passenger carrying
capacity is identified in the cab area.
 When a defect is identified, it could cause
serious problems or deterioration. This
must be rectified prior to the vehicle
going into service.
Caution
It is imperative that all maintenance
procedures are complied with, records
of all work are kept and available to view.
Note
Failure to comply with these requirements
could cause mechanical and/or structural
failure and will invalidate the warranty.
Text with this heading and a shaded background is a
reminder of an operation which, if not carried
out with due care, could involve the risk of
personal injury.
Warning
Caution
Text with this heading and a shaded background
is a reminder of an operation which, if not
carried out with due care, could involve
the risk of damage to material.
Note
Text with this heading and a shaded background
refers to special methods, features or procedures.
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The Wrightbus NBFL has an efficient 4-cylinder
turbo-charged diesel engine that is used to
charge the hybrid batteries. The engine
emission control system utilises a reagent
(Adblue/Urea) to meet the requirements of
euro 5 engine emission legislation.
The hybrid batteries power a direct drive
electric motor into axle.
The air operated braking system is powered
by means of an electrically driven compressor
supplying air to reservoirs through an air dryer.
The air dryer also regulates pressure. Service
One and Service Two reservoirs each supply a
separate system for the front and rear brakes.
The park reservoir supplies the spring
actuated, air released rear brakes .
The auxiliary reservoirs supply the air suspension
and body services such as the doors.
General
An electrically driven power steering pump
is located under the driver, accessible
through an exterior side access panel.
The front suspension is an independent
wishbone system, supported by air springs
and controlled by hydraulic dampers.
The rear suspension system consists of a
drop centre axle located by radius rods and
supported by air springs and controlled by
hydraulic dampers.
The 24 volt multiplex electrical system uses
a 600 volt DC / DC converter to charge the
24 volt battery from the 600 volt battery.
An electronically controlled air suspension system
is installed which allows a kneeling system to
operate.
Caution
It may be an offence to use a vehicle
that does not consume reagent (Urea)
if it is required for the reduction of pollutant
emissions.
The use of a reagent (Urea) is mandatory
for this vehicle in order to comply with the
certificate of conformity.
Emissions - Diesel Engines 2005/55/EC/6.5.2.5/6
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Vehicle Identification Plate (V.I.N)
Vehicle details can be identified from the V.I.N. plate; a typical example is shown above.
Please quote the V.I.N. number with any enquiries concerning the vehicle.
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Vehicle Identification Sheet
Chassis Bodywork
Operator
Body Builder
Body Type
Body Number
Company
Address
Telephone No.
Out of Hours Telephone No.
Fax No.
V.I.N. No.
Model
Registration No.
Date into service
Engine Type
Engine Number
Wheel Tyre Size
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Drivers Seat Adjustment
There are 2 levers on the left hand side of the seat base. These are for adjusting the height of the front and rear of the
seat. The wire loop at the front of the seat is pulled up to adjust the fore and aft position of the seat. There are also 3
knurled knobs at the base of the seat back, 1 on the left side and 2 on the right side. The lower one on each side is for
adjusting the rake of the seat back. The upper one on the right side is for adjusting the lumbar support.
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Controls Layout
1.SwitchPanel
2. Drive Selector
3. Park Brake Control
4. Accelerator Pedal
5. Brake Pedal
6. Hidden Switches
7. Multifunction Switch
8. Drivers Information Screen
9. Warning Lights
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9
8
7 3
5 4
2
6
Optional
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Dash Layout - Upper Console
1. Rear Fog Lights Switch.
This function will only operate when the
driving lights are on.
2. Reverse Bleeper Override Switch.
Pressing this switch overrides the reversing
bleeper.
3. Interior Lights Master Switch.
This switch controls the operation of the interior
saloon lights. When in the on position the switch
will allow the saloon lights to be controlled using
switches 4 and 5.
4. N/S Interior Saloon Lights.
This switch turns on the N/S interior lights,
note that the interior light master switch
needs to be on also.
* Note:- The entrance lights and first light on the
N/S of the vehicle are illuminated in conjunction
with the opening of the entrance door.
5. O/S Interior Saloon Lights.
This switch turns on the O/S interior lights,
note that the interior light master switch
needs to be on also.
6. Cab Light Switch.
This switch controls the operation of the
drivers cab lights.
* Note:- When in the off position the cab
lights will be illuminated when the entrance
doors are opened and the vehicle sidelights are
switched on.
7. Battery Protection System Reset
Switch.
The vehicle is equipped with a battery
guard. This switch resets the battery
protection system.
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Dash Layout - Right Hand
8. Camera Toggle Switch.
These switches toggles the cameras that are
viewed on the drivers monitor.
9. Hazard Light Switch
Pressing this switch will activate the Hazard
lights. The switch will flash to warn the
driver the hazard lights are activated.
Note:- Only use in an emergency.
10. Ramp Switch.
The vehicle is fitted with an electronic ramp
which is operated with this switch.
The vehicle must first be stopped at the bus
stop with the mid door open. Press the lower
part of the switch to extend the ramp, a
buzzer will sound when the ramp is in motion.
Press the upper part of the switch to retract the
ramp.
When the ramp is out, an interlock will
prevent the vehicle from driving away.
In the event of an electrical failure, the ramp
can be manually retracted using the ramp
tool located behind the fire extinguisher
glass in the roof.
11. Drive Start Switch.
When the button is pressed, the drive is started.
The main switch and the ignition switch must be
turned on and the control button of the drive
selector must be in position N.
12. Drive Ignition Start Switch
This switch is used to turn on the ignition
once the main switch has been operated. If
the ignition switch is turned off whilst the
drive is active, the drive will stop. The
ignition must not be switched off when in
motion
13. Ferry Lift Switch.
Pressing this switch raises the vehicle body
and thereby increases the ground clearance by
a further 70mm.
14. Exterior Lighting Switch.
The light switch has three positions:
Pressed at the bottom: Dipped
beam / main beam, width indicator lights
and side-marker lights are turned on.
Switch in central position: Daylight
running lights, width and marker lights
turned on.
Pressed at the top: Daylight running
lights only.
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Dash Layout - Right Hand and L/H Steering Wheel Stalk
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15. Blower Speed Switch.
Controls the speed of the blower unit.
Turn clock-wise to increase the blower
speed and anti-clock-wise to reduce
blower speed.
16. Temperature Selector.
Controls the temperature for the cab area.
Turn clock-wise for warmer air and
anti-clockwise for cooler air.
17. Air Flow Selector (Cab Area).
Selects where the blower will direct the air
flow.
18. Saloon Temperature Adjust
Switch.
These switches adjust the desired temperature
in the saloon area. The digital display shows
the temperature setting.
19. Windscreen Air Flow Override
Switch.
Pressing this switch directs the air flow to
the windscreen, overriding the air flow
selector knob. When enabled the green
LED illuminates.
20. Air Con Switch.
This switch enables the drivers air conditioning
unit.
22. L/H Steering Wheel Stalk
This switch controls the wipers, horn, headlights
and indicators.
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21. Drive Selector Switches
This control unit has 3 positions.
Position D
Select position ‘D’ to drive the vehicle forward.
Position N
Only select neutral at a speed under 5 km/hr.
and when the vehicle is stationary.
Position R
The reverse drive may only be selected with
the vehicle stationary. The brake pedal must
be operated before changing to position R
(Reverse) from position D. Never put the drive
in reverse when driving forward. In position
R, the rear lights will come on and the reverse
buzzer will sound if the ignition is turned on.
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Dash Layout - Right Hand Side Console
23. Parking Brake
The parking brake is applied by
pulling back the lever until it locks into
position. To release the parking brake,
the sleeve on the lever must first be
lifted, then push the lever forward.
Warning
It is essential to apply the parking
brake when leaving the vehicle.
24. Cab Checker Unit
Provides a remote diagnostic functionality without the need to physically access the
T1000 recorder unit. Two LEDs provide recording confirmation and camera fail alert.
Green only- Recording ok and all cameras ok
Red only- System is booting up
Green and red- Recording ok, one or more cameras fail
Neither- Recording error, all cameras ok
An integrated push switch commands the T1000 to utilise the driver monitor to display
the health and then cycle through all the cameras to allow a camera function check,
including alignment, focus, etc.
An Ethernet pass-thru connector allows direct PC connection to the T1000 from the cab
checker location.
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Dash Layout - Right Hand Side Console
25. Genius (Journey
Data Management
System)
Records the driver ID
Start inhibit –
prevents the vehicle
from starting without
a valid driver’s key.
26. Panic Alarm
Switch
The vehicle is equipped
with a panic alarm.
Pressing this switch
will activate the panic
alarm. To de-activate
the alarm twist anti-
clockwise.
27. Emergency Power
Switch.
Only to be operated when
vehicle has stopped. Flip
up orange cover and
operate switch. Switches
off engine, operates fuel
cut off, isolates the
batteries, releases the
doors and activates the
one strip on internal
lights to aid evacuation.
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Dash Layout - Right Hand Side Console
28. Crew Switch.
This switch is used in conjunction with the
rear crew member to lock and unlock the
rear doors. For more information on this
switch, see rear door control section of this
book.
29. Battery Master Switch.
O - Off position Left in this position
after total shut down .
I - On position Left in this position
throughout use.
Note: Never turn off the main switch
whilst engine is running.
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