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King Long XMQ6127 series Operating Manual

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OPERATION MANUAL
User's Guide
King-Long XMQ6127 series tourist bus
Xiamen King Long United Automotive Industry Co., Ltd.
- 1 -

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  • Page 1: Vehicle Picture

    OPERATION MANUAL User’s Guide King-Long XMQ6127 series tourist bus Xiamen King Long United Automotive Industry Co., Ltd. - 1 -...

  • Page 2: Foreword

    As for the specifications introduced in relate to information of the driving and operation, service and maintenance of the XMQ6127 series tourist 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 Vehicle picture--------------------------------------------------------------------------------------------------------1 Foreword---------------------------------------------------------------------------------------------------------------2 Contents Contents--------------------------------------------------------------------------------------------------------------3-6 Technical parameters and complete vehicle description Technical parameters ------------------------------------------------------------------------------------------------7 Introduction to data plate--------------------------------------------------------------------------------------------8 Product quality assurance -------------------------------------------------------------------------------------------9 Technical document -------------------------------------------------------------------------------------------------9 Vehicle body structure----------------------------------------------------------------------------------------------10 Schematic illustration of the driver zone-------------------------------------------------------------------------11 Operation Instruction Instrument instruction--------------------------------------------------------------------------------------------CI-1 Illustration of switch and indicator s--------------------------------------------------------------------------SI-1-3 Air conditioner control panel-----------------------------------------------------------------------------------P-A-1 Heating Operation---------------------------------------------------------------------------------------------P-H-1-3...

  • Page 4: Contents

    Contents Safety hammer---------------------------------------------------------------------------------------------------OI-10 CAN module location & function description------------------------------------------------------------O-E-1-2 Switch control box----------------------------------------------------------------------------------------------O-E-3 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...
  • Page 5 Contents Vehicle maintenance and service General knowledge------------------------------------------------------------------------------------------------M-1 Maintenance of engine and chassis subassembly--------------------------------------------------------------M-1 Body maintenance ------------------------------------------------------------------------------------------------M-1 ABS/EBS system maintenance and service -------------------------------------------------------------------M-1 Electrical system maintenance and notices --------------------------------------------------------------------M-2 Tire transposition--------------------------------------------------------------------------------------------------M-2 Adjustment of the brake pedal freeplay------------------------------------------------------------------------ M-3 Bus cleaning--------------------------------------------------------------------------------------------------------M-3 Cleaning air filter --------------------------------------------------------------------------------------------------M-4 Cleaning outside of radiator -------------------------------------------------------------------------------------M-5 Coolant specification ---------------------------------------------------------------------------------------------M-5 Oil specification recommendation of the fuel and the lubricant---------------------------------------------M-6...

  • Page 6: Contents

    Contents 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 The table of Lubricant, Power steering oil and Grease-------------------------------------------------------A-3 Air braking schematic diagram (with air suspension) ------------------------------------------------------- A-4 Electrical elementary diagram of vehicle ------------------------------------------------------------------A-5-8 - 6 -...

  • Page 7: Technical Parameters And Complete Vehicle Description

    Technical parameter and complete vehicle description Technical parameters of the complete vehicle （vehicle No. GA200001） Product model 6127 Engine model ISL8.9E5 400 Engine type In-line six-cylinder water-cooling electrically controlled common rail direct-injection diesel engine （mm） 114×145 Cylinder diameter ×stroke (ml) 8900 Displacement 16.6:1...

  • Page 8: Introduction To Data Plate

    Technical parameter and complete vehicle description Introduction to specification 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 insist that the end user must make breaking-in maintenance of the rolling-out new vehicles in their initial driving mileage of 5000 km. The end user should make proper operation and maintenance strictly according to relevant regulations in the instruction book.

  • Page 10: Vehicle Body Structure

    C type luggage rack , icebox, middle passenger door, toilet, combination reading lamp, electric mirrors, DVD player, front and middle flip LCD TV ,reversal monitor , .etc. 8. Air-conditioning system Cooling /heating A/C system: KING LONG top mounted dependent air-conditioning system, WEBASTO heating system. Defroster: cooling /heating defrosting device.

  • Page 11: Schematic Illustration Of The Driver Zone

    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 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 13 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 14 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 2012 08-07 C N G 0000 CATALYST Figure-6 CNG and CATALYST 3.1.5 The sixth display inside temperature，outside temperature and engine compartment temperature.
  • Page 15 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 CI-1...
  • Page 16 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. CI-1...
  • Page 17 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 18 Operation Instruction Figure-17 Set MotPPR Figure-18 Clear Trip A Figure-19 Clear Trip B CI-1...
  • Page 19 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 20 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. CI-1...
  • Page 21 Operation Instruction Set Backlight Backlight 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 22 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 23 Operation Instruction Empty Empty Empty Empty Empty Empty Empty Empty 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 Pre-heater Yellow Alarm of oil pressure Engine fault Yellow High beam...
  • Page 24 Operation Instruction Clearance Lamp Green Avoid side slide Charge Parking light Low beam Green Alarm of water temperature Alarm of Fuel Low 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...
  • Page 25 Operation Instruction Brake Light Fault CRUISE Cruise Safety Door Brake Light Break Wear Antifreeze controller CI-1...

  • Page 26: Illustration Of Switch And Indicator S

    Operation Instruction Illustration of switch and indicator Number of switches , indicators and their own positions may vary with the vehicle model and configuration state, please refer to the flowing sheet : Switch Name Color Function Notes Pressed on up: foot control function is Retarder foot control turned ON...
  • Page 27 Operation Instruction only use this Vehicle body Pressed on top: the vehicle body raise button when White raise/lower switch Pressed on bottom: the vehicle body descend vehicle stopping Pressed switch down Pressed on top: the vehicle will return to Kneeling/Restoration only when the White the normal height...
  • Page 28 Operation Instruction Switch Name Color Function Notes Pressed on top: the electric horn is turned on White Horn Pressed on bottom: the air horn is turned on 1) While only turn on the switch, could supply power only Pressed on top: turn off the vehicle minutes;...
  • Page 29 Operation Instruction Rear Pressed on top: close the door White passenger Pressed on bottom: open the door door switch Pressed on top: turned off the power, folded Flip TV the TV White switch Pressed on bottom: turned on the power, unfolded the TV The powder will be burst out and coated on engine...
  • Page 30 Operation Instruction Color Indicator lamp Function Front passenger door opening alarm Rear passenger door opening alarm Yellow Kneeling working indication Green The 2th height state indication Yellow ECAS alarm indication ECAS fault indication White Engine start indication Yellow Exceeding emission standard indication Yellow Engine slight fault alarm White...
  • Page 31 Operation Instruction Air Conditioner （KING LONG A/C KL-XB3） The introduction of control panel SK-17-1（SK-17-1Y） 1. Control panel and functions P-A-1...
  • Page 32 Operation Instruction 2. Control panel operation P-A-1...
  • Page 33 Operation Instruction P-A-1...
  • Page 34 Operation Instruction P-A-1...
  • Page 35 Operation Instruction P-A-1...
  • Page 36 Operation Instruction P-A-1...
  • Page 37 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 38 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 39 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 40 Operation Instruction ZF GEARBOX 6HP604C OPERATION 1.1 Pushbutton 1.1.1 Digital Speed Range Selector 1.1.2 CAN Speed Range Selector 1.1.2.1 Lighting of the CAN Speed Range Selector 0-G-1...
  • Page 41 Operation Instruction 1.1.2.2 Pushbutton Settings 0-G-1...
  • Page 42 Operation Instruction 1.2 Starting the Engine 1.3 Selecting the Gear 0-G-1...
  • Page 43 Operation Instruction 1.4 Setting Off 1.5 Driving Ranges 0-G-1...
  • Page 44 Operation Instruction 1.5.1 Downhill Travel 1.5.2 Downhill Travel 1.5.3 Kickdown 0-G-1...
  • Page 45 Operation Instruction 1.5.4 Retarder Operating Mode Defined in Section 1.9 Defined in Section 1.9 Refer to Section 1.8 or vehicle manufacturer’s Operating Instructions 0-G-1...
  • Page 46 Operation Instruction 1.6 Stopping, Parking 0-G-1...
  • Page 47 Operation Instruction 1.7 Towing 1.7.1 Towing Away Vehicle with Operational Transmission 1.7.2 Towing a Vehicle with Suspected Transmission Damage 0-G-1...
  • Page 48 Operation Instruction 1.8 Temperature Monitoring 1.9 Limit Values for Oil Temperature 1.9.1 Transmission Oil Temperature Before Heat Exchanger 1.9.2 Oil Temperature in Transmission Oil Sump 0-G-1...
  • Page 49 Operation Instruction 1.9.3 Actions to be Taken When the Relevant Permissible Oil Temperature is Exceeded 0-G-1...
  • Page 50 Operation Instruction 1.10 Status Monitoring/Warning Lamps 1.11 Transmission Response to a Malfunction 0-G-1...
  • Page 51 Operation Instruction 1.11.1 Limp-Home Mode 1.12 Auxiliary Control Unit 0-G-1...
  • Page 52 Operation Instruction 1.12.1 Operating Instructions for the Auxiliary Control Unit 0-G-1...
  • Page 53 Operation Instruction WABCO ABS BASIC INTRODUCTION 0-AB-1...
  • Page 54 Operation Instruction 0-AB-1...
  • Page 55 Operation Instruction 0-AB-1...
  • Page 56 Operation Instruction 0-AB-1...
  • Page 57 Operation Instruction 0-AB-1...
  • Page 58 Operation Instruction ECAS System Introduction 1. System introduction 0-EC-1...
  • Page 59 Operation Instruction 3. System function 0-EC-1...
  • Page 60 Operation Instruction 0-EC-1...

  • Page 61: Toilet Operation

    Operation Instruction TOILET OPERATION (1). Functions and Operations ①.When using the toilet, please lock the door to ensure the system is functioning properly. ②.Occupied Light: This indication light is controller by the toilet door lock. It can probably be installed on the door of the toilet module, or be located at the front of the Coach. The passengers can be aware of the status of the toilet.
  • Page 62 Operation Instruction ④. Hand Wash System: The toilet is Faucet Soap dispenser equipped with a water pump for the hand wash faucet. When the button is pushed, the water Hand-wash pump is turned on for a certain period of time button (normally 3-5 seconds).
  • Page 63 Operation Instruction ⑨. Fresh -Water Holding Tank System: The holding tank is to store the fresh water for toilet flush and hand wash, please check the water level before use. Make sure water is full. If the Water Level Warning System indicates lack of water, please watering in time.
  • Page 64 Operation Instruction ⑤. When clean the inside of the toilet module, remove the cover of the floor drainage. The water can be drained directly out of the coach through the floor drain. Please do not spray water at the electrical junction box, the fan, and other electrical equipment to Drainage avoid wetting them and resulting in damage.
  • Page 65 Operation Instruction Open/close the passage 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.
  • Page 66 Operation Instruction Door remote controller 2 Door remote controller 1 Door emergency switch Model 1 The model 1 door emergency switch is located on upside of the gate ingress. Operation tips: 1) Please press the red button 1 and flick open the valve cover 2. 2) Please rotate the red handle switch 3 clockwise up to 90 degree.

  • Page 67: 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 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...

  • Page 68: 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 69: Adjustment Of The Steering Wheel

    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...

  • Page 70: Ignition Switch

    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"...

  • Page 71: Lamplight Operating Handles

    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.

  • Page 72: Wiper Operating Handle

    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.

  • Page 73: Passenger Control Panel

    Operation Instruction Passenger control panel instruction 1. air outlet 2. service button 3. reading lamp button 4. lamp 5. loudhailer 6. stop button When the passenger require to read something, may press the button 3 for turning on the reading lamp; may press the cover 1 for cooling air; may press the button 6 for requiring stop the vehicle accordingly.

  • Page 74: Safety Hatch

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

  • Page 75: 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 side window for escaping in case of danger. Model 1 OI-10...
  • Page 76 Operation Instruction Central Electricity Distributor (VITI ) Installation position The central electricity distributor always installed in the compartment of the instrument desk or located in front-left side cabin door box under the driving area. 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.
  • Page 77 Operation Instruction CAN bus module: 0-E-1...

  • Page 78: Switch Control Box

    Operation Instruction Switch control box (Model: JKH2025A) CQ2025 A wiring diagram (Printed on opposite cover of the switch control box) 0-E-2...

  • Page 79: 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 80: 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 81 Vehicle Starting and Driving 3 Fuel pre-filter with water separator (drain accumulated water) Model for Euro II 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 82 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 deposited water in diesel filter in time and check fuel pipe for no leakage.
  • Page 83 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 84: 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 85 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.

  • Page 86: 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 87 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 88 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 89 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 fault) c. Red zone – engine overspeed range (risk of immediate engine damage) Always observe tachometer while driving the vehicle.

  • Page 90: 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 91: 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 92: 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 93: 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 94: 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 95: 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 96: 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 97: Electrical Rearview Mirror

    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.

  • Page 98: Power Steering System

    Vehicle Starting and Driving Inspection every two weeks before and after driving Model 1 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.

  • Page 99: 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 100 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...

  • Page 101: 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 102: Procedures For Engine Start Up

    Vehicle Starting and Driving Engine start up and shut down Procedures for engine start up Don’t release parking brake and keep to place the gear box lever in neutral. The vehicle is not possible to move in the gear position. Turn the ignition key into “start”...

  • Page 103: 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 104: 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. 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.

  • Page 105: 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 106: 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 107: General Knowledge

    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.

  • Page 108: 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 109: Adjustment Of The Brake Pedal Freeplay

    Maintenance and service Tire transposition diagram(three axles) 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.

  • Page 110: 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 111 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 112: 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 113 Maintenance and service 3) This item is a quality index of -45 degree dilute antifreeze. 4) To measure freezing point, should be done in special lab according to SH/T 0090; In emergency, may adopts portable refractometer to check and the test result is for reference. While existing disputes to two measuring results, is subject to the SH/T 0090.
  • Page 114 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 115 Maintenance and service Power steering hydraulic oil: Fulfill standard: General 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 116: 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 117 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 118: Daily Maintenance Operation

    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 119: Transmission

    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 120 Maintenance and service System Item Operation Technical requirement Front axle Brake clearance （DF & F S applicable series） Rear axle （ DF Brake clearance & FS series） applicable Fasteners Check/tighten Check and tighten the bolts, rods, height control suspension valves, air springs, shock absorbers, anti-roll bars. The top covers of air Check Listening and wiping the liquid soap.
  • Page 121 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 in the dry condition Brake brake Check...
  • Page 122 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 over 60℃, for removing the impurity Oil level more than CF...

  • Page 123: Rear Axle

    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 Engine oil Replace Replace and fill oil level within required range Engine Coolant...
  • Page 124 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 125 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 126 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 127 Maintenance and service Maintenance operation and regulation more than 80000km or corresponding time interval. ZF Series axle Oil or Grease change required, depending on whichever occurs first. Assembly Model Maintenance Maintenance Oil Classes Remark （ Table for Name Operation Interval Lubricant）...
  • Page 128 Maintenance and service Assembly & System Application Range Oil Change Interval Oil Classes Name - Scheduled routes 360,000 km or 3 3 ZF-Ecofluid M Transmission ZF Ecolite - Average speed from 20to 60km/h years 02B(1)/02E/ Series without Intarder - Long-distance coach journeys 540,000 km or 3 3 02H/02L （Manual）...
  • Page 129 Maintenance and service ZF Automatic Gearbox Products Assembly & System Name Application Range Oil Change Interval Oil Classes Automatic oil sump temperature below 120,000km Transmission Transmission ZF Ecomat Series 100 centigrate or 3years （ ATF ） Fluids （ ） automatic 14A/14B/14C/14E （HP502C/592C/602C/604C）...

  • Page 130: 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 5000KM or the days 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 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 5000KM or the days 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 Maintenance period chart 1、1st line is the item of break-in of new vehicle (prescript items completed after driving 5000KM or the days 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 133 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 days 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 134 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 days 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 135 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 136 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 137 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 138 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 139 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 140 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...
  • Page 141 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 142 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 143: 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 Damageor distortion of the Repair or replace the axle housing the rear coupling flange sealing surface Adjust or replace the coupling axle...
  • Page 144 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 145 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 146: 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 147 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 148 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 failured...
  • Page 149 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 150: 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 151 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 152 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 153 Common trouble and elimination Fault Possible cause Eliminating method symptom compressor clutch connecting cable reconnect the cable； not connected well； change the clutch or repair； clutch damaged； refer to the above-mentioned items； compressor malfunction lamp light up； not working refrigerant light not lighting up； relay out of work；...
  • Page 154 Appendix Driver tools table（one each） Part name Part name Tool box Flat-tip screwdriver 6*100MM Combination wrench 8 Hammer 1 pound 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...
  • Page 155 Appendix Tightening torque of main bolts and nuts Position Tightening torque（N·m） Front tyre nut 412～480 Rear tyre nut 294～421 Bolt, connecting lower knuckle and ball pin 245～304 Steering kingpin lockpin nut 60～70 Fixing nut, upper steering knuckle 274～343 Binding nut, tie rod 90～110 Locked bolt and nut between pitman arm and pitman arm shaft 407～434...
  • Page 156 Appendix Bolts torque table Torques for bolts with metric unified threads Torques N.m*(ft-lb) Dimension of bolt 10.9 12.9 3(2) 5(3) 5(4) 6(4) 9(7) 10(7) 10(7) 15(11) 18(13) 25(18) 35(26) 45(33) 50(37) 75(55) 83(61) 88(65) 123(91) 147(108) 137(101) 196(145) 235(173) 211(156) 300(221) 358(264) 290(213)

  • Page 157: The Table Of Lubricant, Power Steering Oil And Grease

    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/H – 4/SG Transmission Gear oil SAE 85W-90 ZF TE-ML20 or API GL – Main reducer Gear oil SAE 85W-90 API GL –...
  • Page 158 Appendix Air braking schematic diagram...
  • Page 159 Electric schematic diagram of the complete vehicle (1)
  • Page 160 Electric schematic diagram of the complete vehicle (2)
  • Page 161 Electric schematic diagram of the complete vehicle (3)
  • Page 162 Electric schematic diagram of the complete vehicle (4)

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