King Long XMQ6900J series Operating Manual
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King Long XMQ6900J series Operating Manual

City bus
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OPERATION MANUAL
User's Guide
King-Long XMQ6900J series city bus
Xiamen King Long United Automotive Industry Co., Ltd.

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  • Page 1 OPERATION MANUAL User’s Guide King-Long XMQ6900J series city bus Xiamen King Long United Automotive Industry Co., Ltd.

  • Page 2: Foreword

    As for the specifications introduced in relate to information of the driving and operation, service and maintenance of the XMQ6900J series city bus, please read them carefully and make proper operation, maintenance and repair so as to ensure it in good condition.

  • Page 3: Table Of Contents

    Contents Contents Foreword Foreword---------------------------------------------------------------------------------------------------------------2 Contents Contents----------------------------------------------------------------------------------------------------------------3 Main overall technical parameters Technical parameters -------------------------------------------------------------------------------------------------7 Introduction to name plate--------------------------------------------------------------------------------------------8 Product quality assurance --------------------------------------------------------------------------------------------8 Technical document --------------------------------------------------------------------------------------------------8 Vehicle body structure------------------------------------------------------------------------------------------------9 Schematic illustration of the driver zone--------------------------------------------------------------------------10 Operation Instruction Instrument instruction-----------------------------------------------------------------------------------------------I-1 Illustration of switch and indicator s----------------------------------------------------------------------------SI-1 Air conditioner control panel-----------------------------------------------------------------------------------P-A-1 Bus centre controller---------------------------------------------------------------------------------------------P-B-1 Open or close the passenger door-----------------------------------------------------------------------------O-K-1...

  • Page 4: Contents

    Contents Switch control box----------------------------------------------------------------------------------------------O-E-1 Vehicle starting and driving Check oil level of the engine--------------------------------------------------------------------------------------S-1 Check level of the coolant-----------------------------------------------------------------------------------------S-2 Check fuel pre-filter with water separator-----------------------------------------------------------------------S-3 Check fuel level-----------------------------------------------------------------------------------------------------S-4 Check vehicle lighting, intermittent lights and brake lights---------------------------------------------------S-5 Check the level of AdBlue and the daily maintenance of SCR system--------------------------------------S-7 Drain water in air tank---------------------------------------------------------------------------------------------S-8 Check engine oil pressure------------------------------------------------------------------------------------------S-9 Check Pneumatic pressure---------------------------------------------------------------------------------------S-10...
  • Page 5 Contents Starting the vehicle------------------------------------------------------------------------------------------------S-28 Parking the vehicle------------------------------------------------------------------------------------------------S-29 Vehicle maintenance and service General knowledge------------------------------------------------------------------------------------------------M-1 Maintenance of engine and chassis subassembly--------------------------------------------------------------M-1 Body maintenance ------------------------------------------------------------------------------------------------M-1 ABS system maintenance and service --------------------------------------------------------------------------M-1 Electrical system maintenance and notices --------------------------------------------------------------------M-2 Tire transposition--------------------------------------------------------------------------------------------------M-2 Adjustment of the clutch pedal freeplay------------------------------------------------------------------------M-3 Adjustment of the brake pedal freeplay-------------------------------------------------------------------------M-3 Bus cleaning--------------------------------------------------------------------------------------------------------M-3 Cleaning air filter --------------------------------------------------------------------------------------------------M-4...
  • Page 6 Contents Transmission--------------------------------------------------------------------------------------------------------C-9 Rear axle-----------------------------------------------------------------------------------------------------------C-10 Front axle and steering system----------------------------------------------------------------------------------C-11 Braking system----------------------------------------------------------------------------------------------------C-14 Electrical equipment and the starting system ---------------------------------------------------------------C-16 Air conditioner system-------------------------------------------------------------------------------------------C-18 Appendix Driver's tool table ---------------------------------------------------------------------------------------------- A-1 Tightening moment of the bolts and the nuts in major position ------------------------------------------A-2 Air braking schematic diagram -------------------------------------------------------------------------------- A-4 Electrical schematic diagram-------------------------------------------------------------------------------------A-4...

  • Page 7: Technical Parameters

    Technical parameter and complete vehicle description Technical parameters of the complete vehicle (Vehicle No.EC600024-25) XMQ6900J Product model Engine model ISBE6.7E5 250B Engine type In-line six-cylinder water-cooling direct-injection diesel engine 107X124 Cylinder diameter ×stroke （mm） 6700 Displacement (ml) Compression ratio 17.2:1 184/2300 Rated capacity / rotation speed (kw/rpm) 1200 /1200-1600...

  • Page 8: Introduction To Name Plate

    Technical parameter and complete vehicle description Introduction to data plate Bus data plate The bus data plate may be affixed to either the upside of the front passenger door frame or to the side of the front passenger door step (the position may vary with vehicle model). There are many parameters on the plate, such as vehicle model, gross mass, vehicle serial number, vehicle capacity, VIN (short for vehicle identification number), chassis serial number, engine serial number, engine model, rated power, production data and etc..

  • Page 9: Product Quality Assurance

    Technical parameter and complete vehicle description Product quality assurance We make breaking-in maintenance of the rolling-out new vehicles in their initial driving mileage of 5000 km. Users should make proper operation and maintenance strictly according to relevant regulations in the instruction book. Please refer to “workshop manual” for product quality assurance and abide by related specification.
  • Page 10 Technical parameter and complete vehicle description Body Structure 1. Structural style Semi-integral body structure 2. Structure The bodywork structure adopts closed girder construction of five major assembly parts, which are combined welded by rectangle steel pipes with advantages of strong structural stiffness, torsion resistance and bending resistance as well as relatively simple craftwork.
  • Page 11 Technical parameter and complete vehicle description B. Hint: a. The door remote control acts only when the parking brake is on the parking gear. b. The door could only be opened when the external mechanical lock isn't locked up. c. In order to avoid impact, make sure that the door is completed closed or opened, before you make the next door switch operation.

  • Page 12: Schematic Illustration Of The Driver Zone

    Technical parameter and complete vehicle description Schematic illustration of the driver zone Rearview mirror heating 10 Emergency electric power cut off switch Rearview mirror control switch 11 Wiper operation handle Station reporter 12 A/C operation rotation button Rocker switch 13 Cigar lighter/USB charging socket Light operation handle 14 Door air valve switch Combination instrument...

  • Page 13: Operation Instruction

    Operation Instruction Instruction of instrument (Siemens Edition） Function Description ABS indicator ABS work/warning High beam indicator When Highbeam is switched on Left turning indicator When Left turning/hazard switch is turned on Severe Error When the electrical system has severe error. (see1.1 ) General Error When the electrical system has general warning.
  • Page 14 Operation Instruction 1.1 Severe error conditions EDC red lamp; ECAS red lamp; EBS red lamp; coolant level low; battery not charging (after engine starts); worn brake shoes; brake circuit 1/2 pressure low; coolant temperature high; catalyst level low; engine cabin temperature high; oil pressure low (after engine starts). 1.2 General error conditions Hammer not at right position;...
  • Page 15 Operation Instruction pictogram comments pictogram comments Low beam working Engine amber lamp error Front fog light working Engine Malfunction Engine wait to start (do not start Rear fog light working the engine until this symbol disappear) Brake light wroking EBS red lamp warning Lift-axle lock EBS amber lamp warning Steering oil level low...
  • Page 16 Operation Instruction 2.3.4 Acceleration pedal position： Range: 0 – 100 %。 2.3.5 Oil pressure： This information comes from engine ECU. Before engine starts, the value is 0. 2.3.6 Brake system pressure: Brake circuits 1 refers to the front brake system pressure. Brake circuits 2 refers to the rear brake system pressure.
  • Page 17 Operation Instruction If there is error exists, this page will show after driving information page when you press the page change button. Description: Pictogram ：object name; Text: detailed description of the error; Errors can be displayed in this page:  Communication Error: EDC, EBS, TCO, AC, Front node, Top node, Cabin node, Rear node; ...
  • Page 18 Operation Instruction Air conditioner status This page will appear is air conditioner is working and the communication is right. A/C mode include: ventilation; heating; cooling; demist/defrost; auto mode; off Set temp: the temperature currently set to be; Room temp: the real ambient temperature in the bus; Outer temp: outside temperature;...
  • Page 19 Operation Instruction Beeper warning conditions  Brake circuit 1 pressure low  Brake circuit 2 pressure low  Coolant level low  Hammer not at right position  Engine cabin temperature high  Oil pressure low (after engine running)  Service request ...

  • Page 20: Illustration Of Switch And Indicator S

    Operation Instruction Illustration of switch and indicator Number of switches and indicators and position may vary with vehicle model, please consult the flowing sheet and use correctly according to actual condition of vehicle. Switch Name Color Function Notes Pressed on top: retarder is turned ON Retarder Green Pressed on bottom: retarder is turned OFF...
  • Page 21 Operation Instruction Switch Name Color Function Notes Pressed on top: air horn is active, Pressed on horn Green bottom: electric horn is active Pressed on top: engine idle speed raise, adjust engine Engine idle Green Pressed on bottom: engine idle speed lower speed press button once to open front passenger Front passenger door...
  • Page 22 Operation Instruction Switch Name Color Function Notes Pressed on top: turn on guidepost lamp; Exterior guidepost Pressed on bottom: turn off guidepost lamp Pressed on top: turn on assistant brake; only switch on when Assistant brake Yellow Pressed on bottom: to turn it off vehicle need park Vehicle level reset Green...
  • Page 23 Operation Instruction Switch Name Color Function Notes Pressed on top: open the right side bin gate; Right side bin gate Green Pressed on bottom: close the right side bin gate. Pressed on top: turn on powerful function; Powerful/abstemious Pressed on bottom: turn off abstemious transfer switch function.
  • Page 24 Operation Instruction Switch Name Color Function Notes Pressed on top: switching on the height Height adjusting Green adjusting function; switch Pressed on bottom: turning off Pressed on top: switching on the side Side kneeling Green kneeling function; setting switch Pressed on bottom: turning off Engine Pressed on top: switching on the engine engine...
  • Page 25 Operation Instruction Color Indicator lamp Function passenger door open indicating natural gas leakage indicating front passenger door open indicate rear passenger door open indicating exit has been open indicating hollow plate Yellow ECAS alarm indicating ECAS fault indicating gearbox fault warning indicating Green retarder indicating yellow...
  • Page 26 Operation Instruction Color Indicator lamp Function Transmission oil temperature too high Transmission fault White Start-up waiting Yellow Over emission Yellow Kneeling lamp Green Normal height Vehicle in abnormality height Air chamber trouble warning indicator height indicator Yellow Side kneeling indicator Transmission oil temperature warning indicator Transmission trouble warning indicator Engine major trouble...
  • Page 27 Operation Instruction Spheros A/C Controller Instruction 1. Display It indicates the internal temperature and the regulated temperature. PS: the display will always show the vehicle internal temperature even when the motor is off. 2. Key - On/Off 1st touch – turns on the equipment - the equipment operates in refrigeration at high velocity PS: If the led light is blinking, it indicates the compressor still has not started operating.
  • Page 28 Operation Instruction Pre-heater Operation (Webasto) 1. General The standard digital timer enables you to preset the start of the heater operation up to 7 days in advance. It is possible to program 3 different starting times, only one of which can be activated. The standard digital timer features a wakeup alarm function.
  • Page 29 Operation Instruction Press the 7 button – the memory location is flashing – using the 9 and 10 buttons set start of the heater operating time. Day of the week is flashing- set the day of the week. By repeatedly pressing the 6 button, memory locations 2 and 3 can be programmed or the time display mode can be reached.
  • Page 30 Operation Instruction Transmission application (Voith) Starting the engine First apply the parking brake. No button of the push-button switch may be depressed during starting. Bring all buttons into neutral position by depressing the button marked ’N’: all but-tons are released, the ’N’-button is illuminated.
  • Page 31 Operation Instruction Driving in kickdown mode For higher acceleration, depress the accelerator beyond the full-throttle pressure point. This causes the transmission to change gears at a higher speed. Note: Driving in kickdown mode will increase fuel consumption. Driving with buttons or 3 (if available) pressed: When the transmission hunts between two gears when...
  • Page 32 Operation Instruction In vehicles equipped with ABS the converter brake switch is mostly not availably. The location of switch and its handling are described in the operating instructions of the vehicle. Stopping During short stops (e.g. traffic lights, bus stops) the selected button remains depressed and the vehicle is held by the vehicle wheel brake or the parking brake.
  • Page 33 Operation Instruction Open/close the passage door. For the king-long city bus, the method of open and close the passage door is different to above. Details please see the right drawing. The red button is close button; the green button is open button. This device usually located on the bin under the driver seat compartment.
  • Page 34 Operation Instruction Door emergency switch The door emergency switch is located on right upside of the door. Please rotate the switch and throw open the door in emergency. Special attention: The door emergency switch is only used in the emergency mode. Please don't rotate the door emergency switch in driving for fear of danger.

  • Page 35: Adjustment Of The Driver's Seat

    Operation Instruction Adjustment of the driver's seat The driver's seat may be made proper adjustment for the back and forth as well as the backrest angle according to requirement of the driver. Handle 1:seat angle adjustment Handle 2: back and forth adjustment Note: Number of handles varies with vehicle model Attention!

  • Page 36: Horn Button

    Operation Instruction Horn button Model 1 It is on the steering wheel. The horn is hooting when pressing the button 1. The type of steering wheel may vary with vehicle model. Please use the horn only when strictly necessary to warn other drivers and pedestrians.

  • Page 37: Adjustment Of The Steering Wheel

    Operation Instruction Adjustment of the steering wheel Rotate the loosening button 1. Adjust the height and the inclination of the steering wheel to the desired position. After adjusting, press the regulating handle or button down to lock the steering column. Note: Number of handles varies with vehicle model Attention! Adjust the steering wheel only when the vehicle is...

  • Page 38: Ignition Switch

    Operation Instruction Ignition switch Position of the ignition key is shown in fig.1. "K" KEY: for inserting and drawing out position of the startup key 1."L" LOCK: Insert or remove the key in this position. 2."A" ACC: Power supply of the instrument is switched on 3."O"...

  • Page 39: Lamplight Operating Handles

    Operation Instruction Lamplight operating handles The lamplight operating handle is located on right underside of the steering wheel, which control the front small light, headlamp, headlamp dimming, left and right steering by two different motion modes Indicating that the headlamp and the small lamp are all off.

  • Page 40: Wiper Operating Handle

    Operation Instruction Wiper operating handle The wiper operating handle is located on right underside of the steering wheel. (model 1~3) OFF Out of work INT interval wiper operation step LO Slow wiping HI Quick wiping The wiper operating handle is located on left underside of the steering wheel.

  • Page 41: Retarder Operation

    Operation Instruction Retarder operation (for retarder) Terca & Telma handle The hand lever can be mounted under the steering wheel or built into the dashboard. This hand-operated control generally has 5 control positions: Position 0: off Position 1: 25% Position 2: 50% Position 3:75% Position 4: maximum braking effect An indicator light is lit when the retarder is in use.

  • Page 42: Safety Hatch

    Operation Instruction Safety hatch Model 1 The safety hatch is located on scaffold of the vehicle. Please open the safety hatch according to the above diagrammatic representation illustration escaping in case of danger. OI-8...

  • Page 43: Safety Hammer

    Operation Instruction Safety hammer The safety hammer is located on the side window. Please take down the safety hammer and break open the safety window for escaping in case of danger. OI-9...

  • Page 44: Prompt Stop Switch For Get Off

    Operation Instruction Prompt stop switch for get off The stop switch is located at the grab rail (see the right picture).when the vehicle is going to arrive at bus stop, the passenger who need get off press the switch to remind the driver for stopping.

  • Page 45: Switch Control Box

    Operation Instruction Switch control box (Model: CQ2025) CQ2025 A wiring diagram (Printed on opposite cover of the switch control box) O-E-1...

  • Page 46: Vehicle Starting And Driving

    Vehicle Starting and Driving Preparatives for vehicle operation start up: Check daily, before turning engine on: Oil level dipstick 1. Check oil level of the engine The warning “Engine oil pressure” is displayed as a signal item on the combination instrument when the oil pressure is too low, the alarm buzzer sounds, the warning light STOP comes on, stop the engine and check engine oil level at the dipstick.

  • Page 47: Check Level Of The Coolant

    Vehicle Starting and Driving 2 Check level of the coolant The coolant level is automatically monitored. If coolant level gets too low，the digital indicator displays a driver information on the combination instrument. In this case, park vehicle in a safe place as traffic conditions permit, stop engine and visually check the coolant level.
  • Page 48 Vehicle Starting and Driving 3 Fuel pre-filter with water separator (drain accumulated water) Draining accumulated water On a daily basis, check the lower cup of the water separator. If there is water in the cup, unscrew the draining plug one or two turns, to drain the accumulated water.
  • Page 49 Vehicle Starting and Driving 4. Fuel level Turn the ignition key to drive position (on). Check the fuel level on the indicator. If necessary, fill up the fuel tank. (but direct viewing by open the tank cover is preferred). Eliminate deposite water in diesel filter in time and check fuel pipe for no leakage.
  • Page 50 Vehicle Starting and Driving 5. Vehicle lighting, intermittent lights and brake lights Check all instruments and indicator lamps for normal, especially the head lamp, the turning lamp, the brake lamp, the reversing lamp and the danger alarm lamp. Check the bulb and the switch for their damage. To carry out the lamp substitution, hands should be very clean.

  • Page 51: Check The Level Of Adblue And The Daily Maintenance Of Scr System

    Vehicle Starting and Driving 6. Check the level of AdBlue and the daily maintenance of SCR system The volume of AdBlue Check the level of AdBlue. When the vehicle key rotate the ON position, the LED screen of combination instrument will display the remain volume of the AdBlue, please see the right diagram.

  • Page 52: Drain Water In Air Tank

    Vehicle Starting and Driving Drain water in air tank Open the water drain valve of air tank to drain oily water fully. If too much oily water is bled, check to see if desiccant needs to be replaced in air drier. (This may be avoided when adopting the automatic drain valve but it should be checked every two weeks)
  • Page 53 Vehicle Starting and Driving Check daily after turning engine on: 1. engine oil pressure Run the engine. The information on engine oil pressure can be requested through the driver information digital display. If the oil pressure is too low, the oil pressure is automatically shown on the combination instrument. Indication of the oil gauge will show a high value after the cold start of the engine and then it should be kept within the range of 0.3-0.5Mpa (3- 5kg/cm ) along with the increment of the oil temperature as well...
  • Page 54 Vehicle Starting and Driving 2. Pneumatic pressure The air pressure gauge indicates the reserve pressure individually for the front and rear service brake circuits. The reserve air pressure in each brake circuit must be sufficient for the correct operation of the brake system.
  • Page 55 Vehicle Starting and Driving 3. Tachograph working order Indications on tachometer scale: a. Green zone – operating range of maximum performance b. Yellow zone – c. Red zone – engine overspeed range (risk of immediate engine damage) Always observe tachometer while driving the vehicle.

  • Page 56: Steering Wheel Play

    Vehicle Starting and Driving 4. Steering play Steering wheel play Run the engine at idle gear and straighten the front wheels forwards. Turn the steering wheel alternatively to the right and to the left. The steering play (free movement of the steering wheel) is measured on the perimeter of the steering wheel and should be between 20 and 30 mm.

  • Page 57: Check Tire For Abrasion And Pressure And Tire Nut For Fixture

    Vehicle Starting and Driving Control periodically, at least once a week: 1. Check tire for abrasion and pressure and tire nut for fixture The vehicle’s safety and performance depend considerably on the state of the tires, reason why they should be checked daily. Before driving a vehicle, check charging pressure of tire for normal, tire for damage, tire nut for fixture.

  • Page 58: Air Cleaner

    Vehicle Starting and Driving 2. Air cleaner (activate the dust discharge valve to loosen accumulated dust) Model 1 The maintenance of the air cleaner is made up of the substitution of the filtering elements and should be done only when the maintenance indicator indicates the saturation of the element.

  • Page 59: General Leakages (Water, Oil, Fluids And Fuel

    Vehicle Starting and Driving 3. General leakages (water, oil, fluids and fuel) Check the engine, the transmission, the driving axle, the steering system, the cooling system and the oil pipeline, the air pipeline of the complete vehicle for their leakage. S-15...

  • Page 60: Fastening And State Of Seat Belts

    Vehicle Starting and Driving 4. Fastening and state of seat belts Check buckle of the safety belt of the driver seat for normal and ensure for its lockup under the following situations when fastening the safety belt. ● The body dashes forward all of a sudden; ●...

  • Page 61: Check Emergency Devices And Driver's Tools(Fire Extinguisher

    Vehicle Starting and Driving 5. Check emergency devices and driver’s tools Such as extinguisher, crosstie for blocking vehicle, emergency hammer, jack and etc.. Fire extinguisher Fire extinguisher: The pulse super-micro powder fire extinguisher is fixed in the engine compartment, when the compartment is on fire, the fire extinguisher activate automatically or is active by manual work to eradicate the fire The fire button is usually located at auxiliary instrument...

  • Page 62: Windshield Wipers And Conditions Of Wiper Blades And Arms

    Vehicle Starting and Driving 6. Working order of windshield wipers and conditions of wiper blades and arms Model 1 Regularly check the windshield wiper blades for dirt or damage. Press the lever to activate the windshield washer Caution: Do not use the windshield wipers when the windshield is dry.

  • Page 63: Electrical Rearview Mirror

    Vehicle Starting and Driving 7. Electrical rearview mirror Check, adjust and clean the rearview mirror. Rearview mirror control button L: adjusting left rearview mirror. R: adjusting right rearview mirror. Mirror button: rotate the handle to adjust the mirror for 4 directions. S-19...

  • Page 64: Power Steering System

    Vehicle Starting and Driving Inspection every two weeks before and after driving 1. Power steering Ensure that all the maintenance service jobs on the steering system be carried out at the intervals recommended in the maintenance manual to guaranty total efficiency and safety.

  • Page 65: Clutch Actuation System Fluid Level

    Vehicle Starting and Driving 2. Clutch actuation system fluid level Clutch The clutch activating system can present irregular working due to the normal wear of the clutch disc. When suspecting that the clutch disc has reached the wear limit, take the vehicle to a King-Long authorized Dealer or Workshop to carry out the necessary repairs.

  • Page 66: General State And Tension Of Drive Belts

    Vehicle Starting and Driving 3. General state and tension of drive belts Check the tension of engine belt, fan belt and compressor belt, if loose, tension it; if damaged, replace it. Do not start up the engine without the drive belts. In the case of one of the belts breaking, immediately stop the engine and have a new belt put in.
  • Page 67 Vehicle Starting and Driving Air conditioning compressor drive belt The pneumatic tensioning system keeps the tension of air conditioning compressor drive belt correctly adjusted and do not need to be adjusted periodically. Adjusting method of the air conditioner belt is shown in the figure 1 Check tension of belt Apply 98N force to belt with finger Belt crank pulley 3 and middle pulley 2 should lower...

  • Page 68: Check Level Of Battery Electrolyte

    Vehicle Starting and Driving 4. Check level of battery electrolyte Open the battery cover to check level of electrolyte, if the level is lower than scale marked on the battery, please add it in time. Note: During adding electrolyte, never start engine. Battery The battery compartment is located at the second compartment of left or right rear side.

  • Page 69: Procedures For Engine Start Up

    Vehicle Starting and Driving Engine start up and shut down Procedures for engine start up Activate parking brake. Place the gear box lever in neutral. Start up is not possible in gear position. Turn the ignition key into gear position. Start up without stepping on the accelerator.

  • Page 70: Engine Shut Down

    Vehicle Starting and Driving Engine shut down Loosen accelerator pedal. Place the gear box lever in neutral position and apply the parking brake. Turn the ignition key to the off position, without accelerating. Note: After engine runs at heavy loading, temperature of cooling water is higher than 90ºC, so do not stop engine at once.

  • Page 71: Engine Start Up And Shut Down In The Engine Compartment

    Vehicle Starting and Driving Engine start up and shut down in the engine compartment Park the vehicle and activate the parking brake. Put the gear box lever or the automatic transmission selector in neutral (dead point). If the transmission is in gear position, the start up with in the engine compartment will not work. Turn the ignition key to gear position, without activating engine start up.

  • Page 72: Starting The Vehicle

    Vehicle Starting and Driving Starting the vehicle The vehicle could only be started when braking system pressure has reached 5kg/cm above and each instrument and indicator lamp is on the proper condition, and water outlet temperature exceeds 60℃ as well as the parking brake has been released after the engine is started.

  • Page 73: Parking The Vehicle

    Vehicle Starting and Driving Parking the vehicle The parking brake should be always applied when the vehicle is parked. Additionally, in some countries, it is determined by law that a vehicle parked on a slope must have at least one of its wheels wedged, to prevent its accidental moving. In this case, always keep an appropriate wedge available for this purpose aboard the vehicle.

  • Page 74: General Knowledge

    Maintenance and service General knowledge KingLong recommends that the bus be maintained according to the Maintenance Schedule in this section. Perform maintenance at whichever interval occurs first. At each scheduled maintenance interval, perform all previous maintenance checks they are due for scheduled maintenance. King-long Bus General Maintenance Please make periodic inspection and maintenance of bus according to the operation manual to ensure good status.

  • Page 75: Tire Transposition

    Maintenance and service When maintain the brake shoe ,do not damage the ring gear and sensor, clean the ring gear and sensor at the same time. after maintenance ,do remember to put the sensor to the limited position along the ring gear direction. Make sure that the power is in off position when remove and install the components, keep the components clean and dry.

  • Page 76: Adjustment Of The Clutch Pedal Freeplay

    Maintenance and service Tire transposition diagram(three axles) Adjustment of the clutch pedal free play Adjust clearance between push rod and piston of clutch master cylinder to 0.2-0.7mm. Loosen locknut and rotate push rod along the piston direction until it contacts the piston, and then turn back 1/7-1/2 circle.

  • Page 77: Cleaning Air Filter

    Maintenance and service Cleaning the air filter Hint: Please replace filter element under such conditions: it has been washed 5 times; filter element has been damaged; filter element is clogged excessively; after changing the engine oil .When air filter indicator on combination instrument lights, clean the air filter or replace the element.
  • Page 78 Maintenance and service Caution: Vapor spray gun, solution, gasoline or equivalent should not be used during the cleaning. －Before reinstalling air filter element, check element from inside to outside with check lamp for damage; －Check sealing ring for damage or cracks. Caution: Do not start the engine without mounting the air filter.

  • Page 79: Coolant Specification

    Maintenance and service below: mix 700-800g caustic soda with 150g kerosene and then inject the miscible liquids into water, at this time, make engine run at middle speed for 5-10 minutes. 10-12 hours later, make engine run again for 10-15 minutes and then drain aqueous solution and clean cooling system with fresh water. Coolant specification as shown below: the users should choose proper brand according to requirement: Specs ℃...
  • Page 80 Maintenance and service Engine oil viscosity  Since oil viscosity fluctuated with temperature, so the ambient temperature of engine working area is very important to select viscosity grade (as shown in the figure). When temperature exceed lower limit, it may decrease cold start capacity of the engine but will not make any damage to the engine. ...
  • Page 81 Maintenance and service Power steering hydraulic oil: Fulfill standard: Generai Allison C-3. When ambient temperature is low than 10°C, please apply DEXRON-II hydraulic fluid to steering gear; when ambient temperature is higher than 10°C, please apply C-3/10W hydraulic fluid. C-3/10W grade oil can be used in most area .all-year generally. C-3/30 grade oil can be used in non-cold area all-year generally.

  • Page 82: Breaking-In Of A New Vehicle

    Maintenance and service Breaking-in of New Vehicle Engine of new vehicle should be sure not to operate at the maximum power output during the breaking-in period to keep best performance and superior efficiency as well as guarantee durable service life. Please drive cautiously and pay more attention to abnormal phenomenon occurred during breaking-in period.
  • Page 83 Maintenance and service 6. Check connection of transmission control mechanism for looseness. 7. Check connections of steering gear for looseness and damage. 8. Tighten bolts and nuts of front and rear suspension（carry out when full load） 9. Check connections of chassis and driving system according to specified torques. Tighten torques please refer to corresponding instructions.
  • Page 84 Maintenance and service Daily or Refueling Maintenance Check System Item Operation Technical requirement No leakage, damage, and crack. Air cleaner Check Clips without looseness. Fuel-water Release the water and fouling Drain separator Do not pull or lever the cooling fan for starting the engine. Cooling fan Inspect No crack, looseness, bend or damage.
  • Page 85 Maintenance and service Periodical maintenance and operation items and regulations Periodical maintenance of each class: do maintenance during each interval or certain miles . Special instruction: if assembly instruction requires different oil replace period, please follow the instruction’s requirement on maintenance period and operation. If else please refer to this manual for maintenance requirement.
  • Page 86 Maintenance and service System Item Operation Technical requirement Rear axle housing and differential housing, rear Check & fasten axle housing rear cover half axle bolts and nuts, Rear axle （ DF & No loosen Fastening Check & piece adjust FS series） Ventilate Clean stopper...
  • Page 87 Maintenance and service System Item Operation Technical requirement Front axle Brake clearance Check & （ DF & FS adjust series） Rear axle Brake clearance Check & （ DF & FS adjust series） Fasteners Check/tighten Check and tighten the bolts, rods, height control suspension valves, air springs, shock absorbers, anti-roll bars.
  • Page 88 Maintenance and service System Item Operation Technical requirement brake pedal Check & 10－15mm free stroke adjust Shoe drum clearance: 0.30mm ～ 0.50mm, in braking Check condition complete braking, pedal stroke not surpass 1/2 of the whole stroke, check dry tin condition Brake brake Check...
  • Page 89 Maintenance and service Maintenance operation and regulation every 10000km or 3 months Every 10000km include every 5000km maintenance operation System Item Operation Technical requirement Replace Check oil surface within required range Check engine and oil seal without apparent leakage Replace oil when engine water temperature is 60℃, for removing the impurity Oil level more than CF Oil filter...
  • Page 90 Maintenance and service Maintenance operation and regulation every 20000km or 5 months depend on what occurs first. Every 20000km include every 10000km maintenance operation System Item Operation Technical requirement Fuel filter Replace Replace fuel filter element accordingly Steering hydraulic Replace Steering auxiliary oil surface within required range Engine Coolant system –...
  • Page 91 Maintenance and service System Item Operation Technical requirement There are gaps on the surface of the rubber The surface of the rubber become adhesive, brittle and the rubbe drop off seriously The rubber bal Change The connection of the metal and the rubber is damaged. The partia joints depth is up to 6mm The rubber ball joint rotates in the inner hole of the ball head a...
  • Page 92 Maintenance and service System Item Operation Technical requirement front rear wind shield and Check Clean, no crack, sealing good side window glass clean Body paint no crack or peeling, re-paint color the body with paint Check same as original Body, frame pattern, character, company Check Pattern, character, company mark clear, complete...
  • Page 93 Maintenance and service Maintenance operation and regulation every 40000km or 8 months depend on what occurs first. Every 40000km include every 20000km maintenance operation System Item Operation Technical requirement Drive belt, Cooling fan belt tension Check/adjust Check each belt without loosening or damage Cooling fan bearing and bolt Check/adjust No damage, fouling, loosening Engine...
  • Page 94 Maintenance and service Maintenance operation and regulation more than 80000km ZF Series axle Oil or Grease change required, depending on what occurs first. Products Model Maintenance content Maintenance Oil class Remark name interval Filling-up 80,000-90,000KM or NLGI Class 2 grease(lubricant point) 1 year check-up oil level and 90,000~120,000KM...

  • Page 95: Maintenance Period Chart

    Maintenance and service Maintenance period chart 1、1st line is the item of break-in of new vehicle (prescript items completed after driving 2500KM or the day of registration vehicle) 2、Other items are compulsion maintenance program (the circulation is 80000KM/12 months) 3、 For engine、 axle、 transmission please refer to producer’s maintenance manual, if without special maintenance period, please refer to this manual for maintenance information.
  • Page 96 Maintenance and service Maintenance period chart 1、1st line is the item of break-in of new vehicle (prescript items completed after driving 2500KM or the day of registration vehicle) 2、Other items are compulsion maintenance program (the circulation is 80000KM/12 months) 3、For engine、axle、transmission please refer to producer’s maintenance manual, if without special maintenance period, please refer to this manual for maintenance information.
  • Page 97 Maintenance and service Maintenance period chart 1、1st line is the item of break-in of new vehicle (prescript items completed after driving 2500KM or the day of registration vehicle) 2、Other items are compulsion maintenance program (the circulation is 80000KM/12 months) 3、For engine、axle、transmission please refer to producer’s maintenance manual, if without special maintenance period, please refer to this manual for maintenance information.
  • Page 98 Maintenance and service Maintenance period chart 1、1st line is the item of break-in of new vehicle (prescript items completed after driving 2500KM or the day of registration vehicle) 2、Other items are compulsion maintenance program (the circulation is 80000KM/12 months) 3、For engine、axle、transmission please refer to producer’s maintenance manual, if without special maintenance period, please refer to this manual for maintenance information.
  • Page 99 Common trouble and elimination Maintenance period chart 1、1st line is the item of break-in of new vehicle (prescript items completed after driving 2500KM or the day of registration vehicle) 2、Other items are compulsion maintenance program (the circulation is 80000KM/12 months) 3、For engine、axle、transmission please refer to producer’s maintenance manual, if without special maintenance period, please refer to this manual for maintenance information.
  • Page 100 Common trouble and elimination Engine common trouble and its elimination (suitable for diesel engine) Diesel engine can not start Possible causes Remedies 1 ） Too low starting speed 1) Check the starting system and assure the starting speed is not lower than 110rpm.
  • Page 101 Common trouble and elimination Diesel engine power deficient Possible causes Remedies 1 ） Intake blocked 1 ） Check the air cleaner, intake pipe, and clean or replace the air cleaner filter elements. 2 ） high exhaust back pressure 2 ） Check the valve timing, adjust it if necessary; Clean the exhaust pipe.
  • Page 102 Common trouble and elimination Abnormal noise during engine operation Possible causes Remedies 1) Connecting rod bearing bushing and 1) Dismantle and check the bushing and, if necessary, replace it main bearing bushing are worn-out and keep the reasonable clearance as required. and clash voice appears in the crankcase.
  • Page 103 Common trouble and elimination Exhaust with black smoke Possible causes Remedies 1) Intake clogged 1) heck and clean the air cleaner and intake passage. 2) Poor fuel quality 2) Use prescribed fuel. 3) Incorrect distribution timing 3) Adjust the distribution timing according to the instruction. 4) Bad atomization of injector 4) Check and repair or replace 5) The injector spray too much fuel...
  • Page 104 Common trouble and elimination Too low oil pressure Possible causes Remedies 1) Diluted or incorrectly selected 1) Select the proper oil. 2) Inner and outer rotors of oil pump worn-out 2) Replace the oil pump. or too large 3) Oil filter choked 3) Replace the whirling type filter element.

  • Page 105: Clutch

    Common trouble and elimination Chassis constant fault and elimination Clutch Fault Possible cause Eliminating method symptom 1.The noise occurs when the clutch disengages Flywheel support bearing stuck 1） Replace the bearing Release bearing stuck 2） Replace the bearing Abnormal The noise occurs when the clutch sound of the engages clutch...
  • Page 106 Common trouble and elimination Fault Possible cause Eliminating method symptom No braking fluid in the clutch oil tank 1) Check and repair leakage or replace 1) Leakage faulted components. 2) There has leakage during the 2) Disassemble and repair. hydraulic cylinder operation Abrasion of the friction surface of Correct or replace the parts the clutch plate, the flywheel and the...

  • Page 107: Propeller Shaft

    Common trouble and elimination Fault Possible cause Eliminating method symptom There has Driven plate damping spring broken Replace the clutch plate vibration Uneven height of the clutch lever Adjust the height of each release lever during the Performance declination Check the clutch cover assembly and clutch breakdown of the diaphragm spring replace the faulted parts...

  • Page 108: Transmission

    Common trouble and elimination Transmission Fault Possible cause Eliminating method symptom Control mechanism 1) Improper height of the control hinge 1） Adjust the control hinge 2) There has clearance between the 2） Correct or replace the parts control hinge connection 3) The control hinge bend 3）...

  • Page 109: Rear Axle

    Common trouble and elimination Rear axle Fault Possible cause Eliminating method symptom When the vehicle is starting Excessive clearance between 1） Adjust the clearance the differential gear Excessive clearance between 2） Adjust the clearance the driving and the driven gear Looseness of the connecting 3）...

  • Page 110: Front Axle And Steering System

    Common trouble and elimination Fault Possible cause Eliminating method symptom Blocking or damage of the Clean or replace the ventilation ventilation plug plug Axle housing cracks Leakage of Damage or distortion of the Repair or replace the axle housing the rear coupling flange sealing surface Adjust or replace the coupling axle...
  • Page 111 Common trouble and elimination Fault Possible cause Eliminating method symptom 6) Fatigue of the front leaf spring, 6) Replace the faulted parts looseness of the "U" -bolt or damage of the central bolt The steering system 1) Difficulty gear 1） Adjust the gear engagement engagement 2）...
  • Page 112 Common trouble and elimination Fault Possible cause Eliminating method symptom Others 1) Correct the driving pattern Misproportion 1) Breakdown caused untimely abrupt starting or the emergent 2) Make the loading according to the tire wear braking specified capacity 2) Overloading Too low oil level Add the lubricant to the given Lubricant...

  • Page 113: Braking System

    Common trouble and elimination There has oil Clogging of the strainer or the Clean the filter strainer or replace spillage in the filter element the filter element steering oil There has air in the pipeline Add the oil and make the tank exhaustion Braking system...
  • Page 114 Common trouble and elimination Fault Possible cause Eliminating method symptom Tire pressure uneven or tire Operate as required dimension different Improper installation of the Tighten the locknut of the brake brake shoe or damage of the shoe supporting pin and replace the return spring return spring Improper engagement of the...
  • Page 115 Common trouble and elimination Fault Possible cause Eliminating method symptom When compressed air pressure is abnormal: Repair the leakage point There has air leakage inside the air pipeline Disassemble repair The air compressor doesn't compressor work Adjust or wash pressure regulator Disassemble and repair the brake improper adjusted or failed...
  • Page 116 Common trouble and elimination Fault Possible cause Eliminating method symptom speed C-16...
  • Page 117 Common trouble and elimination Fault Possible cause Eliminating method symptom The battery has no power, or is Charge and clean the joint and lack of power or terminal loose screw it Poor contact of the starter switch, short circuit of the Repair or replace it connector lug or bad of the solenoid...

  • Page 118: Air Conditioner System

    Common trouble and elimination Common trouble and troubleshooting of air conditioner system The remedy and trouble analysis under abnormal pressure Pressure Description Analysis Remedy There is bubble in the inspection glass ； the Check cold air in the bus system for the The refrigerant insufficient high...
  • Page 119 Common trouble and elimination Pressure Description Analysis Remedy Discharge the Air mixed in the refrigerant in The high and low The cooling capability refrigerant the system pressure are vacuum is not and change much higher than Insufficient good for the first the desiccators the normal value system has air and the...
  • Page 120 Common trouble and elimination Electric system trouble and remedy Fault Possible cause Eliminating method symptom the power 1. + no power supply； generator D+ no output, exchange lamp on the the generator and repair control 2. D+ not connected well； reconnect the cable D+；...
  • Page 121 Common trouble and elimination Fault Possible cause Eliminating method symptom compressor clutch connecting reconnect the cable； cable not connected well； change the clutch or repair； clutch damaged； refer above-mentioned compressor malfunction lamp light up； items； refrigerant light not lighting up； working relay out of work；...
  • Page 122 Common trouble and elimination CNG public bus gas feeding system Breakdown Breakdown reason distinguish method Disposal way type Engine no high First turn on power switch, then open CNG a. Replace or report for repair speed low pressure filter contamination drain mouth to Lantianda.
  • Page 123 Common trouble and elimination Breakdown Breakdown reason distinguish method Disposal way type Charging valve a. Valve core rubber ring invalidate; a. Replace charging valve or leaking gas report for repair to Lantianda Pressure gauge a. Surface airtight invalidate ( lever lower a.

  • Page 124: Appendix

    Appendix Driver tools table（one each） Part name Part name Tool box Flat-tip screwdriver 6*100MM Combination wrench 8 Hammer Combination wrench 10 Slip joint pliers 8” Combination wrench 12 Nipper pliers 6” Combination wrench 13 Tire pressure gauge 0-1.4MPa Combination wrench 14 Valve core wrench Combination wrench 15 Filter wrench...
  • Page 125 Appendix Tightening torque of main bolts and nuts Position Tightening torque（N·m） Propeller shaft bolt M16×1.5×L 270～330 （Bolt grade: 10.9 G） lock nut,steering knuckle limiting bolt（M16） 80～100 Fixing nut, upper knuckle 280～350 Binding nut, tie rod 75～100 Fixing bolt,clip on both end of steering drag rod（M24） 280～300 Fixing bolt, angle steering (M18) 60～80...
  • Page 126 Appendix Lower slotted nut, rear damper (M16) 100～120 Bolt, bearning cap (M22X1.5) 440～490 Axle shaft bolt (M16X1.5) 140～180 Fixing bolt, bracket of brake chamber (M14X1.5) 90～120 Oil level hole plug (M24X2) 130～150 Fixing nut, rear brake chamber (M16X1.5) 170～190 Bearing block bolt (M14X1.5) 120～140...
  • Page 127 Appendix The table of Lubricant, Power steering oil and Grease Main assembly lubricant Oil site Lubricant Type Level Engine Diesel engine oil 15W/40 API CH – 4/SG Transmission Gear oil SAE 85W-90 API GL – 4 Main reducer Gear oil SAE 85W-90 API GL –...

  • Page 128: Air Braking Schematic Diagram

    Appendix Air braking schematic diagram...
  • Page 129 Appendix Electric schematic diagram of the complete vehicle (1)
  • Page 130 Appendix Electric schematic diagram of the complete vehicle （2）...
  • Page 131 Appendix Electric schematic diagram of the complete vehicle (3)
  • Page 132 Appendix Electric schematic diagram of the complete vehicle (4)

Table of Contents