operation manual

OPERATION MANUAL

User’s Guide

King-Long XMQ6130C series tourist bus

Xiamen King Long United Automotive Industry Co., Ltd.

- 1 -

Foreword

FOREWORD

King-Long XMQ6130C series tourist bus keeps features of superior economy, security and comfort. It has luxury interior trimming, high speed ,strong power, and stable driveability, which could meet applications of passenger inter-city transportation, touring and business affairs, etc.

As for the operation manual introduced in relate to information of the driving and operation, service and maintenance of the XMQ6130C series tourist bus, please read them carefully before driving and make proper operation, maintenance and repair so as to ensure the vehicle in good condition.

Special hint: in no case of unauthorized by Xiamen King Long United

Automotive Industry Co., Ltd, never modify the electrical deployment of the whole vehicle, and should not lap the power supply line in disorder. Improper usage and repair may have a serious negative impact on service performance of the complete vehicle, and thus the manufacturer , Xiamen King Long United

Automotive Industry Co., Ltd. will not takes the responsibility for the damages caused by them.

Any problem in service, please contact our special maintenance network or after-sales department. We will ensure timely and complete maintenance as well as original parts supply.

In order to satisfy all kinds of different demand of the consumers, we strive to improve the quality of the product continuously to optimize our products. We should not give any further notice for any modification of the product in advance .

The contents on the operation manual can only be used as reference. If there are facts not comply with the actual vehicle state, will be subject to the actual state of the products because for some devices and items, the vehicle will be finally equipped only if they have been taken as optional configurations.

Final interpretive right of the instruction book belongs to the technical center of Xiamen King Long United Automotive Industry Co., Ltd.

Xiamen King Long United Automotive Industry Co., Ltd.

JULY. 2015

- 2 -

Contents

Contents

Vehicle picture--------------------------------------------------------------------------------------------------------1

Foreword---------------------------------------------------------------------------------------------------------------2

Contents

Contents--------------------------------------------------------------------------------------------------------------3-6

Main overall technical parameters

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

Instrumen t instruction-----------------------------------------------------------------------------------------CI-1-7

Illustration of switch and indicators--------------------------------------------------------------------------SI-1-4

Air conditioner control panel-------------------------------------------------------------------------------P-A-1-4

Heating system operation------------------------------------------------------------------------------------P-H-1-2

Gearbox operation -------------------------------------------------------------------------------------------O-G-1-3

ABS instruction--------------------------------------------------------------------------------------------------O-G-3

ECAS instruction------------------------------------------------------------------------------------------------O-G-3

Open or close the passenger door---------------------------------------------------------------------------O-K-1-2

Adjustment of the driver's seat----------------------------------------------------------------------------------OI-1

Horn button---------------------------------------------------------------------------------------------------------OI-2

Adjustment of the steering wheel-------------------------------------------------------------------------------OI-3

Ignition switch----------------------------------------------------------------------------------------------------OI-4

Lamplight operating handles------------------------------------------------------------------------------------OI-5

Wiper operating handle-------------------------------------------------------------------------------------------OI-6

Passenger control panel-------------------------------------------------------------------------------------------OI-8

Safety hatch--------------------------------------------------------------------------------------------------------OI-9

Safety hammer---------------------------------------------------------------------------------------------------OI-10

- 3 -

Contents

VDO 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

Check Pneumatic pressure---------------------------------------------------------------------------------------S-10

Check Tachometer working order-------------------------------------------------------------------------------S-11

Steering wheel play-----------------------------------------------------------------------------------------------S-12

Check tire for abrasion and pressure and tire nut for fixture------------------------------------------------S-13

Air cleaner----------------------------------------------------------------------------------------------------------S-14

General leakages (water, oil, fluids and fuel) -----------------------------------------------------------------S-15

Fastening and state of seat belts---------------------------------------------------------------------------------S-16

Check emergency devices and driver’s tools (fire extinguisher) -------------------------------------------S-17

Windshield wipers and conditions of wiper blades and arms-----------------------------------------------S-18

Electrical rearview mirror----------------------------------------------------------------------------------------S-19

Power steering system--------------------------------------------------------------------------------------------S-20

General state and tension of drive belts------------------------------------------------------------------------S-22

Check level of battery electrolyte-------------------------------------------------------------------------------S-24

Procedures for engine start up-----------------------------------------------------------------------------------S-25

Engine shut down-------------------------------------------------------------------------------------------------S-26

Engine start up and shut down in the engine compartment--------------------------------------------------S-27

Starting the vehicle------------------------------------------------------------------------------------------------S-28

Parking the vehicle------------------------------------------------------------------------------------------------S-29

Vehicle maintenance and service

- 4 -

Contents

General knowledge------------------------------------------------------------------------------------------------M-1

Maintenance of engine and chassis subassembly--------------------------------------------------------------M-1

Body maintenance ------------------------------------------------------------------------------------------------M-1

ABS system maintenance and service --------------------------------------------------------------------------M-1

Electrical system maintenance and notices --------------------------------------------------------------------M-2

Tire transposition--------------------------------------------------------------------------------------------------M-2

Adjustment of the 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

Breaking-in of a new vehicle---------------------------------------------------------------------------------M-9-10

Daily Maintenance Operation ----------------------------------------------------------------------------------M-11

Maintenance per 5000km-----------------------------------------------------------------------------------M-12-14

Maintenance per 10000km--------------------------------------------------------------------------------------M-15

Maintenance per 20000km----------------------------------------------------------------------------------M-16-18

Maintenance per 40000km -----------------------------------------------------------------------------------M-19

Maintenance per 80000km ------------------------------------------------------------------------------M-19

Maintenance more than 80000km ------------------------------------------------------------------------------M-20

Maintenance period chart -----------------------------------------------------------------------------------M-21-25

Common trouble and its eliminating method

Engine Common trouble and elimination ---------------------------------------------------------------C-1

Propeller shaft------------------------------------------------------------------------------------------------------C-8

Transmission--------------------------------------------------------------------------------------------------------C-9

Rear axle-----------------------------------------------------------------------------------------------------------C-10

Front axle and steering system----------------------------------------------------------------------------------C-11

Braking system----------------------------------------------------------------------------------------------------C-14

Electrical equipment and the starting system ---------------------------------------------------------------C-16

Air conditioner system-------------------------------------------------------------------------------------------C-18

- 5 -

Contents

Appendix

Driver's tool table ---------------------------------------------------------------------------------------------- A-1

Tightening moment of the bolts and the nuts in major position ------------------------------------------A-2

Table of lubricant, oil & power steering oil--------------------------------------------------------------------A-3

Air braking schematic diagram (with air suspension) ------------------------------------------------------- A-4

Electrical elementary diagram of vehicle --------------------------------------------------------------------A-5

- 6 -

Technical parameter and complete vehicle description

Technical parameters of the complete vehicle（DF900038）

Product model

Engine model

Engine type

Cylinder diameter× stroke （mm）

Displacement

(ml)

Compression ratio

Rated capacity / rotation speed

(kw/rpm)

Max. torque / rotation speed

(N·m/rpm)

Overall length （mm）

Overall width (mm)

Overall height

（mm）

Air spring

Leaf spring

Wheelbase （mm）

Wheel track front （mm） rear （mm）

Minimum lift-off clearance（mm）

Approach angle/ departure angle (°)

Front overhang / rear overhang （mm）

Rated passenger (driver included) (person)

Kerb weight（kg）

Max. gross mass （kg）

No

Front axle （kg） load Rear axle （kg）

XMQ6130C

ISL8.9E5380

In-line six-cylinder water-cooling direct-injection diesel engine

114X144.5

8900

16.6：1

279/2100

1700/1300-1400

12950

2550

3300

---

6800

1860

1860

180

8.5/7

2700/3450

73+1

13800

19500

4360

9440

Full load

Front axle （kg）

Rear axle （kg）

Max. speed (km/h)

Fuel consumption (L)

Maximum gradeability (%)

Min. turning diameter (m)

Parking slope (20%)

Fuel tank（L）

Engine oil（L）

Transmission lubricant（L）

Main retarder lubricant（L）

Power steering hydraulic oil（L） clutch lubricant（L）

6500

13000

130

--

≥20

≤24

Parking for 5 minutes

300

27.6

23

16

8

0

- 7 -


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..

Chassis data plate

The chassis data plate is on right (or left) lateral surface of the front wheel position of the main sill with vehicle identification number (VIN) on the frame.

Engine data plate

The engine data plate is on top surface or salient top position of the engine, whose position may be various according to different engine manufacturing plant.

The engine number is stamped on the left or right block of the engine, whose position may be various according to different engine manufacturing plant.

- 8 -


Product quality assurance

We insist that the end user should make breaking-in maintenance of the rolling-out new vehicles in their initial driving mileage of 5000 km. The end user must make proper operation and maintenance strictly according to relevant regulations in the instruction book. Please refer to “workshop manual” for product quality assurance and abide by related specification.

Technical document

The instruction book is used combined to the following specification:

Engine operation instruction or service manual

Note: the instruction book should be modified according to specific configuration of vehicle.

- 9 -


Body Structure

1. Structural style

Semi-integral body structure

2. Structure

The bodywork structure adopts closed girder construction of five major assembly parts, which are combined welded by rectangle steel pipes with advantages of strong structural stiffness, torsion resistance and bending resistance as well as relatively simple craftwork. Main components of skeleton have been performed anticorrosion treatment to ensure steady adhesion of coating and strong capacity of antirust and corrosion-proof.

3. Interior trim

The interior adopts flexible design and the floor adopts steel plate/wood block composite construction, and covered with anti-slip and antifriction leather with favorable sound insulation value.

4. Windows

The front windshield is the hyperboloid triplex glass fixed by the gluing; the rear windshields are the hardened glass fixed by the gluing; the side windows are close cycle window which are made of hardened glass. The driver’s window is fixed with sliding window.

5. Baggage compartment

The baggage compartment adopts transverse run-through design, and they are all made of aluminum.

6. Seat

Driver’s seat: Q15-2 type , adjustable seat with high backrest and three-points style seat belts.

Passenger seats: HX type, 3+2 layout, high back , adjustable style, 3 points seat belts.

7. Interior accessory device

The vehicle is equipped with electronic clock, sunshade, safety hammer, emergency escaping window, curtain and luxury bilateral luggage rack F-1，safe door, guiding seat，reversal monitor, Vehicle traveling data recorder ,reading lamp, toilet ,drinking trough, color TV, DVD system, LCD, guide mike .etc.

8. Air-conditioning system

Cooling system: KING LONG top mounted dependent air-conditioning system.

Defroster: NANFENG cooling /heating defrosting device

Heating system: WEBASTO heater system and NANFENG radiator system.

9. Door

The door adopts the full aluminum remote control out-swing pneumatic doors.

The out-swing door adopts the advanced electrically aerodynamic theory design, with the motion of opening and closing placidly、agilely and safely, therefore, keeping credible and anti-clamp function.

A. Basic function a. There are two electrically switches, the interior one is trigger touch-tone, which located on the dashboard of the front right side of the driver, the outside one is a remote control switch. , both switches can control the door. b. When the circuit is in OFF position , the emergency switch can be used in the interior and exterior, the emergency switch of the door is located inwardly upon the entrance of the door and behind the door on the side panel outwardly , Please rotate the switch and throw open the door in emergency. c. Commonly the door is closed, when touch off any electrically switch, the door would move placidly at a certain velocity, along with it, the step-lamp lights .when touch off the switch again , the door would return placidly at a certain velocity, after the door returned , the step-lamp goes out.

- 10 -

4

3

5


6

1 B. Hint: Tyre TPMS 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.

Note: Deployment on the vehicle may be different with the above description because of different deploying requirement of the clients.

Schematic illustration of the driver zone

7

8

9

10

2

11

12

1

13

14

15

1 Seat belt inserting socket

2 Horn

3 Rocker switch

4 Light operation handle

5 Reversal monitor

6 Combination instrument

7 Steering wheel

8 Electric mirrors pushbutton

9 Engine cabin fire extinguisher pushbutton

10 Wiper control handle

11 Power charging socket

12 Parking brake handle

13 Gearbox operation handle

14 WEBASTO A/C and heating operation panel

15 NANFENG radiator operation panel

- 11 -


Instruction of instrument (VDO Edition）

No. Function

1

2

3

ABS indicator

High beam indicator

Left turning indicator

Description

ABS work/warning

When High beam is switched on

When Left turning/hazard switch is turned on

5

6

7

General Error

Right turning indicator

Retarder indicator

When the electrical system has general warning. (see1.2)

When Right turning/hazard switch is turned on

Retarder work/warning

9 DTCO warning communication error or without drivers card

10 Engine Revolution speed too Need to change the gear or slow down the bus high

11 Trip distance reset button Set trip distance to 0

12

13

14

16

17

LCD illumination adjust button Press the button to adjust the illumination of LCD

Fuel level gauge The fuel remain

Coolant temperature gauge Temperature of engine coolant

Speedometer

Tachometer

Current vehicle speed

Current engine speed

CI-1


1.1 Severe error conditions

EDC red lamp; ECAS red lamp; EBS red lamp; coolant level low; battery not charging (after engine starts); worn brake shoes; brake circuit 1/2 pressure low; coolant temperature high; catalyst level low; engine cabin temperature high; oil pressure low (after engine starts).

1.2 General error conditions

Hammer not at right position; ASR error; air filter block; ECAS amber lamp; EBS amber lamp; rear flap open; toilet water level low; steering oil level low; steering oil pressure low; fuel level low; DM1 error; light error; communication error.

2 LCD Display

Press the page switch button, the pages will be displayed by the following sequence. Detailed description is listed as below:

2.3 Driving Information

When the bus is running, this page will show (Figure-1 ): pictogram comments

Figure-1 driving information

pictogram comments

Gear info (see 2.1.1)

Current time (see 2.1.2)

Front door status (see2.1.7)

Mid door status (see 2.1.7)

Fluid fan error

Acceleration pedal position

System voltage (see 2.1.3)

Preheating indicator

Passenger service/request from cabin(see 2.1.9)

Engine red lamp error

CI-2


pictogram comments pictogram comments

Low beam working Engine amber lamp error

Front fog light working

Rear fog light working

Brake light working

Engine Malfunction

Engine wait to start (do not start the engine until this symbol disappear)

EBS red lamp warning

Lift-axle lock EBS amber lamp warning

Steering oil level low

Steering oil pressure low

Coolant temperature high

(>=98°C)

Coolant level low

Rear flap open (can not start the engine)

Worn brake shoes

Hammer not at right position

Function description

2.3.1 Transmission gear Display：

ECAS status (see2.1.8)

Battery not charging (indicate charging error if this symbol still exist after engine starts)

The bar shows brake circuit 1 pressure

The bar shows brake circuit 2 pressure

The bar shows engine oil pressure

The bar shows SCR remain

： current gear is "neutral"；

： current gear is "forward"；

： current gear is "reverse"；

2.3.2 Time：

This information comes from DTCO.

2.3.3 System voltage：

This value shows the battery voltage when generator is not working; and shows the voltage by generator after engine starts.

CI-3


2.3.4 Acceleration pedal position：

Range: 0 – 100 %。

2.3.5 Oil pressure：

This information comes from engine ECU. Before engine starts, the value is 0.

2.3.6 Brake system pressure:

Brake circuits 1 refers to the front brake system pressure.

Brake circuits 2 refers to the rear brake system pressure.

The symbol becomes red if the pressure is too low or if sensor is open-load.

2.3.7 Door status：

: green; means door is open

: yellow; means the cap on the emergency switch is open (either inside or outside)

: brown; means the knob in the emergency switch is moving

2.3.8 ECAS status

： ECAS lift ： kneeling

： ECAS severe error ： ECAS general error

2.3.9 Service request

：

Passenger service request

2.2

Error display Page：

：

Request from cabin

Figure -2 text error information

CI-4


If there is error exists, this page will show after driving information page when you press the page change button.

Description:

Pictogram ： object name;

Text: detailed description of the error;

Errors can be displayed in this page:

 Communication Error: EDC, EBS, TCO, AC, Front node, Top node, Cabin node, Rear node;

 Light Error: high-beam, low-beam, reverse light, front fog light, rear fog light, brake light, turning light

 Other Error: brake circuit pressure open-load, fuel-sensor open-load, Engine cabin too hot, worn brake shoes (1-6), fuel level low, water in toilet level low, air filter block,

2.3 DM1 Diagnosis Information

Figure -3 DM1 display page

This page will show when some ECU sends out DM1 message. The diagnosed ECU must support

CAN diagnosis, and provides SPN-FMI code.

Line1: the object that has error (from SPN).

Line2: Error status (from FMI)

Line ECU: name of the ECU that sends the message (i.e. EDC, EBS, AC)

Line SPN-FMI: the SPN and FMI combination

: means this error is not the last one

Other contents are fixed

CI-5


2.4

Air conditioner status

This page will appear is air conditioner is working and the communication is right.

A/C mode include: ventilation; heating; cooling; demist/defrost; auto mode; off

Set temp: the temperature currently set to be;

Room temp: the real ambient temperature in the bus;

Outer temp: outside temperature;

Evap_speed: OFF; High; Mid; Low

Fan_speed: OFF; High; Low

2.5 Engine Cabin Temperature high warning page

If engine cabin temperature is higher than 85°C, this page will appear automatically. The temperature will show on the page. The driver need to press the page change button to switch to the driving page

CI-6


2.6 Beeper warning conditions

 Brake circuit 1 pressure low

 Brake circuit 2 pressure low

 Coolant level low

 Hammer not at right position

 Engine cabin temperature high

 Oil pressure low (after engine running)

 Service request

 Left turning

 Right turning.

CI-7


Illustration of switch and indicator

Number of switches and indicators and position may vary with vehicle model, please consult the flowing sheet and use correctly according to actual condition of vehicle.

Switch Name

Retarder foot-control switch

Daylight lamp

Hazard lamp

Color

white

Function

Pressed on top: retarder is turned OFF

Pressed on bottom: retarder is turned ON white

Red

Luggage compartment lamp white

Pressed on top: interior lighting ON,

Pressed on bottom: interior lighting OFF when the vehicle have a screw loose, switch it on, the whole vehicle lamps light

Pressed on top: lamp lights ,

Pressed on bottom: lamp goes out

Notes

Charging socket white uncover the plastic lid, connect and charging

Ventilator

Front fog lamp

Rear fog lamp

Defroster

Reading lamp white white

Pressed on top: ventilator is active,

Pressed on bottom: ventilator is turned off

Pressed on top: front fog lamps ON,

Pressed on bottom: front fog lamps OFF white yellow

Pressed on top: windscreen heater ON, windscreen heater OFF white

Pressed on top: rear fog lamps ON,

Pressed on bottom: rear fog lamps OFF

Pressed on top: reading lamp ON, Pressed on bottom: reading lamp OFF

SI-1


Switch Name Color Function

Pressed on top: air horn is active, Pressed on horn white bottom: electric horn is active

Front passenger door white

Pressed on top: open front passenger door;

Pressed on bottom: close front passenger door

Rear passenger door white

Pressed on top: open rear passenger door;

Pressed on bottom: close rear passenger door

Notes

WC power switch white

Pressed on top: WC power turned OFF,

Pressed on bottom: WC power turned ON

Diagnose white press this button to make a diagnosis of engine, when engine indicate trouble

Cruise

Cruise setting white

Pressed on top: cruise function is active,

Pressed on bottom: cruise function isn't we advise clients not to use this switch active white cruise setting we advise clients not to use this switch

SI-2


Switch Name

TV overturn switch

Color Function

white

Pressed on top: expand the TV,

Pressed on bottom: collapse the TV

Notes

Screen page up/down switch white

Pressed on top: page up starting

Pressed on bottom: page down starting

Electric driver window switch white

Pressed on top: the glass getting up;

Pressed on bottom: the glass getting down.

Electric driver window defrosting switch white

Pressed on top: turn on defrosting function;

Pressed on bottom: turn off defrosting function.

Rearview mirror defrosting switch white

Pressed on top: turn on defrosting function;

Pressed on bottom: turn off the defrosting function.

Left side bin gate white

Pressed on top: open the left side bin gate;

Pressed on bottom: close the left side bin gate.

SI-3


Switch Name Color

Right side bin gate white

Function

Pressed on top: open the right side bin gate;

Pressed on bottom: close the right side bin gate.

Notes

Electric sun blind white

Kneeling switch white

Vehicle raise/lower white

Pressed on top: the sun blind getting down;

Pressed on bottom: the sun blind getting up.

Pressed on top: turn on kneeling function;

Pressed on bottom: turn off kneeling function. only use this button

Pressed on top: vehicle raise,

Pressed on bottom: vehicle lower when vehicle is stopping

Engine cabin extinguisher switch red

Pressed on : start engine cabin fire extinguisher;

Brake release switch white

Pressed on top: turn on brake release function;

Pressed on bottom: turn off brake release function.

Slope start switch white

Pressed on top: turn on slope-starting function;

Pressed on bottom: turn off slope-starting function.

SI-4


Air conditioner control panel SK-17-1

（KL-30YA）

Select key introduction:

Power key

Select ensure key

Air speed select key

Fresh air select key

Up key

Down key

Temperature display

Control panel operation:

1) How to use the air conditioner

⑴

Start the engine

Indicator light introduction:

low air speed midterm air speed high air speed

Cooling

Setting Temp

Pressure alarm indicator

Fresh air

⑵

turn ON the cooling switch

，

push

⑶ set the suitable temperature ——the setting temperature will be held automatically

⑷ turn OFF the cooling switch ， push

⑸

stop the unit

for one second.

2) Temperature setting

COOLING——The system begins to cool if the set temperature is lower than the temperature inside the bus

——The system stops cooling if the set temperature is higher than (or equal to) the temperature inside the bus

P-A-1


3) Temperature controlling

Press once

2 5

A U T O display the setting temperature and regulation

Press again

Displaying the temperature inside the bus from the

LCD screen

Automatic setting after 5 seconds

20℃

The lamp of setting the temperature will light up when pressing the button of . The setting temperature will be displayed on the LCD screen. Adjust the temperature with the button of and after setting the temperature, the setting temperature light is off. Otherwise, the LCD screen will display the temperature inside the bus 5 seconds later.

Note：

the scope of setting temperature is from 15.0

℃

to 40.0

℃

the scope of displayed temperature is from -40.0

℃

to 40.0

℃

4) Flow rate selection

Press

→ once

25

℃

Press

→

twice

25

℃

Press

→ three times

25

℃

Press

→

four times

25

℃

5) Automatic flow rate selection

Press the and for 2 seconds then the unit will begin automatic flow rate selection, it will change the flow rate depends on the air return temperature. Then the indication light at the above right light . The flow selection is not work at the moment. Press the and button at the same time for 2 seconds can stop the automatic flow rate selection selection will recover. and the indicator light will stop and the air flow rate

6) Working conditions of the automatic flow rate selection

(including 26.5 ).

Medium air flow rate: the temperature of air-return inside the bus is 24.5—26 .

P-A-2


(including 24 ).

When switching air flow rate by different temperature, the switching confirm time is 30 seconds.

7) Temperature control method

Using ON/OFF mode：the temperature controlling precision （DIF）is 2℃，(FIX

SETTING)

For example: the temperature controlling precision（DIF）is 2℃，The setting temperature is 25 .

When the bus inside temperature is 30 :

The cooling system will be stop (OFF) when the temperature reaching 25 .

The cooling system will be start (ON) for cooling (COOLING) when the temperature is first starting, after this the interval time is 30 seconds.

S etting tem perature

C

25° on cooling m ode

(+ C)

T em perature cycle2° C

(- C)

O F F cooling m ode

25 C 27 C

8) Strong cooling

This function of maintenance is used in the season which the air conditioner does not use（over

2 inside of bus

）

. The goal is provide the lubricant to the shaft sealing ring by the pressure of the working compressor. Normally it works 10 minutes and once or twice every month.

9) Operation of strong cooling for 5 seconds, the temperature

light

10)

Defrosting temperature

The LCD screen will display the defrosting temperature1 or defrosting temperature 2 by pressing the button of or .

P-A-3


11) The part below the LCD screen will flash when the defrosting function working.

2 5 . 5 .

A U T O

D is p la y t h e d e f r o s t in g t e m p e r a t u r e

Note：

⑴

The compressor (COMP) and the condenser (COND) fan will sto p working and the evaporate (EVA) fan will run normally when the system defrosting.

⑵

The operation of the defrosting is automatically Controlled. the defrosting operation begins to work when the temperature of the sensor is(ON) at -1

℃

and stops working

(OFF) at 8 .

12)

Set the fresh air vent function

The LCD screen will display the Vent open (Vn) and the setting time when the button pressed for 5 seconds. The button pressed again to show

VF and the setting time. Adjust the setting time by pressing the button of and to the setting time within 1—60min.（Generally the setting time is 10 minutes）. Press the button

for the confirming of the time setting, or the system will confirm the setting time automatically in 5 seconds. Adjust the setting time by the button and within

1—60min when the LCD screen display VF and the setting time.（Generally the setting time is

30 minutes）. Press the button for the confirming of the time setting or the system will confirm the setting time automatically after 5 seconds.

Note：

Restart the (VENT) switch to carry out the new procedures after the setting.

Otherwise, the previous setting will be carried out again.

Only one parameter can be set for each time.

13). check the power.

Press the 10 seconds, it shows the air conditioner voltage. Press the , it shows the

P-A-4


red line voltage of control panel. Press the ,it shows the voltage of air conditioner generator(when the air conditioner is without generator, it only shows the red line voltage of control panel i.e. the voltage of vehicle generator.)If it isn't operation during this process, it will show the air return temperature after 5 seconds.

14),check and cleanup time

Press the for 12 seconds, it shows the working time of air conditioner. During this process it isn’t operation. After 5 seconds, it shows the air return inlet temperature. When the air conditioner is working, press the be cleanup the time as 0.

and

for 2 seconds at the same time. It can

Note: the working time of air conditioner ,it can be calculated the time as hours since the low flow rate is beginning. That can be added up every working time of turn off the unit and control panel power off . It also can check and clean up the working

time at any alarm condition.

P-H-1


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.

When the ignition switched on, the timer displays the current time and the day of the week.

When the heater is switched on, the display and

the buttons are illuminated.

After the power supply has been connected, all symbols on the display will flash.

The current time and weekday must be set.

2. Operation

The timer can be operated in that all flashing symbols

1. heater “on” indicator

2.

3.

4.

5.

6.

7. day of the week time display memory location alarm indicator time program selection

8.

9. instant heating reverse

10. forward

can be adjusted by means of the 10 and 9 buttons.

If the buttons are not pressed within 5 seconds, the time displayed will be stored.

If the 10 and 9 buttons are pressed for more than

2 seconds, the fast time-setting mode is activated.

11. panel

If the ignition is switched off while the heater is operating in the continuous mode, the remaining operating time of 15 minutes is displayed and the heater continues to operate for this period of time.

3. Switch the heater on

Manually: by pressing the button 8 (continuous heating mode)

Automatically: by programming the heater starting time

4. Switch the heater off

Manually: by pressing the button 8

Automatically: after the programmed operating time has elapsed.

With the heater running: by programming the remaining operating time

5. Setting time/day of the week

Press the 6 button for more than 2 seconds-time of the day if flashing-and set the clock using the 9 and 10 buttons. Day of the week is flashing – adjust the day of the week.

6. Viewing the time

With the ignition switched off: press the 6 button.

7. Programming heater starting time:

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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.

8. Recalling/erasing preset times

Repeatedly press the 6 button until the desired memory location is displayed. To erase the preset time, press the 7 button several times until the time of the day is displayed instead of the memory.

9. Programming duration of operating time The heater must be switched off. Press the 9 button for 3 seconds – operating time is flashing – and set the desired operating time (10 to 120 minutes) using the 9 and 10 buttons.

10. Setting the remaining operating time

Set the desired remaining operating time (1 to 120 minutes) using the 9 and 10 buttons. The remaining operating time refers to the time the heater still continues to remain in operation and the ignition switched off.

11. Setting the wakeup time

A wakeup time can only be programmed on the standard digital timer. The wakeup time is not bound to a specific day of the week.

Repeatedly press the 7 button until the bell symbol appears on the display. Set the desired wakeup time using the 9 and 10 buttons. The alarm clock turns off after 5 minutes or when one of the buttons is pressed.

12. Recalling/erasing the wakeup time

Repeatedly press the 7 button until the bell symbol appears on the display – read off wakeup time. To erase the wakeup time: press the 7 button until the bell symbol is no longer visible on the display.

13. remote control

Possible by means of an optional external “instant heating” button

14. Vehicles with ADR equipment

On ADR vehicles it is not possible to program a preset starting time. The remaining time is shown on the display while the heater is in operation. The clock can be set. The alarm clock function can be programmed on the standard digital timer.

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Transmission application (Voith)

Starting the engine

First apply the parking brake.

No button of the push-button switch may be depressed during starting. Bring all buttons into neutral position by depressing the button marked ’N’: all but-tons are released, the ’N’-button is illuminated.

Under certain conditions it may be possible to start the engine after pressing any button other than the ’N’-button. In that case, however, no gear will be engaged even if the push-button switch indicates this. Make sure you only start the engine after having pressed the ’N’-button.

Driving forward

If your vehicle is equipped with a safeguard against inadvertent gear engagement this facility must be operated first. For that purpose step onto the brake pedal.

Press button ’D’ while the vehicle is at standstill and the engine idling.

When the brake is released now, the bus will start moving.

Note: If the vehicle fails to move off possible reasons may be:

– the accelerator was actuated while selecting a gear,

– the safeguard against inadvertent gear engagement was not released.

Please also consult the operating instructions of the vehicle.

When moving off on a gradient, step on the accelerator before releasing the brake in order to prevent the vehicle rolling back.

Note: Driving in the partial load range rather than at full throttle or kickdown mode will have a positive effect on fuel consumption.

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Driving in kickdown mode

For higher acceleration, depress the accelerator beyond the full-throttle pressure point. This causes the transmission to change gears at a higher speed.

Note: Driving in kickdown mode will increase fuel consumption.

Driving with buttons

1 , 2 or 3 (if available) pressed:

When the transmission hunts between two gears when driving uphill, press the button for the lower of the two gears. This will prevent engagement of the higher gear.

Hunting between gears

4 - 3

3 - 2

2 - 1

Pressing the button

3

2

1

Note: Driving with buttons 1, 2 or 3 pressed will increase fuel consumption.

Breaking

With the DIWA transmission breaking is free of wear.

Actuating the brake pedal or the manual switch for converter brake will apply the converter brake.

Depressing the brake pedal further will apply the service brake.

Please note when braking on a slippery road: the converter brake only acts on the driven wheels.

On vehicles without ABS the converter brake should therefore be disabled when road conditions are poor (e. g. in ice or snow) in order to avoid rear wheel lock-up and a possible loss of control over the vehicle.

Switch off the converter brake via the converter brake switch, if available

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In vehicles equipped with ABS the converter brake switch is mostly not availably. The location of switch and its handling are described in the operating instructions of the vehicle.

Stopping

During short stops (e.g. traffic lights, bus stops) the selected button remains depressed and the vehicle is held by the vehicle wheel brake or the parking brake.

ANS-activation

Automatic Neutral at Standstill:

Conditions for activation of ANS :

– accelerator in idling position,

– brake signal,

– driving speed below 1 km/h,

– forward gear selected.

The power flow between engine and transmission is interrupted.

This results in fuel savings.

Reversing

Press button ’R’ while the vehicle is at standstill and the engine idling and - if available – the reverse gear inhibiter button. A change from ’Forward’ to ’Reverse’ or viceversa is only possible after operation of the ’N’ button.

Never engage reverse gear when moving forward – danger of accident!

Parking

For longer stops or when switching off the engine, switch the transmission to neutral (button ’N’) and apply the parking brake.

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Using ABS （WABCO）

ABS works only in the emergency situation when wheel is going to be locked-up. Generally speaking,

ABS works as a driver frequently “points brake”, but the frequency of the driver “points brake” can not in any case compared with ABS. ABS changes 3-5 times one second.

When driving vehicles equipped with ABS, in emergency situation, you should rapidly step on the brake treadle to the limit position and do not release. The ABS will work to maintain vehicle to be stable and steerable.

Attention

* Keep water away from ECU.

* Multimeter can not be used to measure ECU

* Disconnect ABS when batteries are charged.

* Cut off the power when components are installed and removed.

* Disconnect ABS when carrying on the welding operation.

* Inspect the stability of generator voltage regular.

* Replace the broken ABS warning lamp timely.

* Do not change the insurance capacity arbitrarily.

Note: If the ABS warning lamp lights up during vehicle running, it indicates that ABS malfunction occurs, But the conventional braking still works, the vehicle can be driven safely all the same, however, you ’d better go to the designated servicing station as soon as possible to diagnose and repair ABS. If authorized repair station and vehicle manufacturers can not remove the malfunction, please contact

KING LONG or WABCO

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ECAS System Introduction

2. Basic Introduction

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3 System Function:

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Open/close the passage door.

1. Before leaving the vehicle, press the button 1 of the door remote controller to close the door.

1 2

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.

3. If need open the passage door, insert key into the hole 3 and clockwise rotate it about 90°, then clockwise rotate handle 4, follow press the button

2, after that the door would be opened.

Appendix:

The following are all type of door lock and door remote controller of King-Long.

3

4

Lock1

Lock 2

Lock 3

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Door remote controller 1 Door remote controller 2

Door emergency switch

The model 1 door emergency switch is located on right underside of the ingress.

The model 2 door emergency switch is located on right upside of the door.

The model 3 door emergency switch is located inside the door pump cover which is on the top of the door.

Please rotate the switch and throw open the door in emergency.

Special attention: The door emergency switch is only used in the emergency mode. Please don't rotate the door emergency switch in driving for fear of danger.

Model 1

Model 2

Model 3

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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

Note: Number of handles varies with vehicle model

Attention!

The seat should not be adjusted during driving

to ensure driving safety.

Adjust the steering wheel only when the vehicle is stopped and the parking brake is on.

1

2

3

4

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Horn button

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.

Model 1

Model 2

1

1

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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 and the parking brake is on.

After adjusting, press the regulating handle or button down in order to lock the steering column.

1

2

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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" position automatically after the startup

.

Before starting the engine, turn the key to the “ACC” position and then to the “ON” position. At this point, three lights (red, yellow and green) on the dashboard will come on.

Wait for the lights to go out completely before you start the engine. However, make sure that all of the self-check lights have gone out completely before starting the engine. Allow the engine to run at idle speed for three to five minutes after it has been started; but never let it run for more than 10 minutes at idle speed. If the vehicle does not move, increase the fuel to the throttle modestly to increase the rotational speed of the engine a little; this will also prevent the early wear and tear of the engine. Allow the engine to run at idle speed for three to five minutes before turning it off.

Note：

1. If the first attempt to start the engine is not successful, please wait two minutes before trying again.

2. If the engine fails to start after three attempts, check the fuel supply system. If the vehicle runs on natural gas, check the gas supply system.

Attention!

1. Do not remove the ignition key while the vehicle is in movement. And the ignition key should be turned to the LOCK position only after the engine shut down.

2. When leaving the vehicle, even for a short period, take the key out to avoid operation of the vehicle by children or unauthorized persons.

1

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Lamplight operating handles

The lamplight operating handle is located on left underside of the steering wheel, which control the front small light, headlamp, headlamp dimming, left and right steering by two different motion modes

OFF Indicating that the headlamp and the small lamp are all off.

Model 1

Model 2

Is the small lamp indication. The small lamp, the instrument light and the side indicator lamp will all be turned on when anti-clockwise rotating the handle by left hand to position of this identification.

Is the Is the headlamp indication. The headlamp, small lamp, meter lamp and width lamp will all be turned on when continuously anti-clockwise rotating the handle by left hand to position of this identification.

Is the turning indication. By back and forth motions of the operating handle may control the left and right turning lamp and that on the dashboard.

Is dimming indication. By up and down motions of the operating handle gently may actuate the headlamp dimming.

Note：

It’s important to dip the lights promptly when approaching an upcoming vehicle in order to avoid dazzling its driver with the high beam of the headlight.

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Wiper operating handle

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 1 (with retarder)

Model 2 (with exhaust brake)

The wiper may spray water by pressing the end of the handle.

The shifts of the retarder may be converted by back and forth motion of the handle.

Note: do not actuate the wiper without water; press the washer button as needed, then actuate the wiper.

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Passenger control panel instruction

1. air outlet

2. service button

3. reading lamp button

4. lamp

5. loudhailer

6. stop button

Model 4

Model 1

Model 5

1 2 3 4

Model 2

4 6 2 1

1 4 2

Model 6

5

5

Model 3

4 1 2 3

2 3 1 4

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Safety hatch

The safety hatch is located on ceiling of the vehicle.

Please open the safety hatch according to the above diagrammatic representation and illustration for escaping in case of danger.

Model 1

Model 2

Model 3

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Safety hammer

The safety hammer is located on the side column among window.

Please take down the safety hammer and smash the safety window for escaping in case of danger.

Model 1

Model 2 the side

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VDO module


Installation position

1.Central control electric box

installed the step wall behind of driver seat

2.Body module 1

(front control unit)

installed the step wall behind of driver seat

3.Body module 2

(ceiling control unit)

installed in the air duct over the

RH /FR passenger seats

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4.Body module 3-4

(middle &rear control unit)

5.Retarder control unit

6.WABCO ABS control unit

installed in cabin box at the RH RR

installed the step wall behind of driver seat.

installed on the wall of luggage cabin.

7.Instrument control unit

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installed in dash board.


VDO Module function description.

Part A

Name: ZR 32-A

Function description:

It is the central computer of VDO bus CAN system.

ZR 32-A can receive, transmit and deal with message from power train, cluster and nodes. It also has a few of input and output pins.

Part B

Name: MUX2-B


It is the one node of four VDO nodes in our vehicle.

It collects input signals of digital and analog and to control the electric devices, lights, etc.

Part C

Name: WABCO ABS ECU


ECU receive and deal with the signal from the ABS sensor, then transmit to ABS magnetic valve. ABS magnetic valve control the brake pressure by this signal.

Part D

Name: DC/DC convertor


Change the whole vehicle voltage 24V into 12V for the cigarette lighting. There are two convertors for two cigarette lighters .

Part E

There are nine relays and some fuses. The relays are horn relay, wiper relay, ON electric power

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relay, ACC electric power relay, air condition relay and four UPL system’s relay. Their names have been marked on the wire. The capacity and the name of fuses also could be found on the fuse box cover or the

King Long Instrument Wiring

Harness.

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Switch control box (Model: CQ2025)

CQ2025 A wiring diagram (Printed on opposite cover of the switch control box)

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The hydraulic fan mechanism

This system should be made to drive the fan’s rotation through pressure yielded from hydraulic oil.

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Vehicle Starting and Driving

Preparatives for vehicle operation start up:

Check daily, before turning engine on:

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. Provide immediately for the oil replenishment to its correct level.

The oil level should always be checked with the vehicle parked on level ground, before starting the engine up, or at least 5 minutes after having shut it down.

Open the engine compartment hood.

Take out the oil dipstick, and clean it with a clean cloth without loose threads, and put it back into its place fitting it in completely.

Once again pull out the dipstick and check the oil level. a. The oil should not exceed the maximum level.. drain the excess. b. If the oil is at operational level, do not add more oil to the crankcase. c. If the oil is at or below the minimum level, add the same type and brand of oil to the crankcase as that already there, until reaching the maximum level..

After the checking, replace and fit the dipstick completely back into its place.

If the oil level is checked after the engine has been run for a period of time, then it should take at least five minutes before the measure to ensure the oil back flow to the oil sump in full.

Oil level dipstick

Oil inlet

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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.

Check the coolant level only when the engine doesn’t work and its temperature is below 50℃.

The anti-freezing rust-inhibiting engine coolant level can be observed from the observe pipe.

The coolant level should be between the maximum level (MAX.) and minimum (MIN.) level indicators in the expansion water tank.

If it is necessary to add coolant to the system: a. Place the heating system command in the position of maximum heating potency. b. Add the coolant to the system up until the maximum level indication. Only use coolant which is recommended. c. The expansion water tank cover should not be opened when temperature of the coolant is still high to avoid being scalded Place the lid on the system and turn it to the limit. d. Pressure valve of the expansion water tank should be opened when adding the coolant to eliminate

Observe pipe

Observe pipe air in coolant pipeline of the diesel engine. e. Run the engine for a short time at varied rotations. f. Stop the engine and check the coolant level.

If necessary add more coolant to the system

Coolant (mixture of glycol and water) should be added to cooling system from time to time to avoid sediment, frost, oxidation and could increase boiling point as well as decrease ice point.

Note: When adding coolant, please choose the same model to avoid sediment. If coolant is degenerative, replace it immediately.

Coolant choosing should be selected products produced by normal factories according to requirement.

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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.

When the accumulation of impurities in the lower cup is noticed, take the vehicle to a workshop to carry out its cleaning.

Changing the fuel pre-filtering element

The fuel filtering element should be replaced periodically, at the intervals recommended in the maintenance manual.

If however, the filtering element is easily saturated and need to be replace at very short intervals, this is an indication of the accumulation of impurities in the interior of the fuel tank, and the cleaning operation should be carried out.

In order to replace the fuel filter element, take the vehicle to a Dealer or a King-Long Workshop.

Fuel system discharge

Activate the manual pump until feeling resistance on pumping.

Start up the engine without accelerating. If the engine does not start running in 20 seconds, interrupt the startup and wait at least one minute before trying again.

Manual pump

If the engine insists on not working, repeat the discharge operation.

Leave the engine running for about a minute to completely eliminate the air from the system by way of the auto-discharge system.

In order to reduce environment pollution problems, do not drain the residues accumulated in the water separator directly into Nature (rivers, lakes or soil). The drained residues should be collected in appropriate containers and taken to receiving centers to have proper final destination (see local legislation).

Model for Euro IV, V

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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. Ensure sealing performance of fuel tank and before opening fuel tank, wipe up clay and dirt.

Before filling up, shut down engine.

Do not drive vehicle without fuel. When the level indicator is on the red bar, refuel the vehicle to avoid air from entering the fuel system.

Fill the tank only with good quality fuel free of contaminants.

The fuel might as well be filled up when running in the humid area to avoid inner rustiness.

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5. Vehicle lighting, intermittent lights and brake lights

Check all instruments and indicating lamps for normal or not, 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 damage or not. To carry out the lamp substitution, hands should be very clean. If possible handle new lamps with tissue paper.

Clean the external of all instruments and indicating lamps to ensure clear indication.

Attention!

The traffic laws regulate the location, lighting intensity, and color of the lenses and the quantity of lamps for each type of vehicle. The King-Long end products definitely must be in conform with these regulations. In view of traffic safety factors; therefore do not change the place of the lamps in vehicle.

Substitute the damaged lamps only for other new genuine ones. Remember that a change of lamps colors can confuse other motorists and result in serious accidents. Avoid unnecessary lamps adaptations.

When substituting lamps, use the new same type and potency as the original old lamps. Do not carry out any lamp adaptation especially in the headlights, as this will affect their operation and performance, putting the vehicle at risk.

On a regular basis revise the illumination system, keeping it always in perfect working conditions.

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6. Check the level of AdBlue and the daily maintenance of SCR system

(1) Check the level of AdBlue.

The volume 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.

The AdBlue consumption is about 5 percent and 7 percent of the fuel consumption in EURO IV emission engine and EURO V emission engine respectively. If the remain volume of AdBlue is less than 12%, the lamp 1 will flash and you need add AdBlue. If the remain volume of AdBlue is less than 6%, this lamp will light and the power of engine will be declined forcibly. This will cause the emission substandard and it is not good to engine.

(2) The daily maintenance of SCR system

1

Please add the AdBlue when it is insufficiency. Ensure the AdBlue meet the requirement. Check the SCR system is well enough and has no leaking before driving. There is obvious add mark in AdBlue tank. If add substandard AdBlue, must stop the vehicle right now and clean the AdBlue tank, re-filling the qualified AdBlue. The air filter should be clean and replace regularly.

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Special attention:

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.

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7.

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)

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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

2

) along with the increment of the oil temperature as well as the normal engine speed.

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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.

The STOP warning light will comes on in case of low brake pressure in the service brake circuits.

Attention!

If the driver information indicator displays the warning “brake pressure” and the STOP warning light comes on with the engine running, it will be an indication that the air pressure is excessively low. Do not drive the vehicle in this condition, as the service brake fail will resulting in serious accident.

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3. Tachometer working order

Indications on tachometer scale: a. Green zone – operating range of maximum performance, economic range. b. Yellow zone – exhaust brake using range c. Red zone – engine overspeed range (risk of immediate engine damage)

Always observe tachometer while driving the vehicle.

Whenever possible keep engine running within the economical range.

On downgrade, select an adequate gearbox speed ratio and monitor vehicle speed to avoid engine operating in the danger range (red zone).

When the exhaust-brake is being operated on down grades, select an adequate gearbox speed ratio to keep engine speed within efficient exhaust-brake operation （yellow）.

Always avoid engine over revving (red zone), as engine operation in this speed range can end up the engine damage immediately or will seriously jeopardize its durability.

The yellow range with red reticle can be used occasionally when the exhaust-brake needs to be used at its efficiency limit, however, at risk of engine durability. Therefore, do not operate in this range in a normal or usual way.

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4. Steering play

Steering wheel play

Run the engine at idle state and straighten the front wheels forwards.

Turn the steering wheel alternatively to the right and to the left.

The steering play (free stroke of the steering wheel) is measured by rotation-angle on the perimeter of the steering wheel and should be 20 or 30 angles.

A

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Check periodically, at least once a week:

1. Check tire pressure ,tire abrasion and tire nut for fixture

The vehicle’s safety and performance depend considerably on the state of the tires, that is why they should be checked as usual.

Before driving a vehicle, check if tire pressure is normal , if tire abrasion is serious and if tire nut is tighten.

Note: At the initial 50km, please tighten tire nuts of new vehicle according to specified torque in appendix.

Tire pressure

Keep the tires always correctly calibrated. The inflation pressure of the wheel tires should be checked at least once a week.

After driving the vehicle for some time, the tires begin heat , in consequence ,the inflation pressure increases accordingly. Under the circumstance, never measure the tire inflation pressure until returning the tire’s normal temperature to reestablish the recommended inflation pressure.

The pressure difference between the assembled tires on the same axles should not be superior to 0.1 bar.

Wheel hubs

Keep them always clean, eliminating eventual mud or other dirt adherence. Substitute the damaged and/or deformed hubs. The utilization of refurbished hubs is not recommended.

Wheel tire nut

With re-tightening the wheel tire fastening nuts of new vehicles after running 50km.

The wheel fastening nuts should be retightened, crosswise, in turns, observing the recommended tightening torque according to the type of fastening nut. If a torque meter is not available, tighten the nuts firmly, only using the vehicle tools without the other additional items.

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2. Air cleaner (activate the dust discharge valve to loosen accumulated dust)

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

Model 1 the saturation of the element.

The cleaning of the main and safety filtering elements is not recommended. The re-utilization of the filtering elements can result in deficient filtering of the air and cause serious damage to the engine.

When washing the engine, conveniently protect the air inlet with a plastic or similar material to avoid the infiltration of water to the air filtering element. After washing the engine, remove the protection from the air inlet.

Periodically press the dust discharge valve with your hand, remove the dust which possibly be caught in the internal part so as to keep them clear.

At the same time, check clip connecting rubber hose of air intake system with steel tube in case of dust entering air intake system due to looseness and decreasing engine life.

. If the indication of saturated air cleaner appears in the display of digital indicator in combination instrument, drive the vehicle to a King-Long Dealer or authorized workshop to inspect and clean the air

Model II intake system and substitute the main filtering element.

1 automatic dust discharge valve

Note:

The main filtering element of the air filter should be substitutes after maximum 2 years use.

The safety filtering element (optional) should be changed at every main filtering element substitution, or after maximum 2 years of use.

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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.

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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;

● The vehicle makes an emergency braking or an abrupt acceleration;

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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 desk in the driver compartment where people could operate it easily.

Operation：1. When the engine compartment caught fire, the driver should stop vehicle and switch off engine immediately, open the fire button cover, and press the fire button, start-up fire extinguisher

2.Fire extinguisher may start-up automatically when it catches fire or its temperature arrives at 170℃.

Important hint:

1. Fire extinguisher can be used for one time only,

DO NOT press the fire button except for emergency condition.

2. The fire extinguisher can not start–up by press the

fire button manually if the vehicle battery is dead or power turn off.

3. If the vehicle needs to be repaired, you could take away the anode and the cathode. And put them back after the reparation completed.

Inner fire extinguisher is fixed under the passenger’s chair, when vehicle caught fire, stop vehicle and use the fire extinguisher.

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Fire button


6. Working order of windshield wipers and conditions of wiper blades and arms

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. Before activating the wipers, push the head of the wiper lever inward to spray detergent onto the windshield.

Check surplus of detergent

Stop vehicle on a flat road, open side cover of instrument desk.

Container of detergent is located inside instrument desk. If detergent is insufficient, add.

Add the clean water into the tank for windshield washer.

There are 2 kinds of water tank.

Model 1

Model 2

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7. Electrical rearview mirror

Check, adjust and clean the rearview mirror.

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.

Model 2

L: adjusting left rearview mirror.

R: adjusting right rearview mirror.

Mirror button: rotate the handle to adjust the mirror for

4 directions.

Model 1

Model 2

Model 3

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Inspection every two weeks before and after driving

1. Power steering

Ensure that all the maintenance service jobs on the steering system be carried out at the intervals recommended in the maintenance manual to guaranty total efficiency and safety.

If any working abnormality in the steering is noticed, immediately supply the necessary repairs.

The habits of forcing the steering too far against wheel obstacles and of activating the steering while the vehicle is stopped are harmful to the steering system and should be avoided.

In emergencies, in the case of damage to the power steering system, the steering may be used without hydraulic help, however, in this condition there will be more steering wheel play and the steering will become noticeably “heavier”. Drive the vehicle very carefully and take it to an authorized

King-Long Dealer or Workshop to re-establish the correct working order of the steering system.

Important: In the case of damage to the hydraulic steering pump or of the total loss of fluid from the hydraulic system, we recommend that the vehicle is not driven further than

50KM in order to avoid further damage to the steering system components.

Power steering fluid level

The power steering fluid level should be checked while the engine is running at idle and the fluid is hot. Run the engine at idle gear and turn the steering from side to side various times to heat the steering system fluid.

Check the level through the inspect window of the container.

Model 1

Model 2

Model 3

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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.

The checking, adjustment or substitution of the drive belts should be carried out with the engine shut down.

Check cross plane of the belt for no cracks. Crackle in the transverse direction (along the belt width direction) is acceptable while that in longitudinal direction and transverse crack cross is unacceptable.

Please replace the strap in case of abrasion or chip dropping off.

Too tight or too loose belt would make against proper operation of engine. Press belt to check tension.

Please refer to the manual book of engine assembly for detailed adjusting method and tension of belt.

The poli-V belts demand technical knowledge, therefore we recommend that this job, when necessary, be carried out at a King-Long authorized Dealer or Workshop.

Ventilator drive belts

If it is necessary to replace the ventilator drive belts in emergency situations, adjust their tension in such a way that upon pressing them with one’s thumb in the middle of the distance between the pulleys, a defection of approximately 20mm is observed. Loosen fastening nut of intermediary pulley before turning the adjusting bolt. After adjusting ventilator belt tension, tighten the fastening nut of intermediary pulley firmly.

2

4

Model :

Adjusting method of the fan belt is shown in the figure

1. Check tension of belt

Apply force of 98N by the finger.

Strap sinkage between the crank pulley 4 and the counter pulley 2 should be 25 ~ 31mm.

2. Adjust tension of cone belt

Adjust bolt 3 and counter pulley 2 up and down until the tension is proper.

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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.

1 2

4

Adjusting method of the air conditioner belt is shown in the figure

1 Check tension of belt

Apply 98N force to belt with finger

Belt crank pulley 4 and middle pulley 2 should lower 10～15mm

2. Adjust tension of cone belt

Adjust nut 1until tension of belt is proper

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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.

2

3

Battery

The battery compartment is located at the second compartment of left or right rear side.

1

4 battery switch control box main power switch inverter

2

3

4

1

To access the battery, open the switch control box panel.

After the vehicle has been parked for the day, the main power switch should be turned off.

Cleaning

Keep the batteries always externally clean and the air vent unobstructed. Avoid battery contact with petroleum derived products.

Charge

Do not allow batteries to maintain a charge inferior to 75% of the total charge.

Do not submit the batteries to excessive overcharges of discharges.

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Engine start up and shut down

Procedures for engine start up

Activate parking brake.

Place the gear box lever in neutral. Start up is not possible in gear position.

Turn the ignition key into gear position.

Start up without stepping on the accelerator. If the engine does not work after about 20 seconds, interrupt the start up process and wait at least 15 seconds before activating start again. To repeat start up, it is necessary to turn the key back to the off position.

Let the ignition key loose as soon as the engine starts running.

The motor rotation adjusts itself automatically in function of the coolant temperature.

Indication:

The start up process is automatically interrupted after 90 seconds of continuous activation. In this case, in order to repeat the start up activation, turn the ignition key back to the off position and wait at least 2 minutes.

After engine start up, the vehicle can be put immediately into operation.

Note： a. The engine should be running at low middle speed for 3-5 minutes on every day's first starting before the driving. b. Never race the engine without warming up. During cold start, increase engine speed slowly and do not make engine run at maximum speed until water temperature of engine reaches to 70°C. At any time, do not make engine run at high speed under no load. c. Never make engine run at idle speed for more than 10 minutes. d. The oil pressure should be displayed on the dashboard in 15 seconds after the engine is started, otherwise, stop engine to check.. e. If parking brake indicator lights, indicating that parking brake has not be released.

Attention!

If on starting up the engine, the engine oil pressure indicator continues indicating low pressure, this means that the engine running order is in danger. Immediately shut down engine, find and correct the failure.

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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. The stalling should be made only after the engine has been running for a period of time and the water temperature lowed to the normal range. The parking brake is achieved by setting the hand brake handle on the control position after the stalling. The shift should be switched to the neutral position and power supply shut down. Please make necessary inspection of engine and then troubleshoot.

Cautions

Cautions during the winter operation

① Please add long life coolant to cooling system.

②

After parking, please exhaust water in air tank in time.

③

Before winter comes, please check level of battery electrolyte, specific gravity and voltage.

Water used in the radiator must be soften.

Never make engine start without preheating or run with trouble. In the cold climate, do not start engine until preheat it with hot water or vapor to more than 30-40ºC.

During driving downhill, do not place gearshift lever in neutral position to slip. Please apply exhaust brake or retarder.

Do not start vehicle until parking brake has been released

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Engine start up and shut down in the engine compartment

Park the vehicle and activate the parking brake.

Put the gear box lever or the automatic transmission selector in neutral (dead point).

If the transmission is in gear position, the start up with in the engine compartment will not work.

Turn the ignition key to gear position, without activating engine start up.

Engine start up

Press the start up switch (start) and activate the back cover course end switch bar in the engine compartment.

Loosen the switches immediately the engine begins running.

When the engine is turned on by way of the start up switch in the engine compartment, this switch should be used as a manual accelerator.

With the engine compartment cover open, the start up by way of the ignition key is impossible.

Engine shut down:

Press the shut down switch (STOP).

To make the engine turn without starting up:

Press the engine start up and shut down buttons simultaneously.

Note: the final placement of the switches in the engine compartment is the responsibility of the vehicle body manufacturer.

Model 1

Model 2

Model 3

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Starting the vehicle

The vehicle could only be started when braking system pressure has reached 5kg/cm

2

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. Please make the startup in shift I.

On normal running condition:

 Pointer of oil gauge should be between 0.3 and 0.5Mpa（3-5kg/cm

2

）

.

 Pointer of water temperature gauge should be between 83℃ and 95℃.

 Pointer of double-pointer barometer should be between 0.55 and 0.8 Mpa（5.5-8kg/cm

2

）

After the vehicle starting, gear shifting should be made step by step and timely. The clutch pedal should not be released abruptly to impulse the starting when the vehicle is stuck in the mud or can not start on a spoil road.

The following problems should also be paid attention to during the driving

① If abnormal noise or odor occurs, please stop vehicle to check.

② Abrupt acceleration or emergency braking should be avoided as might.

③

Don't put foot on the clutch pedal during the driving.

④

Avoid engine overspeed. When driving long downhill, engine may overspeed easily after gearshift, at this time, pay attention to apply exhaust brake or retarder and driving brake to ensure engine run at specified speed.

⑤ During driving downhill, never stop engine, otherwise, resulting in de-pressure in brake pipeline and power steering gear failure.

During normal running condition，if the pointer of water temperature gauge is under the red sign that indicated the vehicle is on normal condition. if the pointer is on “H”

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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.

When parking on public highways, obey the legal determinations as far as the use of parking lights or reflecting panels.

Parking brake handle

Pushing forward the brake handle is of driving state.

Pushing backward the brake handle is of parking state.

Always activate the parking brake when the vehicle is parked.

Besides activating the parking brake, when parking on upward or downward slopes, wedge one of the vehicle wheels to avoid the accidental moving of the vehicle.

Application

Attention!

On applying the parking brake, always check the locking of the lever in the total braking position, on the contrary, the lever may return automatically to the brake off position.

Pull back the parking brake valve lever in such a way that the lever is locked in total braking position. The parking brake warning light should light up.

Note:

In emergencies, with the possible failure of the service brake, the parking brake can be used as an emergency brake. In this case, slowly pull the parking brake lever allowing for a progressive braking without abruptly locking the wheels.

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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.

King-long Bus General Maintenance

Please make periodic inspection and maintenance of bus according to the operation manual to ensure good status. During service, stop bus on a horizontal road and ensure bus steady and engine stopping. Make functional inspection and running test after each service.

Important Notice: If bus often runs under poor conditions (such as poor road surface, high dust concentration, frequent bump etc.), maintenance interval should be shortened. During adding lubricant, before replacing filter or repairing, clean the place around related parts carefully. Please add lubricant with clean containers.

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.

•

For use and maintenance of other parts of chassis, if without special user’s guide or maintenance period, please refer to this manual for maintenance information.

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. Prohibit washing body paint with hot water, buck, kerosene and other liquid which has damage to oil paint.

4. Check connections between body and frame frequently. If find something abnormal, repair it in time.

5. Frequently check fasteners inside vehicle and tighten them in time.

6. Frequently check conditions of passenger door. If find something abnormal, do adjustment in time.

7. Frequently check conditions of all lamps. If find any damage, replace it in time.

ABS system maintenance and service:

1. 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.

2. When the vehicle need electric welding, cut off the ECU .never use the multimeter to measure the ECU box.

3. Inspect the engine voltage for stabilization periodically.

M-1


4. 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.

5. Make sure that the power is in off position when remove and install the components, keep the components clean and dry.

6. Never change the fuse capability or connect the fuse in disorder.

7. Change the indicator in time when it doesn’t work.

8. Do not brush the ECU with water when cleaning it.

Note: for details about the working theory of ABS and maintenance, please refer to the ABS instruction book which is offered by provider.

Because of different allocation requirements, some of the vehicle model may not be equipped with ABS system, please use correctly according to actual condition of vehicle.

Electrical system maintenance and service:

(1) When battery is charged by external power supply, disconnect ECU control box 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.

(4) Parts dismantling must be carried out after electric has been shut off and should keep parts’ cleanness and dry.

(5) Don’t change fuse capacity casually or bestride connect fuse.

(6) When indicator doesn’t work, replace it timely.

(7) Don’t use water to scour ECU when doing ECU cleanness.

(8) Don’t use multimeter to measure ECU.

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.

Tire transposition diagram (two axles)

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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. The value should be between 8mm and 12mm. After adjustment, lock the locknut.

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.

• Don’t pour water onto electrical equipment in order not to damage it.

M-3


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.

Dirty air filter would lead to deficient power and engine worn. In order to assure the life and normal operation of engine, please perform periodic maintenance on air filter.

Check and maintain air filter every 2000km. Under some conditions, such as heavy dust and etc., interval time should be shortened.

The engine must be stalled during the air intake system maintaining and the engine should not be started after withdrawing the filter.

(1) Remove butterfly nut on cover cap and take down cover cap and then take out filter element

(2) Clean interior of the cover and the housing with a clean and dry napery. when cleaning the filter cartridge. prevent the water from entering the air filter.

(3) Exclude dust in unloading valve.

(4) The filter element may be cleaned by hand or by tapping the end surface with a wood bar or blowed by compressed air . Also wash with lotion. But take care not to break element.

Blow with compressed air: blow the filter element from inside to the outside with the dry compressed air of the pressure not exceeding 5bar until there has no dust blown out.

Caution: Outside surface of the filter cartridge should be cleaned with cloth instead of blown with compressed air.

Wet washing: Put filter element in lukewarm containing general cleaning agent and swing it and then clean with fresh water and dry it after dehydration.

Hint: Before wet washing, blow filter element clean.

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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.

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. In order to avoid damage to air radiator fin or water radiator fin, ensure spray of air, water or vapor perpendicular to radiator surface.

It should be sent to the king-long special maintenance station to make decontamination and final disposal if there has much dirt in the water radiator and the air radiator.

1. Clean water radiator fin and air radiator fin termly and eliminate dirt blocking air flow, which is important for ensuring the engine cooling.

2. For zone with many winged insect, please clean radiator fin frequently.

3. If users do not operate according to requirement, resulting in poor engine cooling and grave damage to components.

4. If don’t comply with this requirement, it may cause poor engine cooling and bad damage to components.

5. Anti-freeze and antirust solution (mixture of glycol and water) should be added to cooling system perennially to avoid sediment, frost, oxidation and increase boiling point.

Note: When adding coolant, please choose the same model as much as possible in case of sediment. If coolant is degenerative, replace it entirely and immediately.

6

．Never use water to replace coolant for a long period.

After long running of engine, scale will come into being in cooling system. It should be eliminated in time. Methods as follows: mix 700-800g caustic soda with 150g kerosene and then inject the mixed liquid into cooling water and 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 clean water.

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.

After long operation of engine, please eliminate scale in cooling system in time. Methods as shown

M-5


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:

Content of glycol Pure water Additive

℃

58% 10%

℃ 54% 10%

℃

50% 10%

℃ 46% 10%

℃

42% 10%

℃ 38% 10%

℃

34% 10%

℃ 30% 10%

Fuel recommendation

1. Diesel oil (only apply to diesel vehicle) : only diesel oil 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. No. 0 light diesel oil: Suitable for the zone where venture rate is 10％ and minimum temperature is higher than 4°C.

3. No.-10 light diesel oil: Suitable for the zone where venture rate is 10 percent and minimum temperature is more than -5°C.



6. Natural gas (only apply to Natural Gas Vehicle ):use natural gas of which methane value is low to 65.

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. Engine oil must be replaced in certain period because of high temperature effect and the oil combustion product interfusing in the oil, especially the chemical additive in the oil will cause

"abrasion" of the oil. This kind of abrasion depends on working condition of engine, quality of fuel and engine oil; therefore there has different oil changing interval. (Recommended oil changing interval is 12000km.)

M-6


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.

 Higher sticky engine oil may cause the engine difficult to start, so the ambient temperature of the engine starting is the main reference for selecting viscosity of the winter engine oil. Selecting multifunctional engine oil may avoid oil changing caused by temperature fluctuation.

HINT:

Never add any additive to above engine oil and different kinds of oil should be avoided using at the same time (oil mixture must be the same grade oil and it is recommended to replace in time).

Gear oil:

Recommended gear oil is ATF220

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.

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Power steering hydraulic oil:

Fulfill standard: Generai Allison C-3. When ambient temperature is low than 10°C, please apply

DEXRON-II hydraulic fluid to steering gear; when ambient temperature is higher than 10°C, please apply C-3/10W hydraulic fluid. C-3/10W grade oil can be used in most area .all-year generally. C-3/30 grade oil can be used in non-cold area all-year generally.

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.

Chassis grease:

 Grease added in each part should use 2

＃ lithium base lubricant (suitable for temperature within the range of -30~ +120℃).



Vehicle with centralized lubrication should use 0# lithium base lubricant.

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. Freezing point of the coolant should be noticed to 5℃ lower than the lowest environment temperature. Different type of coolant should not be mixed using.

 Replacing period of the coolant is 2 years.

For specification of the coolant please see the section "filling up coolant” in the chapter "maintenance and service ".

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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. Given break-in mileage of the new vehicle is 5,000 km, please run at speed under 100 km/h in breaking-in period.

Preparation before breaking-in of the new vehicle

1. Wash the vehicle and check connection and tight situation of each place.

2. Check coolant storage in radiator and check each place of cooling system for leakage.

3. Check oil level of engine, clutch control system, transmission, drive axle, steering gear and clutch oil storage tank. If deficient, add and then check each place for leakage.

4. Check and see if braking system works properly and leakage phenomenon exists at connections of all valves and pipelines.

5. Check and see if phenomenon of loosing or clogging exists at each place of steering system.

6. Check and see if electric equipments, lamps and the instruments work properly and check battery electrolyte level.

7. Check whether tire pressure has meet requirement.

8. Check and see if each transmission gear can engage properly.

Maintenance during breaking-in period

1. Running on smooth and good road surface.

2. Drive properly and engage the clutch smoothly. Gear shifting smoothly and impact is not allowed.

Neutral gear sliding is forbidden while engine stop. Emergency brake should occur as few as possible.

3. Speed limitation during breaking-in period: first gear≤10km/h, second gear≤20km/h, third gear≤30km/h, fourth gear≤50km/h, fifth gear≤60km/h, overspeed gear using can not be permitted during breaking-in period .

4. Load limit: No load within 250km and never overload after 250km.

5. Often pay attention to the temperature of transmission, drive axle, wheel hub and brake drum. If overheating severely, find out causes and eliminate in time .

6. Pay more attention to keep the pressure of engine oil and the temperature of engine coolant within the normal range.

Maintenance after breaking-in period

1. Tighten cylinder head and bolts (inc suspension). Tighten torque please refer to corresponding instruction. Tighten torques please refer to corresponding instructions.

2. Check valve clearance.

3. Check lubricant level of final drive and clean ventilation plug.

4. Replace engine oil、axle oil and oil filter element.

5. Replace hydraulic oil and oil tank filter of power steering hydraulic system.

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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.

10. Check hydraulic system components of steering mechanism for fixing and tightness

11. Lubricate and maintain vehicle according to maintain items at 5,000km.

12. Check complete vehicle for oil, water and air leakage.

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Daily Maintenance Operation

System Item

Engine

Air cleaner Check

No leakage, damage, and crack.

Clips without looseness.

Fuel-water separator

Drain

Release the water and fouling

Cooling fan air inlet/ outlet piping

Inspect

Maintenance check

Do not pull or lever the cooling fan for starting the engine.

No crack, looseness, bend or damage.

Pipes without wear and damage, clips without looseness prevent the air leakage.

Do not remove the water tank cover, unless the temperature i less than 50℃, otherwise, it’s dangerous for operator

Coolant level Check

Do not add the cold coolant into the hot engine, unless the engine temperature is less than 50℃

Do not start engine when oil level less than “L” or more than

“H”.

Engine oil level

Vehicle parking level, check the oil after engine stops for 5 minutes

Drive belt

Crankcase

Check / correct No across crack, wear or material break off

Check the breather tube in cold winter, cleanup the ice

Check blocking. breather tube

Engine and

Accessories

Check

No damage and crack

Clutch release bearing clearance

Clutch pedal free stroke

Check / correct

Check / adjust

Free stroke: 30

～40 mm

Clutch

Clutch system Check

Check if clutch separated completely, connection stable and not skidding

Compound brake fluid Clutch brake fluid

Check / add level

Brake chambe stroke

Check / adjust

Air suspension

Vehicle body Check Observe the vehicle body whether tilt or not, the air spring (o piping) of one side is leaky if this side is lower.

If hear the sound of leaking obviously， we can deal with the The air springs Check problem after confirming the specific leaky location

Training

1.Correct operation: no neutral speed skidding; no idle speed running of engine for a long time

2.Correct maintenance: replace oil, oil filter element, diesel filter element , transmission, axle, angle transmission system periodically, clean and replace air filter element periodically

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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.

Maintenance operation and regulation every 5000km or 1 month depend on whichever occurs first.

Maintenance operation and regulation every 5000km

System Item Operation requirement

Working condition

Check

Steering wheel max free rotation at middle

10 degrees

Steering system redirector auxiliary oil and filter element

Fix bolts of each place

Fasten

Ball head

ZF series

Lubricate

Below 10℃ use DEXRON-II; above 10℃ use C-3/10W

Each fastening bolts not loosening, steering arm not loosening, steering wheel swift,

Each turning ball head not loosening, no clogging, clearance normal

Maintenance Free

GX85, GX 100, ZJ

100C

Change oil and filter core manufactured by Shanghai oil refining factory or ATF or related products which of oil tank produced.

25,35,40,55,65

Change oil and filter core of oil tank temperature >1

0℃, adopt CD level 15W/40 oil; Environment temperature <1

No.8 hydraulic drive fluid.

0℃, adopt bolt

Transmission

（ VOITH series transmission

）

Accessories

Lubricant oil Change

No leakage, operation organization effective, no abnormal sound, wrong gear engagement.

The lubricant ATF220 is compulsory for initial fillings of transmissions as well as fillings during first 60,000KM.

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System Item

Front axle

（ DF & FS series

）

Rear axle

（ DF & FS series

）

Air suspension

Brake clearance

Brake clearance

Check adjust

Check adjust

&

&

Fasteners Check/tighten Check and tighten the bolts, rods, height control valves, air springs, shock absorbers, anti-roll bars.

Check Listening and wiping the liquid soap. If find any The top covers of air springs, height control valves and the joints of the air place is leaky, please either tighten the joints or change the seal tape and clean the accumulated water, oil in the piping and the dirt in the joints course

The exterior surface of air springs

The air spring

Check

Change

Find out the places which are abraded, distended, bumped or cut

The surface of the air spring is damaged and appears the cord fabric

Adjust/check If air spring interfere and knock with the components around it, please adjust it in time.

Air suspension

Air suspension shock absorber

The air spring Clean the lubricant grease on the surface, the dirt surface on the piston, the abnormal things placed between the piston and air spring.

The air spring Check

The bumper

The height control valve

Shock absorber

The rod

The rubber liner

Check

Check

Check

Check

Check

If there is leakage in the joints of the air springs and the top cover, the air springs should be taken apart, then check whether the edges of the air springs and the top cover or the tapered sealing zone are distorted. Change it if it is distorted.

It’s damage maybe the root damage of the tapered sealing zone

If a height control valve controls two air springs and one air springs is leaky, the other air springs has not air too.

The external damage, the welding damage and the sealing damage result to the leakage of the shock absorber.

Check the rubber of the rod ball head and the rivet of the sleeve pipe and the ball head. Check the clamp and the tighten bolts if the it is the adjustable rod

Check the ball joints of the anti-roll bar and the rubber liner bushing of the boom

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System Item

Brake

System

Chassis

Electrical equipment

The brake pedal free stroke adjust condition

Shoe drum clearance: 0.30mm

～ 0.50mm, in complete braking, pedal stroke not surpass 1/2 of the whole stroke, check dry tin condition pressure

The brake nuts Inspect

Check whole vehicle brake pressure as required or not. Above 0.6MPa

Inspect fastening of rear brake board’s nut

7.7

－9 (m): 150-180 Nm,

9m above:front;160-205 Nm, rear:196-245 Nm

Check brake pipe and joint sealing

，No leakage

The pipe and joint sealing

Fastening body and chassis connective bolts, nuts

The whole vehicle body butter nozzle

Check

Check

Lubricate

Grease nozzle complete and effective, lubrication good

The whole vehicle light and Check instrument

The battery fluid surface

Check Add firmness, no rust filtration net

M-14


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

Engine

Propeller shaft

Oil Replace

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

Replace Before installation add 1/2—3/4 to filter Oil filter

Air filter

Air inlet/ outlet system

Check

Check

Cooling system Check and Intercooler

Clean air filter element

No air leakage, no damage, each clip fastening good

No leakage, each clip without damage or loosen

Water tank without leakage, damage, fouling

Coolant filter Replace Before re-install the coolant filter, daubs the 15W-40 lubricate oil on the interface of the sealing ring.

No leakage installation

Air compressor Check

Brake system Check

No air, oil, coolant leakage, lock nut and bolt no loosen or damage

No carbon deposit

No leakage fastening bolt universal joint

Check and fasten

Check and fasten

Propeller shaft flange fastening bolts not loosening

Universal joint each bearing no loosening or damage

Brake bottom Check No loosening

（DF series）

Rear axle

（DF series）

Suspension

Brake system

Hub bear

Brake plate

Check No loosening

Check / Change the brake plate when plate abrasion more than change limit pit.

Brake bottom Check No loosening board

Hub bear Check No loosening

Brake plate system

Check / change

Check

Change the brake plate when plate abrasion more than limit pit.

Each fastening bolt not loosening, leaf spring no broken piece, no apparent change of elasticity

Check brake frication piece thickness within required range by check port, visual check brake adjust arm working condition, running and stop brake good, each brake pipeline and air line no leakage

M-15




System Item

Engine

Fuel filter Replace

Steering hydraulic Replace oil

Replace fuel filter element accordingly

Steering auxiliary oil surface within required range

Coolant system – anti-freezing

Propeller shaft

Steering system

Front axle

Rear axle

（DF

& FS series

）

D ust-proof cover

Check

Universal joint condition

Propeller shaft bracket

Middle bearing clearance

Lubricate

Lubricate

Dust-proof cover without crack, damage, clip reliable, bracket no loosening

Universal joint without loosening, no block abnormal sound

Propeller shaft bracket no loosening, screw torque

120

～140Nm

Middle bearing clearance no more than 3mm

Lubricate each butter nozzle with 2# lithium lubricant grease

GX85, GX 100, ZJ

100C

Change oil and filter core of oil

N32 which manufactured by Shanghai oi refining factory or ATF or related products which produced.

tank

25,35,40,55,65

Change oil and tank

Environment temperature >1

0℃, adopt CD leve

15W/40 oil;

Environment temperature <1

0 ℃ , adopt No.8

hydraulic drive fluid

Toe-in of front wheel

Check & adjust

Radial-ply tire: 0

～+2mm

Final drive Filling-up

From injection hole into final drive filling

Parathion-type 90 heavy-duty gear oil (GL-5) to the face.

（for first 1500km, than change for every 24,000km

）

The leaf suspension suspension

The liner bushing of the rod assembly

The air fasten, weld

～294Nm, rear 343～ accordingly 392Nm

Change

Change

The liner bushing is relative sliding with the bal head

The liner bushing is knocked to bend and the tighten bolts of the adjustable rod are becoming invalid which result to the threads of the ball head and the steel pipe damaged.

The crack on the surface of the rubber is very

The rubber ball joints

Change serious. The depth of the crack is up to 2mm and the length of it is up to 8mm

M-16


System Item Operation Technical requirement

The rubber bal joints

The heigh control valve.

The rubber of

Change

Check adjust

Change

The air suspension

The connecting members of

Check

There are gaps on the surface of the rubber

The surface of the rubber become adhesive, brittle and the rubbe drop off seriously

The connection of the metal and the rubber is damaged. The partia depth is up to 6mm

The rubber ball joint rotates in the inner hole of the ball head a will

Check the equilibrium position of the adjustment bar of the heigh control valve.

Change it if the rubber of link rod becomes ageing, brittle, adhesive and lose its elasticity

Check the connecting members of the shock absorber if they are damaged please adjust or change them.

Brake system absorber the rubber

Check change

If the rubber is crack, brittle, adhesive and loses its elasticity please adjust or change them.

Charge the air springs and adjust to the design height, then check

The height

Check adjust the wheel base, the height of the vehicle body and the two side’ wheels’ locations which are relative to the frame. If it is necessary please adjust the height of the air springs and the length of the rod in order to arrive to the design request

Brake pedal free stroke

Check Break pedal free stroke 12

～15mm

Brake valve and pipe joint

Check and fasten

Break valve and pipe joint connection reliable and without air leakage

ABS system Check ABS working properly

Auxiliary

Body, frame brake free stroke

Check Retarder working properly Retarder

Engine exhaust brake

Check Exhaust brake working properly door lock function

Lock function good

Sealing good cabin door sustain pole Check or air spring

Cabin door lock function good, sustain pole or air spring effective outside mirror

Complete, no crack, effective, mirror clean, installation firm and reliable

M-17


System Item

Body, frame

Inside establishment

Compressor, safety valve

Electrical equipment

Air-conditioner

Heating system

Operation Technical front rear wind shield and side window glass body with paint

Check , clean

Clean, no crack, sealing good

Check

Body paint no crack or peeling, re-paint color the same as original pattern, character, company mark

Check Pattern, character, company mark clear, complete

Body and frame

Driver seat

Safety set

Check

Check

Check

Function reliable, working properly, no distortion, crack, fracture, welding split, connective bolts and rivet fix firm and reliable

Fix firm, front rear up down lock function reliable

Installation firm, backrest angle adjust lock function reliable

Safety belt function good, connection reliable, fire extinguisher, urgency hammer complete and effective seat cover, carpet, curtain and armrest

Check Clean, complete and firm

Compressor, air reservoir, Clean, screw

Clean, connection reliable, no air leakage, safety valve normal, pressure at 8Mpa, check air reservoir, if with seeper, replace air drier filter element

Front lamp, horn, meters and signal

Check set complete and effective

Wiper generator Check

Wiper connection rod

Check, adjust

Whole vehicle wiring

Check, adjust

Air-con passage and read lamp control panel

Check

Air vent set

Air-con strap tension and surface condition

Check

Check

Magnetic clutch, fill lubricant

Check

Reliable complete, reliable, insulation good

Air-con passage installation reliable, functional and effective

Installation firm

， working properly

Tension proper, strap without crack, scuffing or distortion

Work properly, lubricant: 2# lithium grease

Air-con pipe

Condenser, evaporator

Coolant and fuel qty

Control switch

Check

Check

Check

Check

No leakage or interference

Clean, no dirt

Up to requirement, fill if necessary

Fuel, water heat pipelines

Heating device

Check

Check

Installation firm, operation normal and reliable

No crack, oil, air or water leakage, joint not loosening, oil and water pipelines smooth

Pipeline connection reliable, operation good

M-18




System Item

Engine

Suspension

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

Belt tension pulley bearing

Cylinder cover bolt

Check/adjust No damage, fouling, loosening

Check/adjust No damage, loosening

Air dryer

Leaf spring bushing

Replace

Check

Replace air dryer

Clearance between leaf spring bush and pin normal, no abnormal abrasion, bush not crack, lubrication normal



System Item Operation Technical

Engine

Clutch

Thermostats Replace

Fuel roughing filter

Cooling system

Radiator

Replace

Release/ clean/ add

Check

Engine suspending Check/fasten

Measure

Radiator without leakage, damage, fouling.

Hose without damage, clips without loosen or damage.

Connection reliable, firm, soft mat no distortion layer or crack

Valve clearance within required range Overhead set- valves and injectors

Clutch brake fluid level Charge

The leaf suspension leaf spring bushing Check

Compound brake fluid

Clearance between leaf spring bushing and pin normal, no abnormal abrasion, bushing without crack, lubrication normal

M-19


Maintenance operation and regulation more than 80000km or corresponding time interval.

ZF Series axle

Oil or Grease change required, depending on whichever occurs first.

Products name

Front

Axle

Rear Axle

Model Maintenance content Maintenance interval

Filling-up grease(lubricant point)

80,000-90,000KM or

1 year

RL 85A

RL 85E

RL 55E

AV132

A80

A131 check-up oil level and change oil regularly 2 years every 20000KM

90,000~120,000KM

Oil class

NLGI Class 2

TE-ML 02

Remark

lubricant grease of Every 2 years shaft of wheel hub change

Oil change 150.000 km / 3 years

TE-ML 12

TE-ML122RL for front axle head of lubricant only

Oil change 150.000 km / 3 years TE-ML 12TE Old model

Rear Axle

A-132

(New

AV-132) lubricant grease of 250,000KM or 2 RENOLIT shaft of wheel hub years LX-PEP change （ include oil seal）

2Rs36/04e

Wheel bearings with individual mounts at the front and rear axles

500.000 km / 2 years

Compact bearings (hub unit) in the wheel heads at the front and rear

500.000 km / 4 years axles

System

ZF

Transmission

ZF parts

No.： 0671

190 122

Application

Oil change interval

Oil classes

- Scheduled routes

- Average speed from 20 to 60 km/h

360,000 km

3 years

- Long-distance coach journeys 540,000 km

- Average speed as of

60 km/h

3 years

ZF-Ecofluid M

02A(1) / 02B(1) / 02D / 02E / 02L

These lubricant classes may generally only be used in broken-in transmissions

M-20


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.

4、“R” meaning: Replacement ; “I” meaning：Inspection & adjusting; “C” meaning：Cleaning

Maintenance Maintenance period item

*1000km

5

5 10 15

20

25 30 35

40

45 50 55 60 65 70 75

80

Month

1 3 5

7

8

9 10 11 12

Engine

Engine

R I R I R I R I R I R I R

R I R I R I R I R I R I R I R I R filter R I R I R I R I R I R I R I R I R

Check & adjust engine idle speed

I I I I

Fixing every bolt and connection on engine

I I I I

Checking seal of pipe

& connector

Coolant

C C C C C C R C C C C C R C C C C belt I I

I I

I I

I

I

I

I I I I

I

I

I I I I I I I I I

I I

I I

I I

I I

I I

I

I

I

I

I I I I I I

I I I I I

I I I I I

I I I I I

I I I I I

I

I

I

I

R

I separator I I I I I I I I I I I I I

Lubricating oil in gearbox of fan angle steering gear

R I R I R I R I R

Air compressor, air reservoir & pipe

I&C I&C I&C I&C I&C

Radiator & expand water tank

I I I I I

I I I I I

Water & oil separator core

I R R R R

Handle pump C C C C C

I I I I I

Intake & exhaust manifold, muffle, exhaust pipe

I I I I I I I I I I I I I I I I I

Turbocharger

Intercooler

I&C I&C I&C I&C I&C

I&C I&C I&C I&C I&C

Engine suspension device

I I I I I

I I

Thermostat I I

M-21








*1000km

5

5 10 15 20 25 30 35

40

45 50 55 60 65 70 75

80

Month

1 3 5

7

8

9 10 11 12

Transmission if not leaking oil mechanism

Lubricant

Transmission

I I I I I I I

I

I

I

I I I

I I I I

I I I I I

I I I I

I

I

R I I I R I I I R

Venthole C I I I C I I I

Propeller shaft

C I I I C I I I C

Drive shaft connecting parts

Add lubricating oil in drive shaft

Universal joint cross

& bearing

I I I I I I

I I I I I I I

I

I I I I

I

I I I

I I

I I

I

I

I

I I I I I

I I I I

I

I

I I I

I I I I I I I I I bracket & clearance

Brake system

Brake pedal free stroke adjustment

I I I I I I I I

Driving brake ， parking brake

I I I I I I I

Brake pipe & connector seal

I I

I

I I

I I

I I I

I

I

I I I I I I I I R I I I

I

I

I I I I I

I I I I

I I I I

I

I

I pressure I I I I I I

I I I I R

I I I I I

ABS system checking I I I I I I I I I I I I I I I I I fixing I I I I I

Retarder C C C C C C C C C

M-22








*1000km

5

5 10 15 20 25 30 35

40

45 50 55 60 65 70 75

80

Month

1 3 5

7

8

9 10 11 12

Brake system

Brake drum & wearing plate abrasion

I I I I I I I I I

Brake shoe plate clearance

I I I I I

FR & RR brake checking

I I I I I

ABS I I I

Brake valve & other valves

I I I

Axle & Tire

I I I I I I I I I I Tire& steel ring I I I I I I I

Checking & fixing RR

I I I I I I differential housing , RR cover half shaft bolt nut

Lubricant steering main pin & brake adjusting arm & cam shaft

I

I I I I

I I I I

I I I I

I I

I I

I I I I I I

I I I

I I I

I I I

Four-wheel maintenance , clean bearing

I I I I I

Checking & fixing front axle bolts ,nuts, bearings

Checking & fixing rear axle bolts, nuts, bearings

Clearance final drive vent hole

I I I I I

I I I I I

C C C C C

Rear gear R I R I R

I I I I I I

Wheel rim, flange, spoke I I I I I I I

I

I

I

Suspension system

Thrust pole , connecting pole installation

Air bag height, seal, integrality

I I I I

I

I I I I I I I

I I

I I

I

I

I I

I I I

I

I

I

I I I I

I I I I

I

I

I I I

I I I I

I fixing piece

M-23








*1000km

5

5 10 15 20 25 30 35

40

45 50 55 60 65 70 75

80

Month

1 3 5

7

Suspension system

8

9 10 11 12 lubricate oil

I I I I I I I I I I I I I I I I I condition

Steel plate suspension bush

Left & right steel plate suspension flexibility

Fixing suspension U type bolt

I I I

I I I

I I I I I I I I I

I I I

Bracket & lifting lug installation & wearing state

I I I drive steering hydraulic oil

Toe-in of front wheel

I I I I I

Steering system

Checking steering

I I I I I I condition, oil leakage

Steering wheel free stroke & working I I I I I I condition

I

I

Checking power steering

I I I I system

Steering booster oil & filter core

R I I I

I I I I

I

I I I

I I I

I

I I

R I

I

I I I I I

I I I I

I

I

I I I

I I R

I I I I I

I I I I I

Oil pump working condition

I I I

Steering angle checking

& adjusting

I I I

Checking the crack of steering framework, steering knuckle & knuckle arm, vertical arm & axle

I I

I I

I I I R I I I I I I I I

I I I I I

M-24

Common trouble and elimination







*1000km

5

5 10 15 20 25 30 35

40

45 50 55 60 65 70 75

80

Month

1 3 5

7

Electrical system

8

9 10 11 12

I I I I I I I I I surface , connector

I I I I I

Wire box installation I I I I I I I I I I I I I I I I I

All wires , circuitry, connectors

I I I I I I I I I

A/C system & pre-heater system

Air conditioner system refrigeration working condition

I I I I

A/C compressor belt rate of tension

A/C system pressure, compressor freeze oil quantity

I I I I I

I I I I I

I I I I I

Autonomous water heat

I I I I I system

Autonomous water heat system-water supply system

I I I I I

Vehicle body, framework

Luggage bin door air spring, stay bar

Engine bin door air spring, stay bar

I I I I I

I I I I I

Vehicle body, framework checking

I I I

C-1


Engine common trouble and its elimination (suitable for diesel engine)

Diesel engine can not start

Possible causes Remedies

1） Too low starting speed

2) Air exists in the injection system

1) Check the starting system and assure the starting speed is not lower than 110rpm.

2) Check the looseness of the joints of the feed line. Unscrew the de-aeration bolt on the fuel cleaner and oil water separator assembly, then press fuel with hand priming pump until the fuel overflows without air bubbles.

3) Fuel pipe clogged

4) Fuel filter choked

3) Determine the location of the clog and clear it.

4) Replace the screw-on filter element of the fuel filter/oil-water separator assembly.

5) Fuel supply pump does not apply 5) Check for leakage in the fuel inlet pipe fuel or applies fuel irregularly Clogging of the fuel supply pump filters and fix or replace.

6) Insufficient fuel injection, without 6) Check the injector atomization situations and replace a new fuel injection or low injection pressure one if it doesn’t work.

7) Starting system problems: 7) Check the connection to be correct and reliable.

Incorrect terminals connection or bad contact;

Insufficient battery charge; Charge the battery.

Bad contact between the brush and Repair or replace the brush and clean the surface of the communicator of the starter communicator with soft sand paper and blow off.

8) Insufficient compression pressure; 8) Replace the piston ring and press in the cylinder sleeve if necessary.

Piston ring worn-out

9) The fuel cut off solenoid valve joint is loose, dirty or corroded smudginess canker

10) Mounting timing incorrect

9) Check the valve clearance, valve spring, valve stem, and valve seat. Grind the valve seat if necessary.

Tighten and wash or replace.

10) Check and adjust it.

C-1


Diesel engine power deficient


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.

3 ） Insufficient boost pressure of 3）Check and eliminate the leakage in the pipe and joints. turbocharged system

4) Turbocharger is out of order;

Compressor and turbine passages are polluted, clogged or damaged;

Bearing failure;

4) Dean or replace the compressor casing and turbine housing.

Replace it.

Carbon deposit and sludge in the Clean it. back of turbine and compressor impellers.

5）middle cooler mangle ,leave out 5）Check and replace it.

6）Fuel line blocked or leaky 6）Check the seal of fuel line and fuel filter choking, or replace screw-on filter element.

7）Check the inject pressure, remove carbon, adjust and repair 7）Poor atomization of injector

8）Incorrect distribution phase

9）Cylinder gasket leakage

8）Check and adjust the distribution timing and valve lash

9）Tighten the cylinder head bolts according to the stated torque and order, or replace the cylinder gasket.

10）Bad valve sealing 10）Grind or replace it.

11 ） Overheat engine or too high 11）Check and repair the radiator, thermostat, and adjust fan belt coolant temperature tension.

12）Piston ring worn-out or broken

13）Sensor doesn’t work

12）replace it

13）Check and replace it.

C-2


Abnormal noise during engine operation


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.

2) The Damper is damaged and invalid.

2) Change components to keep regulated axial clearance

3) The shock absorber is damaged and 3) Check and see if the joint bolts are in good conditions, and ineffective change new ones if necessary.

4) The valve knocks on the piston

4) Check and adjust the valve timing.

5) The driving gear is abrased and get 5) Check the gear side clearance and change the gear or not too large gap. There is knocking according to the abrasion situations. sound at the timing gear box cover.

6) Too big clearance between piston and cylinder and there is knocking sound at the cylinder wall.

6) Change the piston and use the repairing cylinder liner. Keep the proper clearance between piston and cylinder.

7) Puff vibration of supercharger

7) Remove the carbon and waste in the compressor channel and the exhaust channel.

8) The bearing of supercharger is damaged and the rotor knocks on the 8) Change the supercharger assembly shell

9) The valve clearance is too large and

9) Adjust the valve clearance. there is big noise at the cylinder head.

C-3


Exhaust with black smoke

Possible causes

1) Intake clogged

2) Poor fuel quality

3) Incorrect distribution timing

4) Bad atomization of injector

Remedies

1) heck and clean the air cleaner and intake passage.

2) Use prescribed fuel.

3) Adjust the distribution timing according to the instruction.

4) Check and repair or replace

5) The injector spray too much fuel 5) Check and adjust it accordion to the instruction.

6) Check and repair or replace 6) Check and repair leak in the pipe line and joints.

7) Faulty turbocharger 7) Check and replace the assembly.

8) middle cooler damaged and leaked 8) Repair or replace it

Exhaust with white and blue smoke

Possible causes

1) Poor quality fuel and too much water in fuel

2) Too low coolant temperature

1) Replace the fuel.

Remedies

3) Incorrect distribution

2) Check the working temperature of the thermostat, replace it if necessary.

3) Check and adjust it.

4) Too low Pressure 4) Check the working temperature of the thermostat, replace it if necessary.

5) Incorrect installing orientation of piston 5) Check and reinstall correctly. rings

6) Running at low load for long time

7) Seal ring of turbocharger worn-out

6) Operate at proper speed and load

7) Check and replace it.

8) thrust bearing of turbocharger worn-out 8) Check and replace it.

9) Oil return pipe of turbocharger 9) Clean or repair it.

C-4


Too low oil pressure

Possible causes

1) Diluted or incorrectly selected

3) Oil filter choked

1) Select the proper oil.

2) Inner and outer rotors of oil pump worn-out or too large

2) Replace the oil pump.

Remedies

3) Replace the whirling type filter element.

4) Failure of oil filter pressure control

5) Gear of oil pump damage

6) Inlet oil tube of fuel pump crack

4) Repair it.

5) Replace it.

6) Repair or replace it.

7) Fixing bolt of oil pump inlet oil tube loose 7) Tighten the bolt to the required torque.

8) Too large bearing bushings clearance. 8) Check and replace it.

Too high oil pressure


1) Too low ambient temperature and too 1) Use the required grade engine oil. Operate at low speed high oil viscosity after starting, and then check it when the oil temperature is normal.

2) Over-flow valve clogged 2) Check and clean it

Too high oil temperature and oil consumption

Possible causes

1) Leakage in the exterior oil line

2) Too high diesel engine load

3) Use improper oil

4) Piston ring stuck or seriously worn

1) Check and repair it.

Remedies

2) Decrease the load.

3) Use the oil as required.

4) Check and repair, if necessary, replace it.

5) Too much worn out of Cylinder bore

5) Bore the cylinder and use the oversized piston rings or press in a repair –used cylinder sleeve.

6) Valve guide seriously worn out and failed

6) Check and replace. seal of valve stem

C-5


Chassis constant fault and elimination

Propeller shaft

Fault symptom

Possible cause Eliminating method

Propeller shaft jogging

（ vehicle vibrates during driving） assembled incorrectly

2. The propeller shaft is distortion or bending fixing yoke on the same plane

2. Adjust or replace the propeller shaft

3. The universal-joint journal or the 3. Replace the bearing needle bearing has been worn out or damaged

4. The propeller shaft loose

5. The propeller shaft is imbalance

6. The intermediate supporting bearing is worn out or damaged

4. Tighten propeller shaft to specified torque

5. Adjust or replace the propeller shaft

6. Replace the intermediate supporting bearing

Abnormal sound from the propeller shaft (during the starting and the running) supporting bearing is loose or the rubber damp piece material is aging

1. Abrasion or damage of the universal joint

2. Abrasion or damage of the sliding yoke

1. Replace the universal joint

2. Replace the sliding yoke

3. Looseness of the propeller shaft

4. Inadequate lubrication to the needle bearing, the sliding yoke and the

3. Tighten it to specified torque

4. Make the lubrication intermediate bearing

C-8


Transmission

Fault symptom

Difficult gear shift

(Difficult gear engagement)

The transmission gear is off the engaging position


1. Control mechanism

3) The control hinge bend

2. Transmission

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） Correct or replace the control hinge

1） Replace the bearing 1) Abrasion or damage of the bearing

2) Synchronizer operates abnormally

3) The shaft or the gear is wore or damaged

4) Abnormal slip of the gear shifter

2） Correct or replace the parts

3） Correct or replace the parts shaft

3. Others

1) Clutch can not disengage normally

4） Correct

2) The lubrication viscosity is too high

Transmission

1） See " Clutch does not disengage smoothly or can not disengage "

2） Use the lubrication of given grade

1) Shift fork distorted or worn

2) Abrasion of lthe lockup ball or the ball on the gear shifter shaft

1） Check the gear-shifter fork and make adjustment or replacement in case of bending

2） Disassemble and replace the worn-out parts

3) Breakdown or fatigue of the lock spring

3） Replace the spring

4) Excessive clearance of the gear 4） Adjust the gear clearance or replace the engagement

5) Excessive clearance along the

5） Measure the axial clearance and replace gearing axial direction gear the thrust washer if necessary

6) Abrasion of the sliding bearing

6） Replace the bushing slipper or its end surface

7) Abrasion of the main bearing

Control mechanism

7） Replace the main bearing

1) The control mechanism is out of work

1) Check and correct the control hinge

2) Movement of the shifter lever causes vibration of the vehicle

2)

Check damage of the engine rubber suspension and replace the faulted parts

C-9


Rear axle

Fault symptom


When the vehicle is starting

1) Excessive clearance between 1） Adjust the clearance the differential gear

2) Excessive clearance between

2） Adjust the clearance the driving and the driven gear

Abnormal sound from the rear axle

(abnormal sound)

3) Looseness of the connecting flange and the propeller shaft

4) Too small pretightening force of the drive gear bearing

5) Looseness of the fixing bolt and nut of the driving gear

When the vehicle turning

3） Tighten it to specified torque

4） Adjust the pretightening force

5） Tighten it to specified torque

1) There has abrasion or damage to the axle shaft gear, driving

1） Adjust or replace the faulted parts

Abnormal sound of the rear axle

( improper sound)

Leakage of the rear axle lubrication gear, spider, thrust shim and the axle shaft bearing and etc

2) Too low oil level 2） Fill up the lubrication

When the vehicle is running:

1) Excessive clearance between 1) Adjust the clearance the driving and the driven gear

2) Abrasion or damage of the 2) Replace the bearing bearing 3) Make adjustment or replacement

3) Abrasion or damage of the gear

4) Too low oil level

4) Fill up the lubrication

When running with inertance

1) Too small clearance between the driving and the driven gear

1) Adjust the clearance

2) Replace the bearing

2) Abrasion or damage of the 3) Adjust or replace the faulted parts bearing 4) Fill up the lubrication

3) Incorrect gear engaging position

4) Too low oil level

1. Abrasion, looseness or damage of the oil seal

1. Replace the oil seal

2. Looseness of the differential 2. Tighten to specified torque and lock bolt or damage of the replace gasket gasket

3. Damage of the differential

3. Make trimming and replace the differential housing if necessary carrieer mating surface 4. Replace the gasket and tighten

Looseness of the oil draining plug or damage of the gasket screw plug to specified torque

C-10


Fault symptom


Leakage of the rear axle lubrication

Hub bearing jamming

4. Blocking or damage of the 5. Clean or replace the ventilation ventilation plug plug

5. Axle housing cracks

6. Damageor distortion of the 6. Repair or replace the axle housing coupling flange sealing surface 7. Adjust or replace the coupling

7. Malfunction of bearing leads to radial run out of coupling flange flange

8. Axle housing distortion caused by overloading

8. Replace the bearing

9. Adjust or replace the axle housing

1. Excessive pre-tightening force of the hub bearing

1. Adjust the pre-tightening force

2. Inadequate lubrication of the 2. Intensify the lubrication or replace bearing or incorrect usage of the grease the grease

3. Clean and intensify the lubrication

4. Replace the sealing ring 3. The bearing is defiled by the dust

4. Water entering bearing due to malfunction of sealing ring

Front axle and steering system

Fault symptom

Possible cause

Steering wheel shimmy

Eliminating method

1. The steering system

1) Steering gear housing bolt or steering column supporting

1） Tighten to specified torque loose

2) Looseness of the steering

2） Adjust the junction connection point

3) Excessive clearance of the

3） Adjust the clearance steering gear housing

2. The front axle

1) Umbalance or abrasion of the rim, the spoke and the wheel

2) Abrasion of the front wheel bearing

3) Excessive abrasion of the king pin or the bushing

4) Deformation of the knuckle

5) Improper wheel alignment

1） Balance all the components and replace faulted components.

2） Replace the bearing

3） Adjust or replace the faulted parts

4） Replace the knuckle

5） Check and adjust the wheel alignment

C-11


Fault symptom


6) Fatigue of the front leaf spring, looseness of the "U" -bolt or damage of the central bolt

1. The steering system

6) Replace the faulted parts

Disalignment of the steering wheel engagement

2) Malfunction of power steering system

2） Overhaul and eliminate trouble

3） Adjust or replace the power piston steering wheel return to center power piston

4) Fatigue of the return spring

5) Malfunction of slide valve

2. The front axle

4） Replace the spring

5） Check diameter of the slide valve and the housing and replace them if necessary

1) Check and adjust the front wheel alignment 1) Excessive caster angle of the king pin

1. The alignment of front wheel incorrect

2. There has fatigue and damage in the front plate spring

1. Check and adjust the front wheel alignment

2. Replace the faulted spring

3. Bending of the front axle

4. Unsmooth of the braking

5. Looseness of the front hub

3. Adjust or replace the front axle

4. Please refer to the chapter

"braking" bearing nut

6. Inequality of the tire pressure

7. Tires with different dimension applied

5. Tighten to specified torque

6. Inflate to the given pressure

7. Replace the tire by the correct type

Misproportion tire wear

1. The front axle

1) Incorrectness of the wheel

1） Check and adjust the front wheel alignment alignment

2) Abrasion or wreckage of the hub bearing and looseness of the bearing nut

2） Replace the bearing or tighten nut to specified torque.

3） Make an adjustment and replace the faulted parts as needed the ball stud, the king pin and the bushing

2. Tire

1) Tire pressure incorrect

2) Disalignment between the tire and the wheel

1） Supply to the given air pressure

2） Replace the tire or the wheel z

C-12


Fault symptom


3. Others 1) Correct the driving pattern

Misproportion 1) Breakdown caused by the or untimely abrupt starting or the emergent 2) Make the loading according to the tire wear braking specified capacity

2) Overloading

1. Too low oil level

2. Lubricant deterioration or

1. Add the lubricant to the given level impurity in it

3. Abrasion of the steering

2. Replace the lubricant junction

4. Fault of the power steering system

3. Replace the ball stud

4. Overhaul and eliminate trouble.

Heavy operation of the steering

5. Excessive lubricant resistance caused by the pipeline sunken

5. Measure the backpressure and repair or replace the pipeline in case of the set value exceeded

6. Measure the oil pressure and the flow volume; disassemble and steering system breakdown)

Heavy operation of the steering wheel

(breakdown of the front axle) by the ineffective hydraulic pump

7. There has air in the hydraulic pipeline repair the hydraulic pump if the set value belowed

7. Bleed air and add oil.

8. Disassemble and repair rotary

8. Malfunction of rotary valve

9. Abrasion or damage of the valve.

9. Disassemble and repair. power cylinder and damage of the piston O -ring

10. Too much leakage of the oil 10. Disassmeble and repair steering inside the steering gear housing housing.

1. Improper adjustment of the 1. Check and adjust the wheel wheel alignment (excessive caster angle) alignment

2. Too little clearance between 2. Check and adjust the clearance the king pin and bushing

3. Inverse installation of the 3. Adjust the installation thrust bearing

4. Inadequate lubrication of the front axle parts

4. Add the grease to the front axle

5. Over tight or loose connection of the bull

6. Too low tire pressure

7. Excessive abrasion of the tire

5. Check and lubricate the bulb stud

6. Inflate to the rated pressure

7. Replace the tire

C-13


There has oil spillage in the steering oil tank

1. Clogging of the strainer or the filter element

2. There has air in the pipeline

1. Clean the filter strainer or replace the filter element

2. Add the oil and make the exhaustion

Braking system

Fault symptom

Unsmooth of the wheel


1. There has compressed air inside the braking chamber

1. Check and adjust the exhaust valve of the quick releasing valve

2. Improper lubrication of the 2. Adjust the faulted parts camshaft or improper return of the adjusting arm

3. Brake shoe or chamber return spring fatigued or broken

4. The spring braking takes effect

5. Clogging of the exhaust port in the quick release valve

3. Replace the faulted parts

4. Eliminate causes of the spring braking unreleased

5. Disassemble and clean the faulted parts secondary piston return failure valve and replace the faulted parts as needed

1. The clincher or the bolt is 1. Replace the friction lining projected because of abrasion of the braking friction lining

There has abnormal sound when troddening the brake pedal friction lining

3. Deterioration of the friction 3. Replace the friction lining lining 4. Rivet the rivet or tighten bolt

4. Improperly contact between the brake shoe and the friction 5. Adjust or tighten the brake drum lining

5. Uneven abrasion of the brake drum internal surface or weak

6. Adjust the clearance between the brake shoes and tighten the installation supporting pin locknut

6. Looseness of the brake shoe 7. Replace the hub bearing

8. Adjust or replace the brake drum supporting

7. Abrasion of the hub bearing

8. Deformation of the brake drum

C-14


Fault symptom


Unsteady braking

The braking can't be applied under all conditions

1. Tire pressure uneven or tire 1. Operate as required dimension different

2. Improper installation of the 2. Tighten the locknut of the brake brake shoe or damage of the shoe supporting pin and replace the return spring return spring

3. Improper engagement of the 3. Adjust the friction lining braking friction lining

4. Improper adjustment of the left and right brake

4. Adjust the brake

5. Deterioration of the braking 5. Replace the friction lining friction lining

6. Oil on the braking friction 6. Clean with the gasoline to lining eliminate the effect of the leakage at the hub oil seal, oil cylinder

7. Damage of the brake backing cover and the rubber cap

7. Replace it plate

8. Looseness of the leaf spring

8. Tighten the U-bolt

U-bolt

When compressed air pressure is normal:

1. Too short of the brake valve

1. Check ,and replace the braking valve if necessary travel

2. The camshaft doesn't rotate (the bushing is lack of lubricant)

3. Improper adjustment of the 3. Adjust the travel braking chamber pusher stroke camshaft and replace it as needed

4. Improper sliding contact of the relay valve

2. Check working condition of the

4. Disassemble and repair

5. Overheat or deterioration of the braking friction lining

5. Replace the friction lining

6. Improper engagement of the 6. Adjust engagement position of the braking friction lining friction lining

7. There has lubricant on the 7. Clean the oil trace with proper friction lining or the brake drum

8. Water entering brake drum cleanser or replace the friction lining

8. Drying out the water by pressing the pedal gently during the running

C-15


Fault symptom


When compressed air pressure is abnormal:

1. There has air leakage inside the air pipeline

1. Repair the leakage point

2. Disassemble and repair air

2. The air compressor doesn't work compressor

3. Adjust or wash

3. The pressure regulator is 4. Disassemble and repair the brake improper adjusted or failured because of the impurity entering valve

Air leakage in the brake valve

Common trouble and troubleshooting of electrical equipment and starting system

Fault symptom and the vehicle is difficult to start

The battery is lack of power excessively and incapable of charging at low speed

There has abnormal sound during the generator rotates

The charging indicator light doesn't go off during the running

Possible cause

1. The belt is of over loose or excessive abrasion with the shaking during the running

2. Bearing failure or oversize

Adjust the belt and replace the bearing clearance

3. Too much bearing clearance

1. The battery is lack of power short

4. The belt is slipping

1. Charge the battery

2. The generator is damaged 2. Replace the generator

3. Charging indicator lamp loop 3. Check the circuit

4. Adjust the belt

1. The battery is damaged

2. The generator is damaged

3. The belt is slipping

Eliminating method

1. Replace the battery

2. Replace the generator

3. Adjust the belt

C-16


Fault symptom


Difficult in starting

1. The battery has no power, or is 1. Charge and clean the joint and lack of power or terminal loose

2. Poor contact of the starter screw it switch, short circuit of the 2. Repair or replace it connector lug or bad of the solenoid

3. Starter pinion is clogged in the 3. Repair or replace it

Starting gear of the starter can not engage with the flywheel teeth

Starting gear of the starter can not disengage completely

Furthermore, engine bearing is burnt ,water on external of the combustion chamber and the consumption frozen may also caused the breakdown

1. Poor contact of the ignition 1. Clean and tighten switch or socket loose

2. Unsteady connection of the 2. tighten it relay device or the solenoid switch

3. Turnoff of the starter solenoid switch

4. Damage of the starting gear or the gear ring of starter

3. Replace it

4. Repair the teeth or replace it

5. Found out the reason and eliminate it

6. Replace it 5. Malfunction of engage switch

6. Starter armature shaft bent

1. Starter starting gear sleeve too tight or stuck

2. Too little clearance between the starting gear and the flywheel

1. Replace the shaft sleeve or clean and amend it

2. Adjust the clearance or replace the starting gear ring gear or the starter gear damage 3. Clean it

3. Magnetic coil dirty

4. Clogging of the transmission fork shaft

4. Clean and adjust it

5. Replace it

5. Locking of the engage switch

C-17


Common trouble and troubleshooting of air conditioner system

The remedy and trouble analysis under abnormal pressure

No. Pressure Description Analysis

1

2

Remedy

The high and low pressure is lower than normal.

There is bubble in the inspection glass ； the cold air in the bus insufficient difference is not too much；

； high pressure pipe a little bit warm and the low pressure pipe a little bit cold, the temperature

Check the

The refrigerant filling is not enough and the system for the leakage and find out the leaking leaking maintenance

Fill in refrigerant

The high and low pressure are higher

Than normal

The high and low pressure are much

The refrigerant is too much

Drain some part of the refrigerant or refrigerant oil

No liquid flow seen from the inspection glass;

Check the

Air conditioner system and find serious leakage normal . difference between high and low pressure pipe enough refrigerant

The low pressure is nearly to zero or even the negative value;

The high pressure is lower than the normal value expansion valve

No refrigerate in the blocked； system

The front or the rear expansion valve part of the expansion valve has fog temperature sensor damaged or packing error

Changed the expanding valve

Change the expanding valve temperature sensor

Make good package for the expanding valve

The high pressure

3 abnormal;

The pressures than the normal value expansion valve opened too much are higher than the appeared normal values

The high pressure is higher than the normal value and the low pressure is lower than normal

The surface for the air suction pipe of the Expanding valve compressor has frost or damaged condensate

Change the expanding valve

Readjust the expanding valve

Change the expanding valve

C-18


No. Pressure

4

5

6

The high and low pressure are much higher than the normal value and the needle of the gauge swing obviously

The high pressure is higher than the normal value and the low pressure is nearly to zero or negative value and the gauge swing seriously

The low pressure is much higher than the normal value and the high pressure is a little bit higher than the normal value

The high are low

Description Analysis Remedy

Discharge the refrigerant in Air mixed in the

The cooling capability is refrigerant The the system vacuum is not and change

Insufficient and the good for the first the desiccators system has air and the bubbles seen in the inspection glass maintenance filling the refrigerant

The air sent to the bus sometime cold and sometimes warm and the inspection glass looks yellow

Cold is in sufficient

Too much water in the system desiccators reaching the saturation the frosting the expanding valve

The condenser blower doesn’t work normally blockage in the condenser radiator

Change the desiccators and make the vacuum repeatedly and refrigerant

Check the electric circuit cleaning the condenser

7 pressure are higher than the normal values insufficient interior failure

Repair or change the compressor

Evaporator

8

The high and low pressure are lower than the normal value

Evaporator wind flow is insufficient running or low electric circuit in efficiently or the radiator of diagram or clean the evaporator blocked

C-19


Electric system trouble and remedy

Fault symptom

Possible cause the power lamp on the control panel not light malfunction light on the control panel light up

Eliminating method

1. + no power supply；

2. D+ not connected well；

3. harness not tight；

4. control unit failure；

1. system pressure error；

1. generator D+ no output, exchange the generator and repair

2. reconnect the cable D+；

3. reconnect the harness；

4. change the control panel or repair；

1. to connect the manifold gauge and

2. pressure switch defective； eliminate the malfunction；

2. change the pressure switch and

3. pressure switch harness not connected well； repair；

3. reconnect the pressure switch；

4. harness connection not well； 4. harness connection;

5. control panel failure； 5. change the control panel or repair； refrigerant lamp is not lighted up connection problem； failure or connection problem； connect the cable again； connect the harness again； installation position not good ； into the correct position； defective； switch or repair； condenser fan not working reliable；

6. Control panel defective

1. malfunction lamp light up；

2. sensor failure；

3. relay failure；

4. fuse burnt；


1. check the problem according to the item 2；

2. change sensor or sensor connection cable；

3. change the relay or repair the relay of the connecting harness；

4. change the fuse； connection loose；

6. harness connection not tight；

7. air blower connection loose；

8. air blower failure;

9. control panel failure； battery ,make the connection；

6. re-connect the harness；

7. connecting to the venting cable；

8. change the blower or repair；


C-20


Fault symptom

Possible cause Eliminating method compressor not working evaporator blower not working

1. compressor clutch connecting cable not connected well；

2. clutch damaged；

3. malfunction lamp light up；

1. reconnect the cable；

2. change the clutch or repair；

3. refer to the above-mentioned items；

4. refrigerant light not lighting up；

5. relay out of work；

6. no harness connection to the battery；

1. relay not working；

2. battery no charge；

1. change relay or repair or connect the relay connecting cable;

3. battery cable confected；

4. air blower harness not connected 3. reconnect the battery cable； well；

2. change the battery or recharge;

4. change the fuse；

5. harness connection not good；

6. venting blower cable not connecting well；

5. reconnect the harness；

6. reconnect the blower motor connecting cable； adjustable resistor failure；

8. control panel out of work； resistor for repair；

8. change the control panel or repair

C-20

Appendix

No.

1

Driver tools table（one each）

Part name

Tool box

No. Part name

21 Flat-tip screwdriver 6*100MM

22 Hammer 1 pound

25 Tire pressure gauge 0-1.4MPa

28 Pry bar also used as rocker lever 55cm

29 Pry bar also used as handle 50cm

30 Grease gun 400cm

3

31 Socket wrench for wheel nut 32(hexagon)

32 Torque bar 315 X 25 X 25

33 Wrench for front wheel hub bearing nut 70 mm (hexagon)

34 Wrench for rear wheel hub bearing nut 110 mm (hexagon)

35 Final drive locknut 55mm

36 Spare wheel lifter 22X550

37 Wrench for drive axle drain plug 10x10

20 Cross-head screwdriver 6”

The tools above are the state when choose Dongfeng Dena axle, when other axles are applied, driver tools may vary as below name cancel manufacturer

1 60 X72 mm foursquare ZF Front axle

Wrench for front wheel

70mm (hexagon) hub bearing nut

Wrench for rear wheel hub bearing nut (hexagon)

1

1

1

2.25’’or 57 mm hexagon

58 mm

115 mm hexagon

4.03’’or102 mm

MeiChi Front axle

North Benz Front axle

DONG FENG DENA13T

MeiChi Rear axle

Final drive locknut 55 mm(hexagon) 1 51 mm hexagon

Fangsheng rear axle or Dongfeng

Dena or Hangzhou sanhua 9.5T

Socket wrench for wheel

32 mm(hexagon) 1 41 mm hexagon

Dongfeng Dena or Hangzhou sanhua

9.5T nut Dongfeng Dena or Hangzhou sanhua

1 21 mm foursquare

9.5T

Note: The tool box may vary according to different axle condition, for details, please refer to the encasement bill.

A-1

Appendix

Tightening torque of main bolts and nuts

Position

Front tyre nut

Rear tyre nut

Bolt, connecting lower knuckle and ball pin

Steering kingpin lockpin nut

Fixing nut, upper steering knuckle

Binding nut, tie rod

Tightening torque（N·m）

412～480

294～421

245～304

60～70

274～343

90～110

Locked bolt and nut between pitman arm and pitman arm shaft 407～434

Fixing nut, ball pin on both ends of drag rod

Steering gear fixing bolt

Steering gear lock nut

Upper fixing bolt and nut between steering bracket and frame

Lower fixing bolt and nut between steering bracket and frame

Final drive bevel gear flange nut

Fixing nut, Front brake backing plate

Fixing nut, Rear brake backing plate

Fixing bolt, between driven gear and differential

Differential housing nut

Fixing bolt, Front brake chamber bracket

Fixing bolt, Front brake chamber

Fixing bolt, Rear brake chamber

Fixing bolt, retarder housing

Fixing bolt, axle shaft

Drive gear bearing cap bolt

Rear axle oil level check plug

Lock bolt, front shoe axle

U bolt, front axle

U bolt, rear axle

127～157

49～69

196～294

343～392

Lower slotted nut, damper 134～167

Fixing nut, between damper and damper bracket（M20） 88～118

Leaf spring pin locknut

Front engine mounting bracket bolt

54～69

90～110

Coupling bolt, between flywheel housing and frame bracket

Fixing bolt, between clutch and flywheel

Fixing bolt, between flywheel housing and clutch housing

Fixing bolt, between transmission and clutch housing drive shaft coupling bolt

Fixing nut, transmission output shaft rear connecting panel

80～100

90～100

60～75

142～186

215～240

333～549

240～300

294～333

137～217

137～167

275～330

395～539

160～205

196～245

588～686

216～275

59～79

40～59

167～196

128～157

137～176

120～137

A-2

Appendix

Bolts torque table

Torques for bolts with metric unified threads

Dimension of bolt

Torques N.m*(ft-lb)

8.8 10.9 12.9

Torques for bolts with metric fine threads

Dimension of bolt

Torques N.m*(ft-lb)

8.8 10.9 12.9

The torque values allow bolt yield strength up to 90%, assuming a friction coefficient of μ

A-3

Appendix

The table of Lubricant, Power steering oil and Grease

1 Main assembly lubricant

Oil site

Engine

Transmission

Lubricant

Diesel engine oil

Gear oil

Type/table

15W/40

SAE 85W-90

Level/type

API CH – 4/SG

API GL – 4

Main reducer Gear oil SAE 85W-90 API GL – 5

Explanation ：1) Diesel engine oil--API CH -4/SG ,15W/40 , be used upwards -10℃

10W API CH – 4/SG be used between -5℃～-20℃

5W/30 API CH – 4/SG be used upwards -25℃

2) Gear oil – could be used between -20℃～50℃

2 Power steering oil

Oil grade: TE-ML09, or recommend Mobile ATF220

3 Others

Oil Site

Clutch

Brake system

Bearing and ball pin

Coolant

Oil used Nominate

Synthesize grade oil Nominate to use HZY4，DOT 4, or Laike 901

Synthesize grade oil etc., can’t mix to use in different type grade oil

DOT3,DOT4,DOT5.1; Laike 901,Laike

901-4,Laike 901-5

Li - grease 2#

Nominate to use SINOPEC brand, YF-2A (upward -45 °C centigrade) coolant， can’t mix to use different type coolant

A-3

Air braking schematic diagram

Appendix

A-4

Electric schematic diagram of the complete vehicle (1)

Appendix

A-4

Electric schematic diagram of the complete vehicle （2）

Appendix

A-5


Appendix

A-5


Appendix

A-5

operation manual

OPERATION MANUAL

King-Long XMQ6130C series tourist bus

Xiamen King Long United Automotive Industry Co., Ltd.

Foreword

FOREWORD

Xiamen King Long United Automotive Industry Co., Ltd.

JULY. 2015

Contents

Contents

Contents

Contents

Contents

Technical parameter and complete vehicle description

Technical parameters of the complete vehicle（DF900038）

Technical parameter and complete vehicle description

Introduction to specification data plate

Technical parameter and complete vehicle description

Product quality assurance

Technical document

Technical parameter and complete vehicle description

Body Structure

Technical parameter and complete vehicle description

Schematic illustration of the driver zone

Technical parameter and complete vehicle description

Instruction of instrument (VDO Edition）

Technical parameter and complete vehicle description

1.1 Severe error conditions

1.2 General error conditions

2 LCD Display

2.3 Driving Information

Technical parameter and complete vehicle description

2.3.1 Transmission gear Display：

2.3.2 Time：

2.3.3 System voltage：

Technical parameter and complete vehicle description

2.3.4 Acceleration pedal position：

2.3.5 Oil pressure：

2.3.6 Brake system pressure:

2.3.7 Door status：

2.3.8 ECAS status

2.3.9 Service request

2.2

Error display Page：

Technical parameter and complete vehicle description

2.3 DM1 Diagnosis Information

Technical parameter and complete vehicle description

Air conditioner status

2.5 Engine Cabin Temperature high warning page

Technical parameter and complete vehicle description

2.6 Beeper warning conditions

Technical parameter and complete vehicle description

Illustration of switch and indicator

Technical parameter and complete vehicle description

Technical parameter and complete vehicle description

Technical parameter and complete vehicle description

Technical parameter and complete vehicle description

Air conditioner control panel SK-17-1

Select key introduction:

Control panel operation:

Indicator light introduction:

Technical parameter and complete vehicle description

Note：

the scope of setting temperature is from 15.0

to 40.0

the scope of displayed temperature is from -40.0

to 40.0

Technical parameter and complete vehicle description

Technical parameter and complete vehicle description

Note：

The compressor (COMP) and the condenser (COND) fan will sto p working and the evaporate (EVA) fan will run normally when the system defrosting.

The operation of the defrosting is automatically Controlled. the defrosting operation begins to work when the temperature of the sensor is(ON) at -1

and stops working

(OFF) at 8 .

Note：

Restart the (VENT) switch to carry out the new procedures after the setting.

Otherwise, the previous setting will be carried out again.

Only one parameter can be set for each time.

Technical parameter and complete vehicle description

for 2 seconds at the same time. It can