As for the specifications introduced in relate to information of the driving and operation, service and maintenance of the XMQ6900 series tourist bus, please read them carefully and make proper operation, maintenance and repair so as to ensure it in good condition.
Contents Safety hammer-----------------------------------------------------------------------------------------------------3-18 Relays & Fuses----------------------------------------------------------------------------------------------------3-19 Switch control box------------------------------------------------------------------------------------------------3-20 4 . Vehicle starting and driving Check oil level of the engine--------------------------------------------------------------------------------------4-1 Check level of the coolant-----------------------------------------------------------------------------------------4-2 Check fuel pre-filter with water separator-----------------------------------------------------------------------4-3 Check fuel level-----------------------------------------------------------------------------------------------------4-4 Check vehicle lighting, intermittent lights and brake lights-------------------------------------------------4-5 Check the level of AdBlue and the daily maintenance of SCR system--------------------------------------4-6 Drain water in air tank----------------------------------------------------------------------------------------------4-7 Check engine oil pressure------------------------------------------------------------------------------------------4-8...
Page 5
Contents 5 . Vehicle maintenance and service General knowledge------------------------------------------------------------------------------------------------5-1 Maintenance of engine and chassis subassembly-------------------------------------------------------------5-2 Body maintenance ------------------------------------------------------------------------------------------------5-3 ABS/EBS maintenance-------------------------------------------------------------------------------------------5-4 Electrical system maintenance and notices --------------------------------------------------------------------5-5 Tire transposition---------------------------------------------------------------------------------------------------5-6 Adjustment of the brake pedal freeplay-------------------------------------------------------------------------5-8 Bus cleaning--------------------------------------------------------------------------------------------------------5-9 Cleaning air filter -------------------------------------------------------------------------------------------------5-10 Cleaning outside of radiator -------------------------------------------------------------------------------------5-11 Coolant specification ---------------------------------------------------------------------------------------------5-12 Fuel recommendation---------------------------------------------------------------------------------------------5-13...
Page 6
Contents Braking system-----------------------------------------------------------------------------------------------------6-7 Electrical equipment and the starting system ---------------------------------------------------------------6-8 Air conditioner system--------------------------------------------------------------------------------------------6-9 7 . Appendix Driver's tool table--------------------------------------------------------------------------------------------------7-1 Tightening moment of the bolts and the nuts in major position ------------------------------------------7-2 Illustration for spare tyre dismounting & mounting-----------------------------------------------------------7-3 The operation tips for maintenance free battery---------------------------------------------------------------7-4 Table of lubricant, power steering oil, and grease-------------------------------------------------------------7-5 Air braking schematic diagram ----------------------------------------------------------------------------------7-6 Electrical elementary diagram of vehicle --------------------------------------------------------------------7-7...
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..
Technical parameter and complete vehicle description Product quality assurance We insisted that the end user should make breaking-in maintenance of the rolling-out new vehicles in their initial driving mileage of 5000 km. Users must make proper operation and maintenance strictly according to relevant regulations in the instruction book.
Page 11
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 six 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.
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.
Operation Instruction Instruction of instrument (VITI EDITION) Figure-1 The Outline of ZB271M The appearance of the ZB271M dashboard as shown in Figure-1 , it mainly contains eight indicator type measuring instruments, 29 icons which were lighted by the light-emitting diodes, one LCD screen and four buttons, dashboard pin definition go to Appendix A 2.1 Display Part.
Page 14
Operation Instruction ZB271M dashboard has four buttons,S1、S2、S3、S4. S1—Set Button. S2—Up Button. S3—Down Button. S4—Return Button. S1 could set some information of dashboard, for example ,times, blacklight, VehPPK and so on. S2 and S3 could flip the screen up or down. S4 Return main interface.
Page 15
Operation Instruction Figure -5. Figure-4 Fuel and Mileage information 2012 08-07 0000000000 .0 0000000000 .0 Figure-5 Fuel and Mileage information 3.1.4 The fifth interface display CNG and Catalyst. as shown in Figure-6 Figure-6 CNG and CATALYST 3.1.5 The sixth display inside temperature,outside temperature and engine compartment temperature. as shown in Figure-7...
Page 16
Operation Instruction Figure-7 Car and Engine compartment temperature 3.1.6 The seventh、eighth、ninth、tenth and eleventh interface display ECM、TCM、ABS、AIR、Retarded information. as shown in Figure-8、9、10、11、12. Figure-8 ECM Code Figure-9 TCM Code...
Page 17
Operation Instruction Figure-10 ABS Code Figure-11 AIR Code Figure-12 Retarded Code 3.1.7 The thirteenth interface display online module. as shown in Figure-13.
Page 18
Operation Instruction Figure-13 Online Module 3.2 Dashboard Set 3.2.1 First,Press S1 go to set interface, Second, Press S2 and S3 flip the interface up or down. Could Set Time、Set Backlight、Set VehPPK、Set MotPPR、Clear Trip A、Clear Trip B、ClearTA、 Clear Oneway OC. as shown in Figure-14、15、16、17、18、19、20、21 Figure-14 Set Time Figure-15 Set Backlight Figure-16 Set VehPPK...
Page 19
Operation Instruction Figure-17 Set MotPPR Figure-18 Clear Trip A Figure-19 Clear Trip B...
Page 20
Operation Instruction Figure-20 ClearTA Figure-21 Clear Oneway OC 3.2.2 Set Time .First press S1 go to set interface, Second press S2 or S3 choose Set Time position as shown in Figure-14, Third press S1 go to Figure-22. Figure-22 Set Year Finally press S2 and S3 could increase or decrease years.
Page 21
Operation Instruction Figure-24 Set Day Figure-25 Set Hour Figure-26 Set Minute 3.2.3 Set Backlight. First press S1 go to set interface, Second press S2 or S3 choose Set Backlight position as shown in Figure-15, Third press S1 go to Figure-27.
Page 22
Operation Instruction Figure-27 Set Backlight Finally press S2 and S3 could increase or decrease backlight. After set backlight, press S4 two times return main interface. 3.2.4 Set VehPPK. First press S1 go to set interface, Second press S2 or S3 choose Set VehPPK position as shown in Figure-16, Third press S1 go to Figure-28.
Page 23
Operation Instruction Figure-29 Set MotPPR Finally press S2 and S3 could increase or decrease MotPPR. After set MotPPR, press S4 two times return main interface. 3.2.6 Clear Trip A. First press S1 go to set interface, Second press S2 or S3 choose Clear Trip A position as shown in Figure-18.
Page 24
Operation Instruction Appendix B ZB271M Signal Bar instructions Icon Name Color Left turn light Green Right turn light Green Front fog light Green Yellow Rear fog light Yellow Preheater Yellow Alarm of oil pressure Engine fault Yellow High beam Blue Return Alarm of gas pressure Clearance Lamp...
Page 25
Operation Instruction Appendix C ZB271M LCD Alarm instructions Icon Icon Name Icon Icon Name Front Door Low Power Middle Door Alarm of water level ECAS Fault Concentrate lubrication Engine cabin Alarm of oil filter temperature too high Lack water alarm of Alarm of oil filter Rear cabin door Rear Door...
Operation Instruction Illustration of switch and indicator Number of switches , indicators and each own position may vary with the vehicle model and configuration state, please refer to the flowing sheet : Switch Name Color Function Notes Pressed on top: interior lighting OFF White Daylight lamp Pressed on bottom: interior lighting ON...
Page 27
Operation Instruction Pressed on top: the ventilation function is Fresh air switched off White ventilating switch Pressed on bottom: the ventilation function is switched on Pressed on top: the electric horn is turned off White Horn Pressed on bottom: the electric horn is turned on Pressed on top: the function is switched off Disinfection...
Page 28
Operation Instruction Switch Name Color Function Notes Retarder Pressed on top: the retarder foot-control foot-control function is turned on ; White function Pressed on bottom: the retarder foot-control release switch function is turned off 1) While only turn on switch, could supply power only for 2 minutes;...
Page 29
Operation Instruction Pressed on top: turned on the high shift High/low shift function White switch Pressed on bottom: turned on the low shift function The powder will be burst out and coated on engine Engine cabin cylinder block so as to fire Pressed down : extinguisher will be activated block...
Page 30
Operation Instruction Color Indicator lamp Function Engine fault alarm Yellow Exceeding emission standard indication Gearbox oil temperature over-heat alarm Gearbox fault alarm Yellow Kneeling function work indication Green Body keep 2th height state indication Yellow ECAS alarm indication ECAS function fault alarm Yellow Vehicle require maintenance indication White...
Page 31
Operation Instruction CC350-355 series A/C Operation...
Page 36
Operation Instruction Pre-heater Operation (Webasto) Standard Timer 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 37
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 38
Operation Instruction NANFENG Panel Operation Description: 1. Heating panel power switch: while pressing the button 1, the panel lamps are turning on or turning off, meanwhile, the heating opened or closed. 2. MANUAL/AUTO mode setting : while pressing on the button 2, may change over different mode state, once in AUTO mode, the water valve would open automatically and keep heating for room as far as the room temperature is below the temperature value which the system was already pre-established in advance;...
Page 39
Operation Instruction Gearbox Operation Transmission model (Automatic gearbox ZF 6AP1200B) Variant with 3 push buttons, horizontally arranged(details may be different from illustration) Fig.1 Fig.2 Operation Instruction ( as per Fig.1 or Fig.2 panels 1.1 Push-button control with diagnostics connector 1.1.1 Variants 1.1.2 Push-button illumination...
Page 40
Operation Instruction control unit(for potential cases see Section 1.3and 1.4) 1.1.3 Push-button selector position 1.2 Driving range (see Section 1.1),consult the vehicle operation instructions...
Page 41
Operation Instruction 1.3 Starting the engine Starts(see Section 1.1.2)and the transmission will remain Have to be depressed and subsequently(see Section.1.4) 1.4 Engaging a gear 1.4.1 Standard...
Page 42
Operation Instruction cases, the pushbutton depressed will flash (see Section 1.1.2) 1.4.2 Transmission with additional functions 1.4.2.1 Additional function “ Gear Release” Procedure as described under 1.4.1. In addition to the cases mentioned under 1.4.1, engagement of a starting will flash (see Section 1.1.2) 1.4.2.2 Additional function“...
Page 43
Operation Instruction 1.6 Downhill driving 1.7 Change in direction of travel Continue as described under Section 1.4 1.8 Kickdown (forced downshift)...
Operation Instruction Open/close the passenger door. 1. Before leaving the vehicle, press the button 1 of the door remote controller to close the door. 2. Use the key to lock the door. First insert key into the hole 3 and clockwise rotate key about 90°, then anticlockwise rotate handle 4, after that the door would be locked.
Operation Instruction Door remote controller 2 Door remote controller 1 Door emergency switch Model 1 The model 1 door emergency switch is located on right upside of the ingress. The model 2 door emergency switch is located on right underside of the ingress The model 3 door emergency switch is located inside the door pump cover which is on the top of the door.
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 and Handle 2: cushion height adjustment Handle 4: back and forth adjustment Handle 3: adjustment of the driver’s weight Left handle: backrest angle adjustment...
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.
Operation Instruction Adjustment of the steering wheel Pull-up the loosening handle 1 or rotate the loosening button 2. 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 stopped...
Operation Instruction Ignition switch Position of the ignition key is shown in fig.1. 1."L" LOCK: Insert or remove the key in this position. 2."A" ACC: Power supply of the instrument is switched on 3."O" ON: Normal driving position 4."S" START: Initiating position of the engine, and the key may rebound to the "ON"...
Operation Instruction Lamplight operating handles Model 1 The lamplight operating handle is located on left underside of the steering wheel, which control the front small light, headlamp, headlamp dimming, etc Indicating that the headlamp and the small lamp are all off. Model 2 Is the small lamp indication.
Operation Instruction Wiper operating handle Model 1 (with retarder) The wiper operating handle is located on right underside of the steering wheel. (model 1~2) OFF Out of work INT interval wiper operation step LO Slow wiping HI Quick wiping Model 2 (with exhaust brake) The wiper may spray water by pressing the end of the handle.
Operation Instruction Passenger control panel instruction 1. air outlet 2. service button 3. reading lamp button 4. lamp 5. loudhailer 6. stop button Model 1 Model 2 Model 3 3-16...
Page 67
Operation Instruction Safety hatch Model 3 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. Model 1 Model 4 When in emergency and dangerous condition, should 1) push upward with hands and make the hatch open 2) pull down the plastic cover and rotate red handle 3) push dome open...
Operation Instruction Safety hammer Model 2 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. Model 1 Model 3 3-18...
Operation Instruction Relays & Fuses Installation Position The Relays & Fuses Box always installed in the compartment of the instrument desk or a tool cabin belong to front right side panel. The box integrates 50 chip-type fuses, 20 general and special relays, and has 8 standby chip type fuses, one fuse clip, which makes its construction more compact and function more powerful.
Vehicle Starting and Driving Preparative 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.
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 73
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. After draining the water, tighten the draining plug correctly.
Page 74
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 75
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.
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 77
Vehicle Starting and Driving If the AdBlue spill in skin, mild irritation may occur. Wash off with soap and water. If the AdBlue spill in eye, irrigate eyes with large amount of water. The AdBlue is Non-combustible, if heated water evaporates and ammonia will be released.
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 79
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 0.07-0.52Mpa (0.7-5.2kg/cm ) along with the increment of the oil temperature as...
Page 80
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 81
Vehicle Starting and Driving 3. Tachometer working order Indications on tachometer scale: a. Green zone – operating range of maximum performance b. Yellow zone – a little high speed range (warning of engine overspeed ) c. Red zone – engine overspeed range (risk of immediate engine damage) Always observe tachometer while driving the vehicle.
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.
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.
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.
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. 4-14...
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; ●...
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...
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.
Vehicle Starting and Driving 7. Electrical rearview mirror Check, adjust and clean the rearview mirror. Model 1 Rearview mirror control button Model 1 L: adjusting left rearview mirror. R: adjusting right rearview mirror. Mirror button: push down the arrow headed button to adjust the mirror for 4 directions.
Vehicle Starting and Driving Inspection every two weeks before and after driving Model 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. If any working abnormality in the steering is noticed, immediately supply the necessary repairs.
Vehicle Starting and Driving 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 92
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...
Vehicle Starting and Driving 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.
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 start position. Start up without stepping on the accelerator.
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.
Vehicle Starting and Driving Engine start up and shut down in the engine compartment Park the vehicle and activate the parking brake. Model 1 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.
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 the coolant temperature exceeds 60℃ as well as the parking brake has been released after the engine is started.
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.
Maintenance and service General knowledge King Long 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.
Maintenance and service Maintenance of engine and chassis assembly • For the usage and maintenance of the engine, refer to relevant engine operation and maintenance manual. For maintenance of transmission and front-rear axle, please refer to relative users’ guide. • •...
Maintenance and service Body maintenance 1. Keep body clean .Timely clean should be made after daily running and don’t scrape body with tool in order to avoid paint scratch and damage of roll covering. 2. Sealing strips of doors and windows should be kept integrated. Make timely replacement if damaged. 3.
Page 102
Maintenance and service ABS/EBS system maintenance and service: Please cut off ECU control box to avoid the high voltage from outside to make damage to the ECU, when use the outer power supply to charge the battery. When the vehicle need electric welding, cut off the ECU .never use the multimeter to measure the ECU box.
Page 103
Maintenance and service Electrical system maintenance and service: (1) When battery is charged by external power supply, disconnect ECU to prevent outer high voltage damage ECU (electric control unit). (2) When vehicle needs to weld, disconnect ECU. Don’t use multimeter to measure ECU control box. (3) Monitor voltage stability of generator regularly.
Maintenance and service Tire transposition The tire may appear certain abrasion after period of running. The tire should be made transposition as the drawing below after every 8000 km to 10000 km running for proper use and prolonged tire life. Four-wheel locating condition should be checked, dynamic balance and tire transposition be made at once if there shows early and irregular abrasion of the tire.
Maintenance and service Adjustment of the brake pedal free play Loosen locknut of brake pedal push rod and adjust adjusting nut, and then measure the vertical distance from pedal free position to the position where pressing resistance increases apparently when depressing pedal.
Maintenance and service Bus cleaning • Don’t pollute the environment when washing vehicle at washing shop. Be careful to use the high strength dissolve fluid. • Don’t damage paint layer. • • Do not directly inject the water into radiator grill on right (left) back of the bus to prevent the water from entering engine through the 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 108
Maintenance and service Clean outside of the radiator Keep outside of radiator clean. Compressed air current can eliminate all the dirt blocking air flow. For vehicle equipped with intercooler, please keep air radiator fin clean. If there is hard dirt in radiator fin, blow fan side and then the other side with compressed vapor current.
Maintenance and service Charging-up the coolant Anti-freeze and antirust solution (mixture of glycol and water) should be added to cooling system perennially to avoid sediment, frost, oxidation and increase in boiling point. NOTE: When adding coolant, please choose the same brand as much as possible in case of sediment. If coolant is degenerative, replace entirely.
Maintenance and service Fuel recommendation 1. Diesel fuel (only apply to diesel vehicle) : only diesel of which cetane value is not less than 45 according to GB252 standard can be used. Sulfur content should not be more than 0.2%. 2.
Maintenance and service Oil quality and specification recommendation Engine oil Prefer using the engine oil whose quality is equivalent to or higher than level CF-4 or CH-4 of American Petroleum Institute API, or refer to the engine specification. Part of engine oil used for lubricating the piston will be burnt out (consumed) during the engine running.
Page 112
Maintenance and service Gear oil: Apply gear oil in accord with SAE90 API GL-5 grade. Recommended gear oil viscosity grade is related to ambient temperature, as shown in figure. Power steering hydraulic oil: Fulfill standard: please apply DEXRON-II D or DEXRON-III hydraulic fluid to steering gear; Final drive lubricant: Meet the using condition of GL-5(SAE90) grade heavy duty hyperboloid gear oil defined by API and the ambient temperature requirement.
Page 113
Maintenance and service Water tank coolant: Long life anti-freezing and antirust fluid should be added to water tank. The coolant could be general used both in winter and summer without adding and draining water in winter and it can prevent forming scale and corroding cooling system.
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 115
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.
Maintenance and service Daily Maintenance Operation 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 117
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 118
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 119
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 120
Maintenance and service Maintenance operation and regulation every 10000km or 3 months depend on whichever occurs first. 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...
Page 121
Maintenance and service Maintenance operation and regulation every 20000km or 5 months depend on whichever occurs first. Every 20000km include every 10000km maintenance operation System Item Operation Technical requirement Fuel filter Replace Replace fuel filter element accordingly Steering hydraulic oil Replace Steering auxiliary oil surface within required range Engine...
Page 122
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 123
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 124
Maintenance and service Maintenance operation and regulation every 40000km or 8 months depend on whichever 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 125
Maintenance and service Maintenance operation and regulation every 80000km or 12 months depend on whichever occurs first. Every 80000km include every 40000km maintenance operation System Item Operation Technical requirement Thermostats Replace Fuel roughing filter Replace Cooling system Release/ clean/ Radiator Check Radiator without leakage, damage, fouling.
Page 126
As for Cummins engine, ZF Series products, Allison and VOITH products, they will apply for their own special oil or grease change interval, please refer to the covering maintenance illustration from “King Long Bus Maintenance & Service Guide (2014)” 5-22...
Maintenance and service Maintenance period chart 1、1st line is the item of break-in of new vehicle (prescript items completed after driving 5000KM 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 128
Maintenance and service Maintenance period chart 1、1st line is the item of break-in of new vehicle (prescript items completed after driving 5000KM 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 129
Maintenance and service Maintenance period chart 1、1st line is the item of break-in of new vehicle (prescript items completed after driving 5000KM 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 130
Maintenance and service Maintenance period chart 1、1st line is the item of break-in of new vehicle (prescript items completed after driving 5000KM 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 131
Maintenance and service Maintenance period chart 1、1st line is the item of break-in of new vehicle (prescript items completed after driving 5000KM 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 132
Maintenance and service The introduce about the lubricate points in King Long bus At least every 5000 km, all these lubricating points should be lubricated. There are five lubricate zones in bus 1 steering drag rod 2 Steering knuckle kingpin, front brake self-adjusting arm in front axle.
Page 133
Maintenance and service For some buses, maybe there is only one drag link, so there is no points 2/3/4. Part II Steering knuckle kingpin, front brake self-adjusting arm in front axle Both left side and right side have four lubricate points. Two are for steering knuckle kingpin lubricating, the other two are for front brake adjusting arm lubricating.
Page 134
Maintenance and service Part IV Lubricate points in the propeller shaft There are three lubricate points in the propeller shaft. 5-24...
Page 135
Maintenance and service Part V Lubricate points in engine cabin You may find 2 lubricating points when open the engine cabin, one is for A/C bracket, another is for A/C middle idle pulley shaft. There will be not these 2 points if there is no A/C on bus. 5-24...
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. 2) Air exists in the injection system 2) Check the looseness of the joints of the feed line.
Page 137
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 138
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 139
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 140
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.
Common trouble and elimination Chassis constant fault and elimination Propeller shaft Fault Possible cause Eliminating method symptom Propeller shaft sliding yoke Remove and let the sliding yoke and the assembled incorrectly fixing yoke on the same plane The propeller shaft is distortion or Adjust or replace the propeller shaft bending The universal-joint journal or the...
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)...
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 144
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...
Common trouble and elimination Front axle and steering system Fault Possible cause Eliminating method symptom The steering system Steering gear housing bolt or 1) Tighten to specified torque steering column supporting loose Looseness of the steering 2) Adjust the junction connection point Excessive clearance of the 3)...
Page 146
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 147
Common trouble and elimination Fault Possible cause Eliminating method symptom Others 1) Correct the driving pattern Disproportion 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 148
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...
Common trouble and elimination Braking system Fault Possible cause Eliminating method symptom There has compressed air inside Check and adjust the exhaust valve the braking chamber of the quick releasing valve Improper lubrication of the Adjust the faulted parts camshaft or improper return of the adjusting arm Brake shoe or chamber return Replace the faulted parts...
Page 150
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 151
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 152
Common trouble and elimination Common trouble and troubleshooting of electrical equipment and starting system Fault Possible cause Eliminating method symptom There has The belt is of over loose or abnormal excessive abrasion with the sound shaking during the running Adjust the belt and replace the bearing during the Bearing failure or oversize generator...
Page 153
Common trouble and elimination Fault Possible cause Eliminating method symptom The battery has no power, or is Charge, clean the joint and screw it lack of power or terminal loose Poor contact of the starter Repair or replace it switch, short circuit of the connector lug or bad of the solenoid Difficult in...
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 155
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 156
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 157
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 to the above-mentioned items; compressor malfunction lamp light up; refrigerant light not lighting up; working relay out of work;...
Appendix Driver tools table(one each) Part name Part name Tool box Slip joint pliers 8” Combination wrench 8 Nipper pliers 6” Combination wrench 10 Tire pressure gauge 0-1.4MPa Combination wrench 12 Valve core wrench Combination wrench 13 Filter wrench(φ66-φ110) Combination wrench 14 Pry bar also used as rocker lever 55cm Combination wrench 15 Pry bar also used as handle 50cm...
Page 159
Appendix Fangsheng rear axle(imported final drive) Final drive locknut 55 mm hexagon 51 mm hexagon or Hangzhou sanhua 9T and 9.5T rear axle Dongfeng Dena 41 mm hexagon 32 mm hexagon Hangzhou sanhua 9.5T Socket wrench for wheel 21 mm foursquare rear axle 41 mm hexagon 38 mm hexagon...
Page 160
Appendix Tightening torque of main bolts and nuts Position Tightening torque(N·m) Propeller shaft bolt 270~330 M16×1.5×L (Bolt grade: 10.9 G) lock nut, steering knuckle limiting bolt(M16) 80~100 Fixing nut, upper knuckle(M20) 280~350 Binding nut, tie rod(M12) 75~100 fixing nut ,ball pin of steering drag rod(M24) 280~300 Lock nut, steering wheel (M18) 60~80...
Appendix Illustration for spare tyre dismounting & mounting A. Dismounting the spare tyre 1、 loose the 2 nuts below spare tyre and take them down. 2、 fetch out the rubber stopper from front step , while the crowbar is inserted in the groove belong to hoisting rocker, then rotate it anticlockwise, you see, the spare tyre fall down slowly until landing the floor.
Page 164
Appendix 4、 rotate the hoisting rocker clockwise, and make both the bracket and iron chain raise until returning back the initial position, then the spare tyre could be used after the vehicle leave. B. Mounting the spare tyre 1、 Move the spare tyre under spare tyre’s bracket, rotate the rocker anticlockwise until the bracket landing the floor ,next, put it into the spare tyre rim .
Page 165
Appendix 2、 Rotate crowbar clockwise to raise spare tyre until the height that keep rim stick on the lower surface of beam. Attention: keep alignment between 2 bolts in chassis frame and 2 bolt holes in rim, meanwhile, assure bolts come out from rim. 3、...
Page 166
Appendix The Operation Tips for Maintenance Free Lead-acid Batteries 1. Safety 1.1 There is some vitriol liquid in the batteries, which is corrosivity. Please keep away from kids. Please must wear protective glasses and rubber gloves when operating. If the vitriol put into eyes, skin and clothes carelessly, please wash by a lot of water right now, the severe injured should go to hospital.
Page 167
Appendix 4. Installation 4.1 In order to avoid unnecessary failure, should pay attention to safety mark before installation. 4.2 In order to avoid corrosion, should smear Vaseline on battery terminal before installation. Connection should be steady and dependable. Do not knock the terminal to avoid it loosening and inner acids leaking.
Page 168
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 –...
Need help?
Do you have a question about the XMQ6900 Series and is the answer not in the manual?
Questions and answers