operation manual

operation manual
OPERATION MANUAL
User’s Guide
King-Long XMQ6129Y series tourist bus
Xiamen King Long United Automotive Industry Co., Ltd.
-1-
Foreword
FOREWORD
King-Long XMQ6129Y series touring bus keeps features of superior
economy, security and comfort. It has stable performance, strong power, luxury
interior trimming and high speed, which could meet applications of passenger
inter-city transportation, touring and business affairs, etc.
As for the specifications introduced in relate to information of the driving
and operation, service and maintenance of the XMQ6129Y series touring bus,
please read them carefully and make proper operation, maintenance and repair so
as to ensure it in good condition. Special hint: without authorization of 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 strong 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 instruction book can only be used as reference. If there are
facts not comply with the manual, will be subject to the actual state of the
products because for some device 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.
APR. 2014
-2-
Contents
Contents
Vehicle picture--------------------------------------------------------------------------------------------------------1
Foreword---------------------------------------------------------------------------------------------------------------2
Contents
Contents----------------------------------------------------------------------------------------------------------------3
Main overall technical parameters
Technical parameters ------------------------------------------------------------------------------------------------7
Introduction to name plate------------------------------------------------------------------------------------------8
Product quality assurance -------------------------------------------------------------------------------------------8
Technical document -------------------------------------------------------------------------------------------------8
Vehicle body structure-----------------------------------------------------------------------------------------------9
Schematic illustration of the driver zone-------------------------------------------------------------------------10
Operation Instruction
Instrument instruction------------------------------------------------------------------------------------------I-1-7
Illustration of switch and indicator s--------------------------------------------------------------------------SI-1-6
Air conditioner control panel-----------------------------------------------------------------------------------P-A-1
Pre-heater panel-----------------------------------------------------------------------------------------------P-H-1-2
Gearbox operation ---------------------------------------------------------------------------------------------O-K-1
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
VDO module location & function description------------------------------------------------------------O-E-1-2
Switch control box----------------------------------------------------------------------------------------------O-E-3
-3-
Contents
Toilet system-----------------------------------------------------------------------------------------------------O-T-1
Vehicle starting and driving
Check oil level of the engine--------------------------------------------------------------------------------------S-1
Check level of the coolant-----------------------------------------------------------------------------------------S-2
Check fuel pre-filter with water separator-----------------------------------------------------------------------S-3
Check fuel level-----------------------------------------------------------------------------------------------------S-4
Check vehicle lighting, intermittent lights and brake lights---------------------------------------------------S-5
Check the level of AdBlue and the daily maintenance of SCR system--------------------------------------S-7
Drain water in air tank---------------------------------------------------------------------------------------------S-8
Check engine oil pressure------------------------------------------------------------------------------------------S-9
Check Pneumatic pressure---------------------------------------------------------------------------------------S-10
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
General knowledge------------------------------------------------------------------------------------------------M-1
-4-
Contents
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
Daily or Refueling Maintenance Operation-------------------------------------------------------------------M-11
Maintenance first 2500km --------------------------------------------------------------------------------------M-12
Maintenance per 5000km---------------------------------------------------------------------------------------M-13
Maintenance per 10000km--------------------------------------------------------------------------------------M-16
Maintenance per 20000km--------------------------------------------------------------------------------------M-17
Maintenance per 40000km -----------------------------------------------------------------------------------M-20
Maintenance per 80000km
------------------------------------------------------------------------------M-20
Maintenance more than 80000km------------------------------------------------------------------------------M-21
Maintenance period chart---------------------------------------------------------------------------------------M-23
Common trouble and its eliminating method
Engine Common trouble and elimination
---------------------------------------------------------------C-1
Clutch---------------------------------------------------------------------------------------------------------------- C-6
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
-5-
Contents
Air conditioner system-------------------------------------------------------------------------------------------C-18
Appendix
Driver's tool table ---------------------------------------------------------------------------------------------- A-1
Tightening moment of the bolts and the nuts in major position
------------------------------------------A-2
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(DA601421-423)
Product model
6129Y
ISL8.9E5400
Engine model
Engine type
In-line six-cylinder water-cooling direct-injection diesel engine
114X144.5
(mm)
Cylinder diameter× stroke
(ml)
Displacement
8900
Compression ratio
16.6:1
Rated capacity / rotation speed (kw/rpm)
294/2100
Max. torque / rotation speed (N·m/rpm)
1700/1300-1400
Overall length (mm)
12200
Overall width (mm)
2550
Dimensions
Overall height
Air spring
3870
(mm)
Leaf spring
---
(mm)
Wheelbase
6000
Wheel
front (mm)
2064
track
rear
1825
(mm)
180
Minimum lift-off clearance(mm)
Approach angle/ departure angle
Front overhang / rear overhang
Rated
(°)
7/7.4
(mm)
passenger (driver included)
2720/3480
49+1+1 or 53+1+1
(person)
Kerb weight(kg)
13800
Mass parameter
Max. gross mass
Front axle
No
(kg)
18000
(kg)
4360
9440
load
Rear axle
Full
Front axle
(kg)
5500
load
Rear axle
(kg)
12500
Performance
parameter
Max. speed
(kg)
(km/h)
130
Fuel consumption (L)
Maximum gradeability
Min. turning diameter
-(%)
≥20
(m)
≤24
Parking for 5 minutes
Parking slope (20%)
Capacity data
Fuel tank(L)
445
Engine oil(L)
27.6
Transmission lubricant(L)
13
Main retarder lubricant(L)
13
Power steering hydraulic oil(L)
8
-7-
Technical parameter and complete vehicle description
Introduction to specification data plate
Bus data plate
The bus data plate may be affixed to either the upside of the front passenger door frame or to the side of the
front passenger door step(the position may vary with vehicle model). There are many parameters on the plate,
such as vehicle model, gross mass, vehicle serial number, vehicle capacity, VIN (short for vehicle
identification number), chassis serial number, engine serial number, engine model, rated power, production
data and etc..
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.
Product quality assurance
We make breaking-in maintenance of the rolling-out new vehicles in their initial driving mileage of
5000 km. Users should make proper operation and maintenance strictly according to relevant
regulations in the instruction book. Please refer to “workshop manual” for product quality assurance
and abide by related specification.
-8-
Technical parameter and complete vehicle description
Technical document
The instruction book is used combined to the following specification:
Engine operation instruction or service manual
Air conditioner instruction book
Transmission operation manual
Heater instruction book
CAN BUS Instrument system instruction book
Monitor instruction book
ABS anti-braking system instruction book
VCD/DVD instruction book
Note: the instruction book should be modified according to specific configuration of vehicle.
-9-
Technical parameter and complete vehicle description
Body Structure
1. Structural style
Semi-integral body structure
2. Structure
The bodywork structure adopts closed girder construction of five major assembly parts, which are
combined welded by rectangle steel pipes with advantages of strong structural stiffness, torsion
resistance and bending resistance as well as relatively simple craftwork. 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: KE-1 high backrest, adjustable type,
the all seats are equipped with 3 points style
seat belts,
pedal plate.
7. Interior accessory device
The vehicle is equipped with electronic clock, sunshade, safety hammer, emergency escaping window,
curtain and luxury bilateral K-1 type luggage rack,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: King Long cooling /heating defrosting device
Heating system: Webasto heating 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、agile、safe、lock 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, the emergency
switch of the door is located on the lower right side of the entrance of the door , 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 -
Technical parameter and complete vehicle description
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
15
14
13
12
11
10
9
8
7
16
6
5
4
3
2
1
1
2
3
4
5
6
7
8
9
Power charging outlet
Air-conditioner control panel
Radiator operation panel
Parking brake handle
Heater switch
Wiper operation handle
Mirrors operation button
Rocker switch
Steering wheel
10
11
12
13
14
15
16
- 11 -
Combination instrument
Light control lever
TPMS indication panel
Fire extinguisher pushbutton switch
Gearshift lever
Reversal monitor
Rocker switch
Technical parameter and complete vehicle description
Instruction of instrument
(VDO Edition)
No.
Function
Description
1
ABS indicator
ABS work/warning
2
High beam indicator
When High beam is switched on
3
Left turning indicator
When Left turning/hazard switch is turned on
4
Severe Error
When the electrical system has severe error. (see1.1 )
5
General Error
When the electrical system has general warning. (see1.2)
6
Right turning indicator
When Right turning/hazard switch is turned on
7
Retarder indicator
Retarder work/warning
8
Parking brake
9
DTCO warning
communication error or without drivers card
10
Engine Revolution speed too
high
Need to change the gear or slow down the bus
11
Trip distance reset button
Set trip distance to 0
12
LCD illumination adjust button
Press the button to adjust the illumination of LCD
13
Fuel level gauge
The fuel remain
14
Coolant temperature gauge
Temperature of engine coolant
15
LCD display
16
Speedometer
Current vehicle speed
17
Odometer
Current engine speed
I-1
Technical parameter and complete vehicle description
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 ):
Figure-1 driving information
pictogram
comments
pictogram
comments
Gear info (see 2.1.1)
Acceleration pedal position
Current time (see 2.1.2)
System voltage (see 2.1.3)
Front door status (see2.1.7)
Preheating indicator
Mid door status (see 2.1.7)
Passenger service/request
cabin(see 2.1.9)
Fluid fan error
Engine red lamp error
I-2
from
Technical parameter and complete vehicle description
pictogram
comments
pictogram
comments
Low beam working
Engine amber lamp error
Front fog light working
Engine Malfunction
Rear fog light working
Engine wait to start (do not start
the engine until this symbol
disappear)
Brake light working
EBS red lamp warning
Lift-axle lock
EBS amber lamp warning
Steering oil level low
ECAS status (see2.1.8)
Steering oil pressure low
Battery not charging (indicate
charging error if this symbol still
exist after engine starts)
Coolant
temperature
(>=98°C)
high
The bar shows brake circuit 1
pressure
Coolant level low
The bar shows brake circuit 2
pressure
Rear flap open (can not start the
engine)
The bar shows engine oil pressure
Worn brake shoes
The bar shows SCR remain
Hammer not at right position
Function description
2.3.1
Transmission gear Display:
: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.
I-3
Technical parameter and complete vehicle description
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 general error
2.3.9
:ECAS severe error
Service request
:Passenger service request
2.2
:Request from cabin
Error display Page:
Figure -2
text error information
I-4
Technical parameter and complete vehicle description
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
I-5
Technical parameter and complete vehicle description
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
I-6
Technical parameter and complete vehicle description
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.
I-7
Technical parameter and complete vehicle description
Illustration of switch and indicator
Number of switches and indicators and position may vary with vehicle model, please consult the flowing
sheet and use correctly according to actual condition of vehicle.
Switch
Name
Color
Retarder
Green
Function
Pressed on top: retarder is turned ON
Pressed on bottom: retarder is turned OFF
Pressed on top: retarder is turned OFF
Pressed on bottom: retarder is turned ON
Retarder turn off
switch
Daylight lamp
Green
Pressed on top: interior lighting ON,
Pressed on bottom: interior lighting OFF
Hazard
Red
when the vehicle have a screw loose, switch
it on, the whole vehicle lamps light
Luggage
compartment lamp
Green
Pressed on top: lamp lights ,
Pressed on bottom: lamp goes out
Compulsory
radiator
Green
Pressed on top: radiator working ;
Pressed on bottom: to turn it off
Ventilator
Green
Pressed on top: ventilator is active,
Pressed on bottom: ventilator is turned off
Front fog lamp
Green
Pressed on top: front fog lamps ON,
Pressed on bottom: front fog lamps OFF
Rear fog lamp
Yellow
Pressed on top: rear fog lamps ON,
Pressed on bottom: rear fog lamps OFF
Vehicle raise/lower
Green
Pressed on top: vehicle raise,
Pressed on bottom: vehicle lower
Defroster
Yellow
Pressed on top: windscreen heater ON,
windscreen heater OFF
Reading lamp
Green
Pressed on top: reading lamp ON, Pressed on
bottom: reading lamp OFF
lamp
Notes
SI-1
only use this button
when vehicle is stopping
only use this button
when vehicle is stopping
Technical parameter and complete vehicle description
Switch
Name
Color
Function
horn
Green
Pressed on top: air horn is active, Pressed on
bottom: electric horn is active
Engine idle
Green
Pressed on top: engine idle speed raise,
Pressed on bottom: engine idle speed lower
Front passenger door
Green
press button once to open front passenger
door;
press button again to close
Rear passenger door
Green
press button once to open passenger door;
press button again to close
Electric curtain
Green
Pressed on top: to raise curtain;
Pressed on bottom: to lower curtain
TV
green
Pressed on top: TV is turned ON,
Pressed on bottom: TV is turned OFF
Reversal monitor
Green
Pressed on top: reversal monitor turned ON,
Pressed on bottom: reversal monitories
turned OFF
Rearview mirror
defrost(preheating)
Yellow
Pressed on top: preheating ON,
Pressed on bottom: preheating OFF
Diagnose
Green
press this button to make a diagnosis of
engine, when engine indicate trouble
Green
Pressed on top: disinfection turned ON,
Pressed on bottom:
disinfection
turned OFF
Cruise
Green
Pressed on top: cruise function is active,
Pressed on bottom: cruise function isn't
active
we advise clients
not to use this
switch
Cruise setting
Green
cruise setting
we advise clients
not to use this
switch
Red
Pressed on top: Emergency time-delay
parking function is active,
Pressed on bottom: Emergency time-delay
parking function isn't active
only used when
engine failure
Disinfect
Emergency time-delay
parking
SI-2
Notes
adjust
speed
engine
Technical parameter and complete vehicle description
Switch
Name
Color
Function
Red
Pressed on top: turn on guidepost lamp;
Pressed on bottom: turn off guidepost lamp
Assistant brake
Yellow
Pressed on top: turn on assistant brake;
Pressed on bottom: to turn it off
Vehicle level reset
Green
Pressed on top: vehicle level reset
Red
Pressed on top: emergency power turned ON
Pressed on bottom: emergency power is
turned OFF
Green
Pressed on top: Toilet power is turned ON,
Pressed on bottom: Toilet power is turned
OFF
Red
Pressed on top: to turn on heater ;
Pressed on bottom: to turn it off
Green
Pressed on top: expand the TV,
Pressed on bottom: collapse the TV
Fresh air switch
Green
Pressed on top: turn on the changing fresh
air function;
Pressed on bottom: turn off the changing
fresh air function.
Electric driver window
switch
Green
Pressed on top: the glass getting up;
Pressed on bottom: the glass getting down.
Yellow
Pressed on top: turn on defrosting function;
Pressed on bottom: turn off defrosting
function.
Exterior guidepost
Emergency power
Toilet power switch
Heater switch
TV overturn switch
Electric driver window
defrosting switch
Rearview mirror
defrosting switch
Pressed on top: turn on defrosting function;
Pressed on bottom: turn off the defrosting
function.
Left side bin gate
Pressed on top: open the left side bin gate;
Pressed on bottom: close the left side bin
gate.
Green
SI-3
Notes
only switch on when
vehicle need park
Technical parameter and complete vehicle description
Switch
Name
Right side bin gate
Color
Function
Green
Pressed on top: open the right side bin gate;
Pressed on bottom: close the right side bin
gate.
Pressed on top: turn on powerful function;
Pressed on bottom: turn off abstemious
function.
Powerful/abstemious
transfer switch
Green
Pressed on top: the sun blind getting down;
Pressed on bottom: the sun blind getting up.
Driver seat lamp switch
Green
Pressed on top: turn on the driver seat lamp;
Pressed on bottom: turn off the driver seat
lamp.
Kneeling switch
Green
Pressed on top: turn on kneeling function;
Pressed on bottom: turn off kneeling
function.
Coin box switch
Green
Pressed on top: open the coin box;
Pressed on bottom: turn off the coin box.
Turning lamp switch
Green
Pressed on top: turn on the turning lamps;
Pressed on bottom: turn off the turning
lamps.
ACU unlock switch
Green
Pressed on top: ACU unlock;
Pressed on bottom: ACU lock.
Green
Pressed on top: turn on the inner guidepost;
Pressed on bottom: turn off the inner
guidepost.
Electric sun blind
Inner guidepost switch
Notes
SI-4
For
articulate
plate only
Technical parameter and complete vehicle description
Indicator lamp
Color
Function
Red
passenger door open indicating
Red
natural gas leakage indicating
Red
front passenger door open indicate
Red
rear passenger door open indicating
Red
exit has been open indicating
hollow plate
Yellow
ECAS alarm indicating
Red
ECAS fault indicating
Red
gearbox fault warning indicating
Green
retarder indicating
yellow
Fuel filter seeper
Hollow plate
Yellow
Maintain waiting
yellow
Start
Red
Stop
Yellow
Alarm
Red
Water level
hollow plate
Green
WC
Red
Service
SI-5
Technical parameter and complete vehicle description
Indicator lamp
Color
Function
Red
Transmission oil temperature too high
Red
Transmission fault
White
Start-up waiting
Yellow
Over emission
Yellow
Kneeling lamp
Green
Normal height
SI-6
Technical parameter and complete vehicle description
Air conditioner control panel (SK-17-1)
Air conditioner (KL-XIY-J)
Select key introduction:
Power key
Indicator light introduction:
Select ensure key
low air speed
midterm air speed
Air speed select key
high air speed
Fresh air select key
Cooling
Setting Temp
Pressure alarm indicator
Fresh air
Up key
Down key
Temperature display
Control panel operation:
1) How to use the air conditioner
⑴ Start the engine
⑵ turn ON the cooling switch, push
⑶set 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
Technical parameter and complete vehicle description
3) Temperature controlling
For example: adjust the set temperature from 25℃ to
5
2
O
T
U
A
regulation
Press once
Press
again
and
Automatic setting
after 5 seconds
display the setting temperature
20℃
Displaying the
temperature inside
the bus from the
LCD screen
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
to 20℃. Press the button of
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
25
Press
→
once
When starting the
℃
Press
→
twice
25
℃
Press
→
three times
25
℃
Press
→
four times
25
O switch, the wind flowrate will begain from the low level .
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
and
and the
. The
flow selection is not work at the moment. Press the
button at the same time for 2 seconds can stop the automatic flow rate selection
indicator light will stop and the air flow rate
selection will recover.
6) Working conditions of the automatic flow rate selection
High air flow rate: The temperature of air-return inside the bus is higher than 26.5℃
(including 26.5℃).
Medium air flow rate: the temperature of air-return inside the bus is 24.5—26℃.
P-A-2
℃
Technical parameter and complete vehicle description
Low air flow rate: the temperature of air-return inside the bus is lower than 24℃
(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
over 27℃. The cooling delay time is 10 seconds when it’s at the first starting, after this the
interval time is 30 seconds.
on cooling m ode
Setting tem perature 25°
(+ C)
C
Tem perature
cycle2° C
(- C)
O FF 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
When the temperature setting is15℃ and press the button
for 5 seconds, the temperature
setting indicator 2℃. After the strong cooling work for few seconds, the cooling
light
up. The temperature setting turn back to 22℃ when one cooling cycle finish.
10) Defrosting temperature
The LCD screen will display the defrosting temperature1 or defrosting temperature 2 by
pressing the button of
or
.
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Technical parameter and complete vehicle description
11) The part below the LCD screen will flash when the defrosting function working.
O
T
U
A
.
5
.
5
2
D is p la y t h e d e f r o s t in g te m p e r a t u r e
Note:
⑴ The compressor (COMP) and the condenser (COND) fan will stop 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
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, it shows the
Technical parameter and complete vehicle description
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
procss it isn’t operation. After 5 seconds, it shows the air return inlet temperature. When the air
conditioner is working, press the
cleanup the time as 0.
and
for 2 seconds at the same time. It can be
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.
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Technical parameter and complete vehicle description
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.
1. heater “on” indicator
2. day of the week
3. time display
4. memory location
5. alarm indicator
6. time
7. program selection
8. instant heating
9. reverse
10. forward
2. Operation
The timer can be operated in that all flashing symbols
can be adjusted by means of the 10 and 9 buttons.
11. panel
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.
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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Technical parameter and complete vehicle description
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.
appears on the display. Set the
Repeatedly press the 7 button until the bell symbol
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
longer visible on the display.
is no
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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Technical parameter and complete vehicle description
ZF ASTRONIC
Gearbox
Operation description
NOTE
Some deviations from the operating elements and
processes may occur depending on the manufacturer and
vehicle type.
Therefore, also consult the vehicle manufacturer’s
operating manual.
DANGER !
The driver must not leave the vehicle when the engine
is running and a gear is selected.
1.1 Starting the engine
Engage parking brake
Rotary switch is pointing to « N »
(transmission in neutral setting)
Switch on “ignition”
Self-check of
shift system
(« CH » display)
Start the engine
Self-check is
complete.
« N » appears on the
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Technical parameter and complete vehicle description
display, transmission is
in neutral setting
NOTE
Gear shifts are not possible when the engine is at a stand-still.
1.2 Setting off, forwards travel
Start the engine (see 2.1).
Turn rotary switch from
« N » to « D ».
Automatic mode is
activated
The display shows the
starting gear selected. (The
system selects the starting
gear itself, the clutch remains
separated (disengaged).)
Depress accelerator and at
the same time release the
parking brake.
DANGER !
The vehicle may roll away even if the accelerator is
not depressed.
Vehicle sets off (clutch closes automatically).
1.2.1 Uphill start-off
DANGER !
Engage gear, then release the locking brake when
actuating the accelerator pedal, otherwise, the vehicle
will roll backwards.
1.2.2 Correcting the starting gear
The system proposes a starting gear. This can be
corrected to a gear within the range between minimum
and maximum starting gears.
How to make a correction:
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Technical parameter and complete vehicle description
Press tip lever in the « + » or « – » direction.
The display shows the starting gear selected.
Range selector

1.3 Manoeuvring
1st gear (depending on vehicle, 1st and 2nd gear) and R
gear are provided as manoeuvring gears for extremely
slow travel. Manoeuvring mode is not available in the
other gears.
The system detects manoeuvring mode from the position
of the accelerator and the low roadspeed.
When in manoeuvring mode, the vehicle (accelerator) is
very sensitive and clutch activation is different to that of
normal driving mode.
DANGER !
Depending on the accelerator position and the
roadspeed, a change will be made from manoeuvring
mode into setting off mode.
The vehicle may accelerate suddenly.
RISK OF ACCIDENT!
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1.4 Starting to roll on slopes
Precondition: the engine must be running
DANGER !
If the vehicle starts to roll and no gears are selected –
rotary switch pointing to « N » – the engine brake is
ineffective.
Do not allow the vehicle to roll in the opposite
direction of travel to that of the gear selected, i.e.,
vehicle must not roll forwards when in reverse.
If the vehicle rolls forwards – with transmission in
neutral – once the brake is released and the driver shifts
from « N » to « D », then the system selects a gear
suitable for the roadspeed. The clutch closes without
actuation of the accelerator pedal; now, the driveline is closed.
1.5 Changing between manual mode and automatic mode
Always possible, even while the vehicle is in motion.
Changing from manual to automatic mode
tip lever to the left
Changing from automatic to manual mode
tip lever to the left or push tip lever in
the « + » or « – » direction.
Range selector
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1.6 Changing gear
1.6.1 Changing gear in automatic mode
All upshifts and downshifts are performed
automatically.
These depend on: ➢ drive situation
➢ loading
➢ accelerator position
➢ road speed
➢ engine speed
2 arrows and 4 bars = automatic mode;
8th gear is selected.
1.6.2 Changing gear in manual mode
Press tip lever in « + » or « – » direction.
When a shift is performed manually, the shift system
automatically exits automatic mode. If the driver moves
the tip lever to the left, automatic mode is reactivated.
Jumping gears:
Jumping one gear:
Twice in rapid succession, push tip lever in the
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Technical parameter and complete vehicle description
direction required.
Jumping two gears:
Three times in rapid succession, push tip lever in the
direction required.
NOTES
➢ You can use the rotary switch to shift from any gear
to neutral at any time. This shift process always takes
priority.
➢ The position of the accelerator must not be changed
during the shift process because the engine is
automatically controlled.
➢ A shift command is not carried out if this shift would
lead to the maximum engine speed (governing
speed) being exceeded.
DANGER !
The driver may shift to « Neutral » during travel. If
the driver does shift to « Neutral », the driveline is
interrupted.
The engine brake is then no longer effective.
1.6.3 Engine braking effect when changing gear
The engine brake is deactivated by the system during
gear shifts. Once the gearshift is complete, the engine
brake is then automatically reactivated.
If the engine brake is actuated, the system switches back
into automatic mode so that the maximum engine
braking effect is achieved.
DANGER !
The effect of the engine brake is interrupted during
gear shifts. The vehicle may accelerate when
travelling downhill.

1.7 Reversing
Selecting reverse gear:
The vehicle must be at a
stand-still.
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Technical parameter and complete vehicle description
Turn rotary switch to « R ».
« R » appears in the display
(clutch remains separated
(disengaged)).
Depress accelerator and
at the same time, release
brake (clutch closes
automatically).
Vehicle moves backwards.
DANGER !
If the vehicle is rolling, shifts cannot be made into
reverse!
Stop the vehicle immediately.
1.8 Changing direction of travel
Changing from reverse « R » to forwards travel « D »
and vice versa.
DANGER !
A change in the direction of travel, performed by
moving the rotary switch from « R » to « D » and vice
versa « D » to « R », may only be undertaken when
the vehicle is at a standstill otherwise the
transmission will shift into neutral.
Only refer to the display for the direction of travel
selected in the transmission.
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Technical parameter and complete vehicle description
1.9 Stopping vehicle
Do not actuate the accelerator and use the service
brake to bring the vehicle to a standstill.
The clutch opens automatically before the vehicle
reaches a standstill so that engine “stalling” is
prevented.
If remaining at a standstill for long periods of time, we
would recommend selecting the neutral position in the
transmission.
If vehicle is in stationary position, always ensure that
locking or foot brake is engaged.
DANGER !
◆
If the vehicle is at a standstill with the engine
running and a gear selected, the vehicle can be
moved by simple depressing the accelerator!
◆
Before leaving a vehicle with the engine running,
the transmission must be shifted into neutral and
the parking brake engaged.
◆
Actuating the parking brake during travel may
result in the engine coming to a standstill. Powerassisted
steering is then no longer available!
1.10 Switching off engine / parking vehicle
Bring vehicle to a standstill
Engage parking brake
Move rotary switch to « N » neutral
Switch off engine via ignition key
Place chocks under vehicle wheels
DANGER !
The engine cannot be switched off if a gear is
selected.The vehicle may roll away if brakes are not
actuated. Engage locking brake.
NOTE
If the transmission is not shifted into neutral before the
engine is switched off, this is done automatically once
the ignition is « Off ».
1.11 Towing
NOTE
Vehicle manufacturer instructions must be observed
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Technical parameter and complete vehicle description
when towing.
CAUTION
For towing purposes, always disconnect the propeller shaft
flange from the rear axle before setting off. If it cannot be
disconnected, remove both stub shafts.
Avoid polluting the environment in the event of oil loss.
1.12 Tow-starting
The engine cannot be tow-started.
1.13 Clutch protection
« CL » is displayed if there is a risk of clutch overload
resulting from several starting process occurring in
rapid succession or of crawling in too high a starting
gear.
NOTE
Select an operating mode in which the clutch will not be
overloaded, for example:
➢ accelerate vehicle (to close the clutch)
➢ stop the vehicle
➢ set off briskly in a lower gear
➢ To conserve the mechanical components of the clutch
release device, the transmission should be shifted to
neutral if the vehicle stops for long periods of time
(for more than approx. 1 to 2 min., for example, in
traffic jams, at railway crossings etc.).This closes the
clutch and relieves the clutch release device.
Even though the clutch is automated, the driver still has
considerable influence on clutch service life. To keep
levels of wear on the clutch low, we would recommend
that when setting off, you always select the lowest
gear possible.
1.14 Engine overspeed protection
The electronics system only allows shifts to be
undertaken if they lie within the speeds specified by
the vehicle manufacturer. This is done to the benefit of
both engine and transmission.
1.14.1 Manual mode
➢If the vehicle accelerates on downhill gradients, an
automatic shift is not made into a higher gear.
➢ Ensure that the engine does not exceed the
permitted speed range.
CAUTION
The engine may be damaged if the vehicle is accelerated on
downhill gradients and the engine thereby enters the
overspeed range.
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Technical parameter and complete vehicle description
1.14.2 Automatic mode
DANGER !
The vehicle may accelerate on downhill slopes.
The system will undertake an upshift to protect the
engine from damage caused by over speeding (red range)
1.15 Roller test rig
Drive onto the roller test rig
(brake test rig)
Turn rotary switch to « N » Neutral.
When the roller is activated, the system recognizes
the “driving vehicle” function. If only the driving
axle is on the roller, an AS TRONIC ABS error is
detected since the front wheels are not turning.
Reverse gear cannot be selected when the roller is
activated.
If a gear is selected, the clutch closes.
DANGER !
The vehicle may drive off the roller even if the
accelerator is not depressed.
1.16 Displays for ZF-AS TRONIC
The display provides information on the status of the
transmission.
Operating display:
◆
Automatic mode is shown in the
display by means of 4 bars and 2 arrows.
(8th gear is selected in transmission)
◆
Manual mode
◆
4th gear selected in transmission
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Technical parameter and complete vehicle description
◆
Manual mode
◆
8th gear is selected in transmission.
Downshifts of up to 3 gear stages
possible (one gear per bar)
◆
Transmission in neutral position
◆
Reverse gear of the transmission is
engaged.
◆
« CH » = system self-check.
◆
Display appears when ignition is “On”.
Warning indication:
◆
« AL » = airless.
◆
Alternates with the normal display. The
transmission compressed air system has
insufficient pressure.
NOTE
Only set off once there is sufficient pressure in the
pneumatic system. Due to too low air pressure at
vehicle stop, the clutch may not open and thus, the
engine will be “stalled”.
DANGER !
If shifts are undertaken when pneumatic pressure is
too low, the transmission may remain in neutral to
ensure that there is no direct drive and that the
engine brake is ineffective
◆
« FP » = drive pedal (accelerator)
◆
Move accelerator into idle position.
◆
If the display does not go out, there is a
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Technical parameter and complete vehicle description
system error. The vehicle cannot be
driven.
◆
« CL » = clutch
◆
Alternates with the normal display.
Clutch is overloaded.
◆
Remedy: chapter 2.13 clutch protection
◆
« CW » = clutch wear
◆
Proceed to approved workshop to have
clutch exchanged at next opportunity.
◆
«HT» = High temperature
(too high transmission temperature)
◆
«EE» = Electronic Error
◆
Is displayed when the communication
of the display with the transmission
electronics is disturbed.
System error:
◆
« Spanner » = system error
◆
Appears if the operations are only
available with restrictions.
◆
Visit a specialist workshop as soon as
possible.
NOTE
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Technical parameter and complete vehicle description
When certain system errors occur, automatic mode is
deactivated and the transmission system remains in manual
mode.
« STOP » + « Spanner »
= serious system error
◆
Stop the vehicle. Vehicle may no longer
be driven and must be taken to a
workshop.
DANGER !
If possible, do not stop the vehicle when it is in a
danger zone.
1.17 System errors (error messages)
◆
If a « Spanner symbol » appears in the display, a
system error has occurred. Operations may only be
possible with restrictions. If « STOP » and the
« Spanner symbol » appear in the display, a serious
system error has occurred. Stop the vehicle. Vehicle
may no longer be driven (refer to chapter 2.16).
◆
Error messages and the reactions resulting from
these errors can be deleted with the vehicle at a
standstill and the « Ignition off ». (Wait until the
display goes out). If the display does not go out once
the ignition has been turned « Ignition off », use the
battery isolator to switch off the system. Switch the
ignition back on. If the error message is still in place,
the vehicle will have to be taken to a service point.
The error number(s) must be specified when the
service point is contacted.
Calling up error numbers:
Switch on ignition
Turn rotary switch to « N »
Hold tip lever in « + » position
Range selector
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Technical parameter and complete vehicle description
Depending on the version, a 2 or 3-digit error number
appears on the display. This corresponds to the error
currently in place.
If 4 bars are displayed in addition to the number, this
means: error no. + 100 (only applies to two-digit
displays).
If – in addition to displayed figure – 4 bars and
2 arrows are displayed, this means: error number
+ 200 (only for two-digit displays).
Error number from error memory at call:
Switch on ignition
Turn rotary switch to «N» and actuate foot brake in
parallel
Tip lever to be kept in « + » position
Subsequently, the stored errors will appear on the
display.
1.18 Starting the vehicle at very low temperatures
The transmission is filled in accordance with ZF List
of Lubricants TE-ML 02. It can therefore be used in
outside temperatures of down to –30 °C. The following
should be noted:
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Technical parameter and complete vehicle description
◆
At outside temperatures of below
–20 °C and –30 °C,
the transmission will require a warming up
phase once the engine is started.
The engine must be operated for at least
10 minutes with the vehicle at a standstill
until the transmission oil has warmed up.
◆
At outside temperatures of below –30 °C,
warm air must be used to heat the
transmission up to a temperature above
–30 °C before the engine is started.
The vehicle manufacturer’s specifications should
always be observed.
1.18.1 Using the vehicle when the outside temperature is
between 0 °C and –40 °C
If the outside temperature is continually very low,
specifications for starting the vehicle must be
requested from the LPE2-B department at ZF.
1.18.2 Parking the vehicle at very low temperatures
The vehicle may be parked for a long time or the
transmission may be stored at outside temperatures of
down to –40 °C.
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TPMS
OPERATION
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TOILET OPERATION
一
(1). Functions and Operations
①.When using the toilet, please lock the door to ensure the system is functioning properly.
②.Occupied Light: This indication light is controller by the toilet door lock. It can probably be
installed on the door of the toilet module, or be located at the front of the Coach. The passengers can
be aware of the status of the toilet. If the toilet module is vacant, the light indicator will not be on (or
will show green light.) if someone is using the toilet, the light indicator will be on (or will show red
light.)
③. Internal Illuminating System: The dome light inside the toilet has two status. One light is
always on and is a low wattage light so long as toilet module’s power supply is on. The other one,
which is a high wattage light, will only be turned on when a passenger enters the toilet module, closes
and locks the door. At that time, It has just been turned on by the door lock which triggers a
micro-switch.
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Technical parameter and complete vehicle description
Faucet
④. Hand Wash System: The toilet is
Soap dispenser
equipped with a water pump for the hand wash
faucet. When the button is pushed, the water
pump is turned on for a certain period of time
Hand-wash
button
(normally 3-5 seconds). The water will keep
running until the time is up. The waste water is
drained to a holding tank. One can push the
soap dispenser for the hand wash soap.
⑤. Toilet Flush System: Push the
flush button, produce stream (about
300-500ml), the drain valve will open
in a short time and the waste in the
toilet
will
be
flushed
into
the
waster-water holding tank.
Flush button
Toilet cover
⑥.
Door Seal and Ventilation System: The door of the toilet module has a seal strip, which
prevents any odor from getting into the bus; The toilet module is equipped with a fan (a dual fan with
inner and outer two different uses, the fan will be operated in a low speed to vent the air constantly,
when the toilet is vacant, however, it will be operated in high speed for ventilation, when the toilet is
occupied. The outer fan operates in a normal speed), keeping Fresh air in the bus with automatically
ventilation.
⑦. Handles: For the safety and convenience of the
passengers, the toilet module has installed safety
handles inside or also outside of the toilet module.
Internal
handle
⑧. The dashboard indication: in the signal area of dashboard, it can indicate in time: vacant or
occupied, the water state of fresh-water and waste-water holding tank, and emergency (Alarm button
is installed in toilet) and so on, which makes drivers know the usage status of the toilet.
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Technical parameter and complete vehicle description
⑨. Fresh -Water Holding Tank System: The holding tank is to store the fresh water for toilet flush and
hand wash, please check the water level before use. Make sure water is full. If the Water Level Warning
System indicates lack of water, please watering in time. Before watering, taking out overflow pipe,
watering overflow pipe until fresh water tank is full.
⑩. Waste-Water Holding Tank System: The holding tank is to store the waste water after toilet flush
and hand wash. When the Warning System indicates that the holding tank is full, one should stop using
the toilet immediately. After the coach arrives at the tank evacuating area, turning the handle of the
evacuation valve will open the valve to drain the holding tank. Turning the handle back after evacuation
will close the evacuation valve.
二
(2). Caution in Use
①. Main Power: The usage of toilet should be in the condition of power supply state, the main
power is controlled be the driver by operating the switch of power which is on the dashboard. In case,
the toilet is not functioning properly (such as malfunction of some components, running out of clean
water, or the waste water tank is full, etc.), the driver can switch off the main power and lock the door
temporarily and put the toilet out of service. If the toilet is nonuse in a long time period, please switch
off the main power of the toilet.
②. Initialization (aim at inducing system toilet): There is a requirement of 50s for the system
initiation after electrify of toilet, both the act of deduce and the self inspection of controlling function
are natural during the process.
③. Please check Fresh-Water and Waste-Water Holding Tanks before driving, top up fresh water
tank, drain waste water tank, and have a browse
to the whole module to find if somewhere is
abnormal obviously. Waste water tank should be drained in time and the garbage bin should be cleaned
up during driving.
④. Toilet paper, paper towel and other wastes should be thrown into waste basket, rather than left
anywhere in toilet module or even thrown into toilet bowl or basin.
0-T-3
Technical parameter and complete vehicle description
⑤. When clean the inside of the toilet module,
remove the cover of the floor drainage. The water can
be drained directly out of the coach through the floor
drain. Please do not spray water at the electrical
junction box, the fan, and other electrical equipment to
avoid wetting them and resulting in damage. It’s
favourable to use a damped cloth to wipe the surface of
Drainage
on floor
toilet, but not to have any hard object to contact with it
for avoiding any damage of
the surface finish.
Sliding valve should be cleansed regularly to keep the
drain valve operating smoothly always.
⑥.When shut down the toilet module under the
sub-zero temperature environment, please drain all the water in the holding tanks, then press the
button of hand wash or toilet flush for several times, drain the water in the pump, turn on the cover of
filter, and drain the water in the filter as well to avoid freezing to build up water or damaging
electrical parts. If the sliding valve is frozen or water components are frozen, toilet can not be put in
use until they are all unfrozen. You never try to open the frozen valve by force. The valve needs to be
defrosted by warm water before use.
⑦. Please push/ touch the faucet button moderately, do not hold on to longer or turn on by great
force to avoid wasting water or shortening the use life-span of electrical parts.
⑧. Do not insert or pull out casually during any electrical part working.
⑨.When use the toilet, do not change inside circuitry or exchange any disqualification electrical
parts; In case any malfunction occurring, follow instructions to solve it before the toilet module is put in
use renewedly.
⑩. Toilet needs to be cleaned and maintenanced regularly.
0-T-4
Technical parameter and complete vehicle description
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.
Specification:
For the king-long city bus, the
method of open and close the passage door is different
to above. Details please see the right drawing. The red
button is close button; the green button is open button.
This device usually located on the bin under the driver
seat compartment. If need open or close the front
passage door without remote controller, directly press
the green button or red button. The middle passage
door and the rear passage door of city bus controlled
by the knob switch on driver zone.
Appedix:
The following are all type of door lock and door remote controller of King-Long.
0-K-1
3
4
Technical parameter and complete vehicle description
Lock1
Lock 2
Lock 3
0-K-1
Technical parameter and complete vehicle description
Door remote controller 1
Door remote controller 2
Door emergency switch
Model 1
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 2
Model 3
0-K-2
Technical parameter and complete vehicle description
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 angle adjustment
Handle 3: back and forth adjustment
Handle 4: 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.
0I-1
1
2
3
4
Technical parameter and complete vehicle description
Horn button
Model 1
It is on the steering wheel. The horn is hooting when
pressing the button 1.
The type of steering wheel may vary with vehicle model.
Please use the horn only when strictly necessary to warn
other drivers and pedestrians.
1
Model 2
1
0I-2
Technical parameter and complete vehicle description
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.
1
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.
0I-3
2
Technical parameter and complete vehicle description
Ignition switch
Position of the ignition key is shown in fig.1.
"K" KEY: for inserting and drawing out position of the
startup key
1."L" LOCK: Insert or remove the key in this position.
2."A" ACC: Power supply of the instrument is switched on
3."O" 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. Turn the ignition key to the OFF position after the engine has been turned off and has stopped
running.
2. If the first attempt to start the engine is not successful, please wait two minutes before trying again.
3. 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. If engine can not start successfully for the first time, try again after 2 minutes. Please check the fuel
supply system if the engine can not start for the third time.
3. When leaving the vehicle, even for a short period, take the key out to avoid operation of the vehicle
by children or unauthorized persons.
OI-4
1
Technical parameter and complete vehicle description
Lamplight operating handles
Model 1
The lamplight operating handle is located on right
underside of the steering wheel, which control the front
small light, headlamp, headlamp dimming, left and right
steering by two different motion modes
OFF
Indicating that the headlamp and the small
lamp are all off.
Model 2
Is the small lamp indication. The small lamp,
the instrument light and the side indicator lamp will all
be turned on when clock wisely rotating the handle 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 clockwise rotating the
handle 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.
Model 3
Model 4
Is dimming indication. Uplifting 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.
OI-5
Technical parameter and complete vehicle description
Wiper operating handle
Model 1 (with retarder)
The wiper operating handle is located on right underside
of the steering wheel. (model 1~3)
OFF Out of work
INT interval wiper operation step
LO Slow wiping
HI Quick wiping
The wiper operating handle is located on left underside of
the steering wheel. (model 4)
Rotary handle
0 Out of work
J interval wiper operation step
1 low speed wiper operation step
2 HI high speed wiper operation step
The wiper may spray water by pressing the end of the
handle.
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.
Model 2 (with exhaust brake)
Model 3
Model 4
OI-6
Technical parameter and complete vehicle description
Passenger control panel instruction
1.
2.
3.
4.
5.
6.
Model 4
air outlet
service button
reading lamp button
lamp
loudhailer
stop button
Model 1
1
2
3
4
Model 5
4
6
2
1
Model 2
1
4
2
Model 6
5
4
1
2
3
Model 3
2
3
1
4
OI-8
5
Technical parameter and complete vehicle description
Safety hatch
Model 1
The safety hatch is located on scaffold of the vehicle.
Please open the safety hatch according to the above
diagrammatic representation and illustration for
escaping in case of danger.
Model 2
Model 3
OI-9
Technical parameter and complete vehicle description
Safety hammer
Model 1
The safety hammer is located on the side window.
Please take down the safety hammer and break open
the safety window for escaping in case of danger.
Model 2
OI-10
Technical parameter and complete vehicle description
VDO module
Installation position
installed the step wall behind of
1.Central control electric box
driver seat
installed the step wall behind of
2.Body module 1
driver seat
(front control unit)
installed in the air duct over the
3.Body module 2
RH /FR passenger seats
(ceiling control unit)
0-E-1
Technical parameter and complete vehicle description
installed in cabin box at the RH RR
4.Body module 3-4
(middle &rear control unit)
installed the step wall behind of driver seat.
5.Retarder control unit
installed on the wall of luggage cabin.
6.WABCO ABS control unit
installed in dash board.
7.Instrument control unit
0-E-1
Technical parameter and complete vehicle description
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
Function description:
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
Function description:
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
Function description:
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
0-E-2
Technical parameter and complete vehicle description
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.
0-E-2
Technical parameter and complete vehicle description
Switch control box (Model: CQ2025)
CQ2025 A wiring diagram (Printed on opposite cover of the switch control box)
0-E-3
Technical parameter and complete vehicle description
The hydraulic fan mechanism
This system should be made to drive the fan’s rotation through pressure yielded from hydraulic oil.
0-E-4
Vehicle Starting and Driving
Preparatives for vehicle operation start up:
Check daily, before turning engine on:
Oil level dipstick
1. Check oil level of the engine
The warning “Engine oil pressure” is displayed as a signal
item on the combination instrument when the oil pressure
is too low, the alarm buzzer sounds, the warning light
STOP comes on, stop the engine and check engine oil level
at the dipstick. 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.
S-1
Oil inlet
Vehicle Starting and Driving
2 Check level of the coolant
The coolant level is automatically monitored.
If coolant level gets too low,the digital indicator
displays a driver information on the combination
instrument. In this case, park vehicle in a safe place as
traffic conditions permit, stop engine and visually
check the coolant level.
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 compensation 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 compensation 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 compensation tank should be
opened when adding the coolant to eliminate 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
Observe pipe
Observe pipe
Anti-freeze and antirust solution (mixture of glycol and water) should be added to cooling system from
time to time to avoid sediment, frost, oxidation and increase boiling point.
Note: When adding coolant, please choose the same model to avoid sediment. If coolant is degenerative,
replace it immediately.
Coolant specification as shown below: users should choose products produced by normal factories
according to requirement
S-2
Vehicle Starting and Driving
3 Fuel pre-filter with water separator (drain accumulated water)
Draining accumulated water
On a daily basis, check the lower cup of the water
separator. If there is water in the cup, unscrew the
draining plug one or two turns, to drain the accumulated
water.
After draining the water, tighten the draining plug
correctly.
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 changed periodically,
at the intervals recommended in the maintenance manual.
If however, the filtering element is easily saturated
needing substitution at very short intervals, this is an
indication of the accumulation of impurities in the
interior of the fuel tank, and the cleaning of the latter
should be carried out.
In order to change 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.
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).
S-3
Model for Euro II
Release valve
Manual pump
Model for Euro IV, V
Vehicle Starting and Driving
4. Fuel level
Turn the ignition key to drive position (on).
Check the fuel level on the indicator. If necessary, fill up
the fuel tank. (but direct viewing by open the tank cover is
preferred).
Eliminate deposite water in diesel filter in time and check
fuel pipe for no leakage. 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 to empty tank. 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.
S-4
Vehicle Starting and Driving
5. Vehicle lighting, intermittent lights and brake lights
Check all instruments and indicator lamps for normal, especially the head lamp, the turning lamp, the brake
lamp, the reversing lamp and the danger alarm lamp.
Check the bulb and the switch for their damage. To carry out the lamp substitution, hands should be very
clean. If possible handle new lamps with tissue paper.
Clean the external of all instruments and indicator lamps to ensure clear indication.
Attention!
The traffic laws regulate the location, lighting intensity, and color of the lenses and the quantity of
lanterns for each type of vehicle. The King-Long vehicles leave the factory in strict obeyance of these
specifications. Traffic safety depends on these factors; therefore do not change the place of the lanterns.
Substitute the damaged lanterns only for other original ones. Remember that a change of lantern colors
can confuse other motorists and result in serious accidents. Avoid unnecessary lantern adaptations.
When substituting lamps, use the same type and potency as the original lamps. Do not carry out any
lamp adaptation in the headlights, as this will affect their adjustment and performance, putting the
vehicle traffic safety at risk.
On a regular basis revise the illumination system, keeping it always in perfect working conditions.
S-5
Vehicle Starting and Driving
6. Check the level of AdBlue and the daily maintenance of SCR system
(1)
The volume of AdBlue
Check the level of AdBlue.
When the vehicle key rotate the ON position, the LED
screen of combination instrument will display the
remain volume of the AdBlue, please see the right
diagram.
The AdBlue consumption is 5 percent of the fuel
consumption. 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
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.
Special attention:
S-7
1
Vehicle Starting and Driving
If the AdBlue spill in skin, mild irritation may occur. Wash off with soap and water. If the AdBlue spill in
eye, irrigate eyes with large amount of water. The AdBlue is Non-combustible, if heated water evaporates
and ammonia will be released.
S-7
Vehicle Starting and Driving
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)
S-8
Vehicle Starting and Driving
Check daily after turning engine on:
1. engine oil pressure
Run the engine.
The information on engine oil pressure can be requested through the driver information digital display.
If the oil pressure is too low, the oil pressure is automatically shown on the combination instrument.
Indication of the oil gauge will show a high value after the cold start of the engine and then it should be
kept within the range of 0.3-0.5Mpa (3- 5kg/cm2) along with the increment of the oil temperature as well
as the normal engine speed.
S-9
Vehicle Starting and Driving
2. Pneumatic pressure
The air pressure gauge indicates the reserve pressure individually for the front and rear service brake
circuits.
The reserve air pressure in each brake circuit must be sufficient for the correct operation of the brake
system.
The STOP warning light comes on in case of low brake pressure in the service brake or parking 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 if the air pressure gauge displays low air pressure in one or both brake circuits, as the
service brake could fail resulting in serious accident.
S-10
Vehicle Starting and Driving
3. Tachometer working order
Indications on tachometer scale:
a. Green zone – operating range of maximum
performance
b. Yellow zone –
c. Red zone – engine overspeed range (risk of
immediate engine damage)
Always observe tachometer while driving the vehicle.
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.
S-11
Vehicle Starting and Driving
4. Steering play
A
Steering wheel play
Run the engine at idle gear and straighten the front
wheels forwards.
Turn the steering wheel alternatively to the right and to
the left.
The steering play (free movement of the steering wheel)
is measured on the perimeter of the steering wheel and
should be between 20 and 30 mm.
S-12
Vehicle Starting and Driving
Control periodically, at least once a week:
1. Check tire for abrasion and pressure and tire nut for fixture
The vehicle’s safety and performance depend considerably on the state of the tires, reason why they
should be checked daily.
Before driving a vehicle, check charging pressure of tire for normal, tire for damage, tire nut for fixture.
Note: At initial 50km, please tighten tire nuts of new vehicle to specified torque in appendix.
Tire pressure
Keep the tires always correctly calibrated. The inflation pressure should be checked with the tires cold at
least once a week.
After driving the vehicle for some time, the tires heat and in consequence of the heat, the inflation
pressure increases. Never, under any circumstance, empty heated tires to reestablish the recommended
inflation pressure.
The pressure difference between the assemble tires on the same axle 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 nut
Without fail re-tighten the wheel 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
strongly, using the vehicle tools without additional levers.
S-13
Vehicle Starting and Driving
2. Air cleaner (activate the dust discharge valve to loosen accumulated dust)
Model 1
The maintenance of the air cleaner is made up of the
substitution of the filtering elements and should be
done only when the maintenance indicator indicates
the saturation of the element.
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.
Model II
Periodically press the dust discharge valve with your
hand, in order to incomplete the dust which possibly
be caught in the internal part maintaining 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
decrease in engine life.
The air cleaner restriction is electronically controlled.
If the indication of saturated air cleaner appears in the
display of digital indicator in combination instrument,
send the vehicle to a King-Long Dealer or authorized
workshop to inspect and clean the air intake system
and substitute the main filtering element.
1 automatic dust discharge valve
Indication
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 third main filtering element
substitution, or after maximum 2 years of use.
S-14
Vehicle Starting and Driving
3. General leakages (water, oil, fluids and fuel)
Check the engine, the transmission, the driving axle, the steering system, the cooling system and the oil
pipeline, the air pipeline of the complete vehicle for their leakage.
S-15
Vehicle Starting and Driving
4. Fastening and state of seat belts
Check buckle of the safety belt of the driver seat for normal and ensure for its lockup under the following
situations when fastening the safety belt.
● The body dashes forward all of a sudden;
● The vehicle makes an emergency braking or an abrupt acceleration;
S-16
Vehicle Starting and Driving
5. Check emergency devices and driver’s tools
Such as extinguisher, crosstie for blocking vehicle, emergency hammer, jack and etc..
Fire extinguisher
Fire extinguisher:
The pulse super-micro powder fire extinguisher is fixed
in the engine compartment, when the compartment is on
fire, the fire extinguisher activate automatically or is
active by manual work to eradicate the fire
The fire button is usually located at auxiliary instrument
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.
Fire button
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.
S-17
Vehicle Starting and Driving
6. Working order of windshield wipers and conditions of wiper blades and arms
Model 1
Regularly check the windshield wiper blades for dirt or damage.
Press the lever to activate the windshield washer
Caution: Do not use the windshield wipers when the windshield
is dry. 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.
S-18
Model 2
Vehicle Starting and Driving
7. Electrical rearview mirror
Check, adjust and clean the rearview mirror.
Model 1
Rearview mirror control button
Model 1
L: adjusting left rearview mirror.
R: adjusting right rearview mirror.
Mirror button: push down the arrow headed button to
adjust the mirror for 4 directions.
Model 2
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 3
S-19
Vehicle Starting and Driving
Inspection every two weeks before and after driving
Model 1
1. Power steering
Ensure that all the maintenance service jobs on the steering
system be carried out at the intervals recommended in the
maintenance manual to guaranty total efficiency and safety.
If any working abnormality in the steering is noticed,
immediately supply the necessary repairs.
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.
Model 2
Power steering fluid level
Model 3
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.
S-20
Vehicle Starting and Driving
3. General state and tension of drive belts
Check the tension of engine belt, fan belt and compressor belt, if loose, tension it; if damaged, replace it.
Do not start up the engine without the drive belts. In the case of one of the belts breaking, immediately
stop the engine and have a new belt put in.
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.
S-22
Vehicle Starting and Driving
Air conditioning compressor drive belt
The pneumatic tensioning system keeps the tension of air conditioning compressor drive belt correctly
adjusted and do not need to be adjusted periodically.
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
S-23
Vehicle Starting and Driving
4. Check level of battery electrolyte
Open the battery cover to check level of electrolyte, if the level is lower than scale marked on the battery,
please add it in time.
Note: During adding electrolyte, never start engine.
Battery
The battery compartment is located at the second compartment of left or right rear side.
1 battery
2 switch control box
3 inverter
2
1
3
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.
S-24
Vehicle Starting and Driving
Engine start up and shut down
Procedures for engine start up
Activate parking brake.
Place the gear box lever in neutral. Start up is not possible in gear position.
Turn the ignition key into gear position.
Start up without stepping on the accelerator. 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.
S-25
Vehicle Starting and Driving
Engine shut down
Loosen accelerator pedal.
Place the gear box lever in neutral position and apply the parking brake.
Turn the ignition key to the off position, without accelerating.
Note: After engine runs at heavy loading, temperature of cooling water is higher than 90ºC, so do not stop
engine at once. 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
S-26
Vehicle Starting and Driving
Engine start up and shut down in the engine compartment
Park the vehicle and activate the parking brake.
Put the gear box lever or the automatic transmission
selector in neutral (dead point).
If the transmission is in gear position, the start up with in
the engine compartment will not work.
Turn the ignition key to gear position, without activating
engine start up.
Model 1
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.
Model 2
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.
S-27
Model 3
Vehicle Starting and Driving
Starting the vehicle
The vehicle could only be started when braking system pressure has reached 5kg/cm2 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/cm2).
 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/cm2)
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”
S-28
Vehicle Starting and Driving
Parking the vehicle
The parking brake should be always applied when the vehicle is parked.
Additionally, in some countries, it is determined by law that a vehicle parked on a slope must have at least
one of its wheels wedged, to prevent its accidental moving.
In this case, always keep an appropriate wedge available for this purpose aboard the vehicle.
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.
S-29
Maintenance and service
General knowledge
KingLong recommends that the bus be maintained according to the Maintenance Schedule in this section.
Perform maintenance at whichever interval occurs first. At each scheduled maintenance interval, perform all
previous maintenance checks they are due for scheduled maintenance.
King-long Bus General Maintenance
Please make periodic inspection and maintenance of bus according to the operation manual to ensure good
status. 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.
2.
3.
Please cut off ECU control box to avoid the high voltage from outside to make damage to the ECU,
when use the outer power supply to charge the battery.
When the vehicle need electric welding, cut off the ECU .never use the multimeter to measure the ECU
box.
Inspect the engine voltage for stabilization periodically.
M-1
Maintenance and service
4.
5.
6.
7.
8.
When maintain the brake shoe ,do not damage the ring gear and sensor, clean the ring gear and
sensor at the same time. after maintenance ,do remember to put the sensor to the limited position
along the ring gear direction.
Make sure that the power is in off position when remove and install the components, keep the
components clean and dry.
Never change the fuse capability or connect the fuse in disorder.
Change the indicator in time when it doesn’t work.
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)
M-2
Maintenance and service
Tire transposition diagram(three axles)
Adjustment of the brake pedal free play
Loosen locknut of brake pedal push rod and adjust adjusting nut, and then measure the vertical distance
from pedal free position to the position where pressing resistance increases apparently when depressing
pedal. 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
Maintenance and service
Cleaning the air filter
Hint: Please replace filter element under such conditions:
it has been washed 5 times; filter element has been
damaged; filter element is clogged excessively; after
changing the engine oil .When air filter indicator on
combination instrument lights, clean the air filter or
replace the element.
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.
M-4
Maintenance and service
Caution: Vapor spray gun, solution, gasoline or equivalent should not be used during the cleaning.
-Before reinstalling air filter element, check element from inside to outside with check lamp for
damage;
-Check sealing ring for damage or cracks.
Caution: Do not start the engine without mounting the air filter.
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
Maintenance and service
below: mix 700-800g caustic soda with 150g kerosene and then inject the miscible liquids into water, at
this time, make engine run at middle speed for 5-10 minutes. 10-12 hours later, make engine run again
for 10-15 minutes and then drain aqueous solution and clean cooling system with fresh water. Coolant
specification as shown below: the users should choose proper brand according to requirement:
Specs ℃
Max. boiling point ℃
Content of glycol
Pure water
Additive
-45 ℃
108.00 ℃
58%
32%
10%
-40 ℃
107.50 ℃
54%
36%
10%
-35 ℃
107.00 ℃
50%
40%
10%
-30 ℃
106.50 ℃
46%
44%
10%
-25 ℃
106.00 ℃
42%
48%
10%
-20 ℃
105.50 ℃
38%
52%
10%
-15 ℃
105.00 ℃
34%
56%
10%
-10 ℃
104.50 ℃
30%
60%
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.
4. No.-20 light diesel oil:
Suitable for the zone where venture rate is 10 percent and minimum
temperature is more than -14°C.
5. No.-35 light diesel oil:
Suitable for the zone where venture rate is 10 percent and minimum
temperature is more than -29°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
Maintenance and service
Engine oil viscosity
 Since oil viscosity fluctuated with temperature, so the ambient temperature of engine working area
is very important to select viscosity grade (as shown in the figure). When temperature exceed lower
limit, it may decrease cold start capacity of the engine but will not make any damage to the engine.
 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 Ecofliud A+
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.
M-7
Maintenance and service
Power steering hydraulic oil:
Fulfill standard: Generai Allison C-3. When ambient temperature is low than 10°C, please apply
DEXRON-II hydraulic fluid to steering gear; when ambient temperature is higher than 10°C, please
apply C-3/10W hydraulic fluid. C-3/10W grade oil can be used in most area .all-year generally. C-3/30
grade oil can be used in non-cold area all-year generally.
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 ".
M-8
Maintenance and service
Breaking-in of New Vehicle
Engine of new vehicle should be sure not to operate at the maximum power output during the
breaking-in period to keep best performance and superior efficiency as well as guarantee durable service
life. Please drive cautiously and pay more attention to abnormal phenomenon occurred during breaking-in
period. Given break-in mileage of the new vehicle is 2,500 km. keep 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.
M-9
Maintenance and service
6. Check connection of transmission control mechanism for looseness.
7. Check connections of steering gear for looseness and damage.
8. Tighten bolts and nuts of front and rear suspension(carry out when full load)
9. Check connections of chassis and driving system according to specified torques. Tighten torques please
refer to corresponding instructions.
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.
M-10
Maintenance and service
Daily or Refueling Maintenance Check
System
Item
Operation
Air cleaner
Check
Fuel-water
separator
Drain
Cooling fan
Inspect
air inlet/
piping
Engine
outlet
Coolant level
Check
Clips without looseness.
Release the water and fouling
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
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”.
Check / correct
Drive belt
Check / correct No across crack, wear or material break off
Crankcase
breather tube
Check
and
Check
Check / adjust
Clutch system
Check
Brake
stroke
chambe
Air
Vehicle body
suspension
The air springs
Vehicle parking level, check the oil after engine stops for 5
minutes
Check the breather tube in cold winter, cleanup the ice
blocking.
No damage and crack
Clutch release bearing clearance
Clutch pedal free
stroke
Clutch brake fluid
Check / add
level
Training
No leakage, damage, and crack.
Engine oil level
Engine
Accessories
Clutch
Maintenance
check
Technical requirement
Free stroke: 30~40 mm
Check if clutch separated completely, connection stable and
not skidding
Compound brake fluid
Check / adjust
Check
Observe the vehicle body whether tilt or not, the air spring (o
piping) of one side is leaky if this side is lower.
Check
If hear the sound of leaking obviously, we can deal with the
problem after confirming the specific leaky location
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
M-11
Maintenance and service
Periodical maintenance and operation items and regulations
Periodical maintenance of each class: do maintenance during each interval or certain miles .
Special instruction: if assembly instruction requires different oil replace period, please follow the
instruction’s requirement on maintenance period and operation. If else please refer to this manual for
maintenance requirement.
Maintenance operation and regulation every 2500km or 1 month
System
Item
Lubricant
surface
Transmission
(ZF series)
Propeller shaft
Rear axle ( ZF
series)
Operation
oil
Technical requirement
Transmission lubricant oil surface within required
range, transmission each part and oil seal without
apparent leakage
The lubricant
ZF-Ecofluid M 02E is
compulsory for initial fillings of transmissions as
Check
Lubricant oil
First filling
Transmission fix
bolt
Transmission air
hole
Transmission and
Accessories
Fasten
Check
clean
Check
well as fillings during transmission break-in(for
first 7500km only)
/
Air hole smooth
No leakage, operation organization effective, no
abnormal sound, wrong gear engagement.
Transmission shaft
cross shaft flex
sleeve
Transmission shaft
bolt and nut
Check and
fasten
7.7-9m: T=180Nm
9m above:T=250-270Nm
Oil level
Check
TE-ML 12TE,1 time per month
Lubricate
Every
grease Filling-up
2# lithium grease
nuzzle
Front axle(DF Fastening piece
Check &
adjust
& FS series)
Toe-in of front Check & Radial-ply tire: 0~+2mm (for first 1500km only,
wheel
adjust
than adjust for every 20000km)
From injection hole into final drive filling
Final drive
Filling-up
Parathion-type 90 heavy-duty gear oil (GL-5) to
the face.(for first 1500km, than change for every
Rear axle(DF &
24,000km)
FS series)
Gear oil level
Check
Every
grease Filling-up
nuzzle
Axle shell oil
2# lithium grease
M-12
Maintenance and service
System
Item
Operation
Technical requirement
Check & fasten
Rear axle housing and differential housing, rear
axle housing rear cover half axle bolts and nuts,
No loosen
Rear axle(DF &
FS series)
Front axle
Rear axle
Fastening
piece
Ventilate
stopper
& All wheel nuts
Tire (include
spare Tire)
Check
adjust
Clean
&
Fasten
Screw torque
7.7-9m: front 450 Nm rear 450 Nm
9m above: DF: front 470 Nm, rear 490 Nm
Check,
air
charge, replace
Tire pressure: 0.67 ~ 0.75MPa,clean, no crack,
erosion or distortion, replace Tire if abraded too
much
Maintenance operation and regulation every 5000km
System
Item
Operation
Technical requirement
Working condition
Check
Steering wheel max free rotation at middle
10 degrees
redirector auxiliary
oil
and
filter Check
element
Fix bolts of each
Fasten
place
Lubricate
Ball head
Steering system
Below 10℃ use DEXRON-II; above 10℃
use C-3/10W
ZF series
Change
oil
GX85, GX 100, ZJ
and filter core
100C
of oil tank
Change
oil
IPS
series
and filter core
25,35,40,55,65
of oil tank
Transmission
(
ZF
series
mechanism
transmission)
Transmission
bolt
Transmission
Accessories
Lubricant oil
fix
Fasten
and
Check
Each fastening bolts not loosening, steering
arm not loosening, steering wheel swift,
Each turning ball head not loosening, no
clogging, clearance normal
Maintenance Free
For first 5000km only, N32 which
manufactured by Shanghai oil refining
factory or ATF or related products which
produced.
For first 5000km only, Environment
temperature >10℃, adopt CD level 15W/40
oil; Environment temperature <10℃, adopt
No.8 hydraulic drive fluid.
No leakage, operation organization effective,
no abnormal sound, wrong gear engagement.
Change
M-13
The lubricant
ZF-Ecofluid M 02E is
compulsory
for
initial
fillings
of
transmissions as well as fillings during
transmission break-in(only first 7500km)
Maintenance and service
System
Item
Operation
Front
axle
( DF & FS
series)
Rear
axle
( DF & FS
series)
Air
suspension
Brake clearance
Check
adjust
&
Brake clearance
Check
adjust
&
Fasteners
Check/tighten
Check and tighten the bolts, rods, height control
valves, air springs, shock absorbers, anti-roll bars.
The top covers of air
springs,
height
control valves and the
joints of the air
course
Check
Listening and wiping the liquid soap. If find any
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
The exterior surface
of air springs
Check
Find out the places which are abraded, distended,
bumped or cut
The air spring
Change
The surface of the air spring is damaged and
appears the cord fabric
The air spring
Adjust/check
If air spring interfere and knock with the
components around it, please adjust it in time.
Check/clean
Clean the lubricant grease on the surface, the dirt
on the piston, the abnormal things placed between
the piston and air spring.
The air spring
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.
The bumper
Check
It’s damage maybe the root damage of the tapered
sealing zone
The height control
valve
Check
If a height control valve controls two air springs
and one air springs is leaky, the other air springs
has not air too.
Shock absorber
Check
The external damage, the welding damage and the
sealing damage result to the leakage of the shock
absorber.
The rod
Check
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
The rubber liner
Check
Check the ball joints of the anti-roll bar and the
rubber liner bushing of the boom
The
air
surface
Air
suspension
Air
suspension
shock
absorber
spring
Technical requirement
M-14
Maintenance and service
System
Brake
System
Chassis
Electrical
equipment
Item
Operation
The brake pedal
free stroke
The
braking
condition
Check
adjust
Check
The
brake
pressure
The brake nuts
Check
The pipe and joint
sealing
Fastening body and
chassis connective
bolts, nuts
The whole vehicle
body butter nozzle
The
whole
vehicle light and
instrument
The battery fluid
surface
The
wire
joint
firmness, no rust
Air-con
radiator
filtration net
Check
Inspect
Technical requirement
&
10-15mm
Shoe drum clearance: 0.30mm ~ 0.50mm, in
complete braking, pedal stroke not surpass 1/2 of the
whole stroke, check dry tin condition
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
Check
Lubricate
Grease nozzle complete and effective, lubrication
good
Check
Check
Add distilled water,
Check
No rust
Clean
M-15
Maintenance and service
Maintenance operation and regulation every 10000km or 3 months
Every 10000km include every 5000km maintenance operation
System
Item
Operation
Technical requirement
Oil
Replace
Check oil surface within required range
Check engine and oil seal without apparent leakage
Replace oil when engine water temperature is 60℃, for
removing the impurity
Oil level more than CF
Engine
Oil filter
Replace
Before installation add 1/2—3/4 to filter
Air filter
Check
Clean air filter element
Air inlet/ outlet
system
Check
No air leakage, no damage, each clip fastening good
Cooling system
and Intercooler
Check
No leakage, each clip without damage or loosen
Coolant filter
Replace
Before re-install the coolant filter, daubs the 15W-40
lubricate oil on the interface of the sealing ring.
Fuel
pump
installation
Check
No leakage
Air compressor
Check
No air, oil, coolant leakage, lock nut and bolt no loosen or
damage
Water tank without leakage, damage, fouling
No carbon deposit
Brake system
fastening bolt
Propeller shaft
universal joint
Check
Check
and fasten
Check
and fasten
Check
No leakage
Propeller shaft flange fastening bolts not loosening
Universal joint each bearing no loosening or damage
Brake bottom
No loosening
board
Front
axle
Hub bear
Check
No loosening
(DF series)
Brake plate
Check / Change the brake plate when plate abrasion more than
change
limit pit.
Brake bottom Check
No loosening
board
Rear axle
Hub bear
Check
No loosening
(DF series)
Brake plate
Check / Change the brake plate when plate abrasion more than
change
limit pit.
Check
Each fastening bolt not loosening, leaf spring no broken
The
leaf
Leaf spring
Suspension
piece, no apparent change of elasticity
Check brake frication piece thickness within required range
by check port, visual check brake adjust arm working
Rear
braking
Check
Brake system
condition, running and stop brake good, each brake pipeline
system
and air line no leakage
M-16
Maintenance and service
Maintenance operation and regulation every 20000km or 5 months depend on what occurs first.
Every 20000km include every 10000km maintenance operation
System
Engine
Item
Operation
Technical requirement
Fuel filter
Replace
Replace fuel filter element accordingly
Replace
Steering auxiliary oil surface within required range
Check
Check the density of anti-freezing
Check
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
Steering
oil
hydraulic
Coolant system –
anti-freezing
Dust-proof cover
Propeller shaft
Universal
condition
Propeller
bracket
Middle
clearance
joint
Check
shaft
Check
bearing
Check
Middle bearing clearance no more than 3mm
Lubricate each butter nozzle with 2# lithium
lubricant grease
Lubricate
Lubricate
Change oil and
GX85, GX 100, ZJ
filter core of oil
100C
tank
Steering system
Change oil and
IPS
series filter core of oil
25,35,40,55,65
tank
Front axle
Toe-in of
wheel
Final drive
front
N32 which manufactured by Shanghai oi
refining factory or ATF or related products which
produced.
Environment temperature >10℃, adopt CD leve
15W/40 oil;
Environment temperature <10 ℃ , adopt No.8
hydraulic drive fluid
Check & adjust
Radial-ply tire: 0~+2mm
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
Rear axle(DF
& FS series)
every 24,000km)
Check
and
fasten,
weld
accordingly
The
leaf
suspension
Change
The
air
suspension
The liner bushing of
the rod assembly
The rubber
joints
ball
Change
Change
M-17
Not loosening, crack, fracture, misplacement,
screw U bolt, front 196~294Nm, rear 343~
392Nm
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
serious. The depth of the crack is up to 2mm and the
length of it is up to 8mm
Maintenance and service
System
Item
Operation Technical requirement
There are gaps on the surface of the rubber
The rubber bal
Change
joints
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
The
heigh Check
control valve. adjust
Check the equilibrium position of the adjustment bar of the heigh
control valve.
The rubber of
The link rod
Change it if the rubber of link rod becomes ageing, brittle, adhesive
and lose its elasticity
Change
The
air
The
suspension
connecting
Check
members of
change
the
shock
absorber
Check
the rubber
change
Body, frame
If the rubber is crack, brittle, adhesive and loses its elasticity please
adjust or change them.
The height
Check
adjust
Charge the air springs and adjust to the design height, then check
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
Brake system
Check the connecting members of the shock absorber if they are
damaged please adjust or change them.
ABS system
Auxiliary
brake,
stop
brake
free
stroke
Retarder
Engine
exhaust brake
door
lock
function
cabin
door
sustain pole
or air spring
inside
and
outside mirror
Check
and
fasten
Check
ABS working properly
Check
Effective, 20% dual direction stopping at slop reliable
Check
Retarder working properly
Check
Exhaust brake working properly
Check
Lock function good
Sealing good
Check
Cabin door lock function good, sustain pole or air spring
effective
Check
Complete, no crack, effective, mirror clean, installation firm and
reliable
Break valve and pipe joint connection reliable and without air
leakage
M-18
Maintenance and service
System
Body, frame
Inside
establishment
Compressor,
air reservoir,
safety valve
Electrical
equipment
Item
Operation
Technical requirement
front rear wind shield and
side window glass
Check
clean
Clean, no crack, sealing good
body with paint
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
Check
Driver seat
Check
Safety set
Check
seat cover, carpet, curtain and
armrest
Check
Clean, complete and firm
Compressor,
safety valve
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
Check
set complete and effective
Check
Check,
adjust
Check,
adjust
Effective
air
reservoir,
Front lamp, horn, meters and
signal
Wiper generator
Wiper connection rod
Whole vehicle wiring
Air-conditioner
Heating system
Air-con passage and read
lamp control panel
Air vent set
Air-con strap tension and
surface condition
Magnetic clutch, fill lubricant
,
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
Reliable
complete, reliable, insulation good
Check
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
Check
No leakage or interference
Condenser, evaporator
Check
Clean, no dirt
Coolant and fuel qty
Check
Up to requirement, fill if necessary
Control switch
Check
Fuel, water heat pipelines
Check
Heating device
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
Check
Check
Check
M-19
Maintenance and service
Maintenance operation and regulation every 40000km or 8 months depend on what occurs first.
Every 40000km include every 20000km maintenance operation
System
Item
Operation
Technical requirement
Drive belt, Cooling fan belt tension Check/adjust
Engine
Cooling fan bearing and bolt
Check/adjust
Check each belt without loosening or damage
No damage, fouling, loosening
Belt tension pulley bearing
Check/adjust
No damage, fouling, loosening
Cylinder cover bolt
Check/adjust
No damage, loosening
Air dryer
Replace
Replace air dryer
Suspension Leaf spring bushing
Check
Clearance between leaf spring bush and pin
normal, no abnormal abrasion, bush not
crack, lubrication normal
Maintenance operation and regulation every 80000km or 12 months depend on what occurs first.
Every 80000km include every 40000km maintenance operation
System
Item
Operation
Technical requirement
Thermostats
Replace
Fuel roughing filter
Replace
Cooling system
Release/ clean/
add
Radiator
Check
Radiator without leakage, damage, fouling.
Hose without damage, clips without loosen or
damage.
Engine suspending
Check/fasten
Connection reliable, firm, soft mat no distortion
layer or crack
Overhead set- valves and
injectors
Measure
Valve clearance within required range
Clutch
Clutch brake fluid level
Charge
Compound brake fluid
The leaf
suspension
leaf spring bushing
Check
Clearance between leaf spring bushing and pin
normal, no abnormal abrasion, bushing without
crack, lubrication normal
Engine
M-20
Maintenance and service
Maintenance operation and regulation more than 80000km
ZF Series axle
Oil or Grease change required, depending on what occurs first.
Products
name
Front
Axle
Rear Axle
Rear Axle
Model
RL 85A
RL 85E
RL 55E
AV132
A80
A131
Maintenance content
Maintenance
Oil class
interval
Filling-up
80,000-90,000KM or NLGI Class 2
grease(lubricant point) 1 year
check-up oil level and 90,000~120,000KM
TE-ML 02
change oil regularly 2 years
every 20000KM
lubricant grease of Every 2 years
shaft of wheel hub
change
Oil change
150.000 km / 3 years
TE-ML 12
Oil change
TE-ML 12TE
A-132
(New
AV-132)
150.000 km / 3 years
lubricant grease of
shaft of wheel hub
change ( include oil
seal)
Wheel bearings with individual mounts at the
front and rear axles
Compact bearings (hub unit) in the wheel
heads at the front and rear
axles
250,000KM
years
or
Remark
for
front
axle head of
lubricant
only
TE-ML122RL
2 RENOLIT
LX-PEP
2Rs36/04e
Old model
ZF
parts
No.: 0671
190 122
500.000 km / 2 years
500.000 km / 4 years
Oil
change
Oil classes
interval
System
Application
Transmission
- Scheduled routes
360,000 km
- Average speed from 20
3 years
to 60 km/h
- Long-distance coach
journeys
540,000 km
- Average speed as of 60 3 years
km/h
M-21
ZF-Ecofluid M
02A(1) / 02B(1) / 02D / 02E / 02L
These lubricant classes may generally only be
used in broken-in transmissions
Maintenance and service
Maintenance period chart
1、1st line is the item of break-in of new vehicle (prescript items completed after driving 2500KM or the day of
registration vehicle)
2、Other items are compulsion maintenance program (the circulation is 80000KM/12 months)
3、For engine、axle、transmission please refer to producer’s maintenance manual, if without special maintenance period,
please refer to this manual for maintenance information.
4、“R” meaning: Replacement ; “I” meaning:Inspection & adjusting; “C” meaning:Cleaning
Maintenance Maintenance period
item
*1000km
2.5
Month
1
5
10
15
3
20
25
5
30
35
7
40
45
8
50
55
9
60
65
10
70
75
11
80
12
Engine
Engine oil
R
I
R
I
R
I
R
I
R
I
R
I
R
I
R
I
R
Oil filter
R
I
R
I
R
I
R
I
R
I
R
I
R
I
R
I
R
Fuel filter element
R
I
R
I
R
I
R
I
R
I
R
I
R
I
R
I
R
Air filter element
C
C
C
C
C
C
R
C
C
C
C
C
R
C
C
C
C
Check& adjust belt
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Check
&
adjust
engine idle speed
Fixing every bolt and
connection on engine
Checking seal of pipe
& connector
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
Coolant
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
R
Fuel system
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Oil & water separator
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Lubricating oil in
gearbox of fan angle
steering gear
R
Air compressor, air
reservoir & pipe
Radiator & expand
water tank
I
R
I
R
I
R
I
R
I&C
I&C
I&C
I&C
I&C
I
I
I
I
I
Fuel tank & oil pipe
I
I
I
I
I
Fuel pump
I
I
I
I
I
Water & oil separator
core
I
R
R
R
R
Handle fuel pump
C
C
C
C
C
Water pump
I
I
I
I
I
Intake &
manifold,
exhaust pipe
exhaust
muffle,
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Turbocharger
I&C
I&C
I&C
I&C
I&C
Intercooler
I&C
I&C
I&C
I&C
I&C
I
I
I
I
I
Engine
device
suspension
Valve clearance
I
I
Thermostat
I
I
M-22
Maintenance and service
Maintenance period chart
1、1st line is the item of break-in of new vehicle (prescript items completed after driving 2500KM or the day of
registration vehicle)
2、Other items are compulsion maintenance program (the circulation is 80000KM/12 months)
3、For engine、axle、transmission please refer to producer’s maintenance manual, if without special maintenance
period, please refer to this manual for maintenance information.
4、“R” meaning: Replacement ; “I” meaning:Inspection & adjusting; “C” meaning:Cleaning
Maintenance Maintenance period
item
*1000km
2.5
Month
1
5
10
15
3
20
25
5
30
35
7
40
45
8
50
55
9
60
65
10
70
75
11
80
12
Clutch
Release or meshing if
not smoothly
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Oil pipe system
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Clutch plate abrasion
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Free stroke of clutch
pedal
I
I
I
I
I
I
I
I
I
Clutch oil
I
I
I
I
I
I
I
I
R
I
I
I
I
I
I
I
I
I
Clutch
stroke
cylinder
&
Transmission
Transmission if not
leaking oil
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Selector mechanism
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Lubricant oil
R
Venthole
C
I
I
I
I
I
C
I
I
I
R
I
I
I
I
R
C
I
I
I
C
I
I
I
C
Propeller shaft
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
Fixing the bolt
I
I
I
I
I
I
I
I
I
Middle
bearing
bracket & clearance
I
I
I
I
I
Brake system
Brake
pedal
free
stroke adjustment
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
Air dryer
I
I
I
I
I
I
I
I
R
I
I
I
I
I
I
I
R
Brake air pressure
I
I
I
I
I
I
I
I
I
I
I
I
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
Brake board fixing
I
I
I
I
I
I
I
I
I
Retarder
C
C
C
C
C
C
C
C
C
Driving
brake
parking brake
Brake
pipe
connector seal
,
&
M-23
Maintenance and service
Maintenance period chart
1、1st line is the item of break-in of new vehicle (prescript items completed after driving 2500KM or the day of
registration vehicle)
2、Other items are compulsion maintenance program (the circulation is 80000KM/12 months)
3、For engine、axle、transmission please refer to producer’s maintenance manual, if without special maintenance
period, please refer to this manual for maintenance information.
4、“R” meaning: Replacement ; “I” meaning:Inspection & adjusting; “C” meaning:Cleaning
Maintenance Maintenance period
item
*1000km
2.5
Month
1
5
10
15
3
20
25
5
30
35
7
40
45
50
55
60
65
70
75
80
8
9
10
11
12
I
I
I
I
I
Brake system
Brake
drum
&
wearing plate abrasion
Brake shoe plate
clearance
FR & RR brake
checking
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Engine exhaust brake
I
I
I
I
I
ABS unit checking
Brake valve & other
valves
I
I
I
I
I
I
Axle & Tire
Tire& steel ring
Checking & fixing RR
axle
housing
&
differential housing , RR
cover half shaft bolt nut
Lubricant steering main
pin & brake adjusting
arm & cam shaft
Fixing wheel nut
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
Tire transposition
I
Four-wheel
maintenance , clean
bearing
Checking & fixing front
axle bolts ,nuts, bearings
Checking & fixing rear
axle bolts, nuts, bearings
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
C
C
C
C
C
Rear axle gear oil
R
I
R
I
R
Front wheel alignment
I
Tires air pressure
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Wheel rim, flange, spoke
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Clearance
vent hole
final
drive
I
I
Suspension system
Thrust pole , connecting
pole installation
Air bag height, seal,
integrality
Suspension
system
fixing piece
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
M-24
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Maintenance and service
Maintenance period chart
1、1st line is the item of break-in of new vehicle (prescript items completed after driving 2500KM or the day of
registration vehicle)
2、Other items are compulsion maintenance program (the circulation is 80000KM/12 months)
3、For engine、axle、transmission please refer to producer’s maintenance manual, if without special maintenance
period, please refer to this manual for maintenance information.
4、“R” meaning: Replacement ; “I” meaning:Inspection & adjusting; “C” meaning:Cleaning
Maintenance Maintenance period
item
*1000km
2.5
Month
1
5
10
15
3
20
25
5
30
35
7
40
45
8
50
55
9
60
65
10
70
75
11
80
12
Suspension system
Suspension
lubricate oil
system
Absorber
working
condition
Steel plate suspension
bush
Left & right steel plate
suspension flexibility
Fixing suspension
type bolt
U
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
Valves function
I
I
I
Bracket & lifting lug
installation & wearing
state
I
I
I
Steering system
Checking
steering
system
working
condition, oil leakage
Steering wheel free
stroke
&
working
condition
Checking power steering
hydraulic
pressure
system
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
Steering booster oil &
filter core
R
I
I
I
R
I
I
I
R
Fixing bolts
I
I
I
I
I
I
I
I
I
Lubricating steering ball
I
I
I
I
I
I
I
I
I
Oil
pump
condition
I
I
I
I
I
I
Checking the crack of
steering
framework,
steering
knuckle
&
knuckle arm, vertical
arm & axle
I
I
Main pin clearance
I
I
working
Steering angle checking
& adjusting
drive steering hydraulic
oil
I
Toe-in of front wheel
I
I
I
I
I
I
I
I
I
R
I
M-25
I
I
I
I
I
I
I
I
I
I
Common trouble and elimination
Maintenance period chart
1、1st line is the item of break-in of new vehicle (prescript items completed after driving 2500KM or the day of
registration vehicle)
2、Other items are compulsion maintenance program (the circulation is 80000KM/12 months)
3、For engine、axle、transmission please refer to producer’s maintenance manual, if without special maintenance
period, please refer to this manual for maintenance information.
4、“R” meaning: Replacement ; “I” meaning:Inspection & adjusting; “C” meaning:Cleaning
Maintenance Maintenance period
item
*1000km
2.5
Month
1
5
10
15
3
20
25
5
30
35
40
7
45
50
55
60
65
70
75
80
8
9
10
11
12
Electrical system
All lights
I
I
I
I
I
I
I
I
I
Battery
electrolyte
surface , connector
I
I
I
I
I
I
I
I
I
Wire box installation
I
All wires , circuitry,
connectors
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
A/C system & pre-heater system
Air conditioner system
refrigeration
working
condition
A/C compressor belt rate
of tension
A/C system pressure,
compressor freeze oil
quantity
Autonomous water heat
system-fuel
supply
system
Autonomous water heat
system-water
supply
system
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
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
Rearview mirror fixing
I
I
I
I
I
Vehicle
body,
framework checking
I
I
C-1
I
Common trouble and elimination
Engine common trouble and its elimination (suitable for diesel engine)
Diesel engine can not start
Possible causes
1) Too low starting speed
Remedies
1) Check the starting system and assure the starting speed is not
lower than 110rpm.
2) Air exists in the injection system
2) Check the looseness of the joints of the feed line. 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
3) Determine the location of the clog and clear it.
4) Fuel filter choked
4) Replace the screw-on filter element of the fuel filter/oil-water
separator assembly.
5) Fuel supply pump does not apply
fuel or applies fuel irregularly
5) Check for leakage in the fuel inlet pipe
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 9) Check the valve clearance, valve spring, valve stem, and
is loose, dirty or corroded smudginess valve seat. Grind the valve seat if necessary.
canker
Tighten and wash or replace.
10) Mounting timing incorrect
10) Check and adjust it.
C-1
Common trouble and elimination
Diesel engine power deficient
Possible causes
1)Intake blocked
Remedies
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
4) Dean or replace the compressor casing and turbine housing.
polluted, clogged or damaged;
Bearing failure;
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)Poor atomization of injector
7)Check the inject pressure, remove carbon, adjust and repair
8)Incorrect distribution phase
8)Check and adjust the distribution timing and valve lash
9)Cylinder gasket leakage
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
12)replace it
13)Sensor doesn’t work
13)Check and replace it.
C-2
Common trouble and elimination
Abnormal noise during engine operation
Possible causes
Remedies
1) Connecting rod bearing bushing and
1) Dismantle and check the bushing and, if necessary, replace it
main bearing bushing are worn-out
and keep the reasonable clearance as required.
and clash voice appears in the
crankcase.
2) The Damper is damaged and
2) Change components to keep regulated axial clearance
invalid.
3) The shock absorber is damaged and
ineffective
4) The valve knocks on the piston
5)
The driving gear is abrased and get
too large gap. There is knocking
3) Check and see if the joint bolts are in good conditions, and
change new ones if necessary.
4) Check and adjust the valve timing.
5) Check the gear side clearance and change the gear or not
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.
7) Puff vibration of supercharger
6) Change the piston and use the repairing cylinder liner. Keep the
proper clearance between piston and cylinder.
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
there is big noise at the cylinder head.
9) Adjust the valve clearance.
C-3
Common trouble and elimination
Exhaust with black smoke
Possible causes
Remedies
1) Intake clogged
1) heck and clean the air cleaner and intake passage.
2) Poor fuel quality
2) Use prescribed fuel.
3) Incorrect distribution timing
3) Adjust the distribution timing according to the instruction.
4) Bad atomization of injector
4) Check and repair or replace
5) The injector spray too much fuel
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
Remedies
1) Replace the fuel.
in fuel
2) Too low coolant temperature
2) Check the working temperature of the thermostat,
replace it if necessary.
3) Incorrect distribution
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
6) Operate at proper speed and load
7) Seal ring of turbocharger worn-out
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
Common trouble and elimination
Too low oil pressure
Possible causes
Remedies
1) Diluted or incorrectly selected
1) Select the proper oil.
2) Inner and outer rotors of oil pump worn-out
2) Replace the oil pump.
or too large
3) Oil filter choked
3) Replace the whirling type filter element.
4) Failure of oil filter pressure control
4) Repair it.
5) Gear of oil pump damage
5) Replace it.
6) Inlet oil tube of fuel pump crack
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
Possible causes
Remedies
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
Remedies
1) Leakage in the exterior oil line
1) Check and repair it.
2) Too high diesel engine load
2) Decrease the load.
3) Use improper oil
3) Use the oil as required.
4) Piston ring stuck or seriously worn
4) Check and repair, if necessary, replace it.
5) Too much worn out of Cylinder bore
6) Valve guide seriously worn out and failed
seal of valve stem
5) Bore the cylinder and use the oversized piston rings or
press in a repair –used cylinder sleeve.
6) Check and replace.
C-5
Common trouble and elimination
Chassis constant fault and elimination
Propeller shaft
Fault
symptom
Possible cause
1.
2.
Propeller
shaft jogging
(vehicle
vibrates
during
driving)
3.
4.
5.
6.
7.
Abnormal
sound from
the propeller
shaft (during
the starting
and the
running)
1.
2.
3.
4.
Eliminating method
Propeller
shaft
sliding
yoke
assembled incorrectly
The propeller shaft is distortion or
bending
The universal-joint journal or the
needle bearing has been worn out or
damaged
The propeller shaft loose
1.
The propeller shaft is imbalance
The intermediate supporting bearing
is worn out or damaged
Bracket
of
the
intermediate
supporting bearing is loose or the
rubber damp piece material is aging
Abrasion or damage of the universal
joint
Abrasion or damage of the sliding
yoke
Looseness of the propeller shaft
Inadequate lubrication to the needle
bearing, the sliding yoke and the
intermediate bearing
5.
6.
C-8
2.
Remove and let the sliding yoke and the
fixing yoke on the same plane
Adjust or replace the propeller shaft
3.
Replace the bearing
4.
7.
Tighten propeller shaft to specified
torque
Adjust or replace the propeller shaft
Replace the intermediate supporting
bearing
Make adjustment or replacement
1.
Replace the universal joint
2.
Replace the sliding yoke
3.
4.
Tighten it to specified torque
Make the lubrication
Common trouble and elimination
Transmission
Fault
symptom
Possible cause
1.
1)
2)
Difficult
gear shift
(Difficult
gear
engagement)
3)
2.
1)
2)
3)
4)
3.
1)
The
transmission
gear is off
the engaging
position
Eliminating method
Control mechanism
Improper height of the control hinge
There has clearance between the
control hinge connection
The control hinge bend
Transmission
Abrasion or damage of the bearing
Synchronizer operates abnormally
The shaft or the gear is wore or
damaged
Abnormal slip of the gear shifter
shaft
Others
Clutch can not disengage normally
1) Adjust the control hinge
2) Correct or replace the parts
3) Correct or replace the control hinge
1) Replace the bearing
2) Correct or replace the parts
3) Correct or replace the parts
4) Correct
1) See " Clutch does not disengage
smoothly or can not disengage "
2) Use the lubrication of given grade
2) The lubrication viscosity is too high
Transmission
1) Shift fork distorted or worn
1) Check the gear-shifter fork and make
2) Abrasion of lthe lockup ball or the
adjustment or replacement in case of
ball on the gear shifter shaft
bending
2) Disassemble and replace the worn-out
parts
3) Breakdown or fatigue of the lock 3) Replace the spring
spring
4) Excessive clearance of the gear 4) Adjust the gear clearance or replace the
engagement
gear
5) Excessive clearance along the 5) Measure the axial clearance and replace
gearing axial direction
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
7) Replace the main bearing
Control mechanism
1) The control mechanism is out of 1) Check and correct the control hinge
work
2) Movement of the shifter lever causes 2) Check damage of the engine rubber
suspension and
replace the faulted
vibration of the vehicle
parts
C-9
Common trouble and elimination
Rear axle
Fault
symptom
Possible cause
Eliminating method
When the vehicle is starting
1) Excessive clearance between
the differential gear
2) Excessive clearance between
the driving and the driven gear
3) Looseness of the connecting
Abnormal
flange and the propeller shaft
sound from
4) Too small pretightening force of
the rear
the drive gear bearing
axle
5) Looseness of the fixing bolt and
(abnormal
nut of the driving gear
sound)
When the vehicle turning
1) There has abrasion or damage
to the axle shaft gear, driving
gear, spider, thrust shim and the
axle shaft bearing and etc
2) Too low oil level
When the vehicle is running:
1) Excessive clearance between
the driving and the driven gear
2) Abrasion or damage of the
Abnormal
bearing
sound of
3) Abrasion or damage of the gear
the rear
4) Too low oil level
axle
When running with inertance
( improper 1) Too small clearance between
sound)
the driving and the driven gear
2) Abrasion or damage of the
bearing
3) Incorrect gear engaging position
4) Too low oil level
1. Abrasion, looseness or damage
of the oil seal
2. Looseness of the differential
Leakage of
lock bolt or damage of the
the rear
gasket
axle
3. Damage of the differential
lubrication
carrieer mating surface
Looseness of the oil draining plug or
damage of the gasket
C-10
1) Adjust the clearance
2) Adjust the clearance
3) Tighten it to specified torque
4) Adjust the pretightening force
5) Tighten it to specified torque
1) Adjust or replace the faulted parts
2) Fill up the lubrication
1)
Adjust the clearance
2)
3)
4)
Replace the bearing
Make adjustment or replacement
Fill up the lubrication
1)
Adjust the clearance
2)
3)
4)
Replace the bearing
Adjust or replace the faulted parts
Fill up the lubrication
1.
Replace the oil seal
2.
Tighten to specified torque and
replace gasket
Make trimming and replace the
differential housing if necessary
Replace the gasket and tighten
screw plug to specified torque
3.
4.
Common trouble and elimination
Fault
symptom
Possible cause
4.
Leakage of
the rear
axle
lubrication
5.
6.
7.
8.
1.
2.
Hub
bearing
jamming
3.
4.
Eliminating method
Blocking or damage of the
ventilation plug
Axle housing cracks
Damage distortion of the
coupling flange sealing surface
Malfunction of bearing leads to
radial run out of coupling
flange
Axle housing distortion caused
by overloading
Excessive pre-tightening force
of the hub bearing
Inadequate lubrication of the
bearing or incorrect usage of the
grease
The bearing is defiled by the
dust
Water entering bearing due to
malfunction of sealing ring
5.
Clean or replace the ventilation
plug
6.
7.
Repair or replace the axle housing
Adjust or replace the coupling
flange
8.
Replace the bearing
9.
1.
Adjust or replace the axle housing
Adjust the pre-tightening force
2.
Intensify the lubrication or replace
the grease
Clean and intensify the lubrication
Replace the sealing ring
3.
4.
Front axle and steering system
Fault
symptom
Possible cause
1.
1)
2)
3)
Steering
wheel
shimmy
2.
1)
2)
3)
4)
5)
Eliminating method
The steering system
Steering gear housing bolt or
steering column supporting
loose
Looseness of the steering
connection point
Excessive clearance of the
steering gear housing
The front axle
Unbalance or abrasion of the
rim, the spoke and the wheel
Abrasion of the front wheel
bearing
Excessive abrasion of the king
pin or the bushing
Deformation of the knuckle
Improper wheel alignment
C-11
1) Tighten to specified torque
2) Adjust the junction
3) Adjust the clearance
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
alignment
the
wheel
Common trouble and elimination
Fault
symptom
Possible cause
Eliminating method
6) Fatigue of the front leaf spring,
looseness of the "U" -bolt or
damage of the central bolt
1. The steering system
1) Difficulty
in
the
gear
engagement
2) Malfunction of power steering
system
Failure
of
3) Improper contact with the
steering
power piston
wheel return
4) Fatigue of the return spring
to center
5) Malfunction of slide valve
6) Replace the faulted parts
1) Adjust the gear engagement
2) Overhaul and eliminate trouble
3) Adjust or replace the power piston
4) Replace the spring
5) Check diameter of the slide valve
and the housing and replace them
if necessary
2. The front axle
1)
Check and adjust the front wheel
1)
Excessive caster angle of the alignment
king pin
1. The alignment of front wheel 1. Check and adjust the front wheel
incorrect
alignment
2. There has fatigue and damage 2. Replace the faulted spring
in the front plate spring
3. Bending of the front axle
3. Adjust or replace the front axle
Disalignment
4. Unsmooth of the braking
4. Please refer to the chapter
of the steering
5. Looseness of the front hub
"braking"
wheel
bearing nut
5. Tighten to specified torque
6. Inequality of the tire pressure
7. Tires with different dimension 6. Inflate to the given pressure
applied
7. Replace the tire by the correct
type
1. The front axle
1) Incorrectness of the wheel 1) Check and adjust the front wheel
alignment
alignment
2) Abrasion or wreckage of the 2) Replace the bearing or tighten nut
hub bearing and looseness of
to specified torque.
the bearing nut
Misproportion
3) Over looseness or tightness of 3) Make an adjustment and replace
or untimely
the ball stud, the king pin and
the faulted parts as needed
tire wear
the bushing
2. Tire
1) Tire pressure incorrect
1) Supply to the given air pressure
2) Disalignment between the tire 2) Replace the tire or the wheel
and the wheel
z
C-12
Common trouble and elimination
Fault
symptom
Possible cause
Eliminating method
3. Others
Misproportion 1) Breakdown caused by the
or untimely
abrupt starting or the emergent
tire wear
braking
2) Overloading
1. Too low oil level
2. Lubricant deterioration or
impurity in it
3. Abrasion of the steering
junction
4. Fault of the power steering
system
5.
Heavy
operation of
the steering
6.
wheel
(the
steering
system
breakdown)
7.
Heavy
operation of
the steering
wheel
(breakdown
of the front
axle)
1) Correct the driving pattern
2) Make the loading according to the
specified capacity
1.
2.
Add the lubricant to the given
level
Replace the lubricant
3.
4.
Replace the ball stud
Overhaul and eliminate trouble.
5.
Measure the backpressure and
repair or replace the pipeline in
case of the set value exceeded
Measure the oil pressure and the
flow volume; disassemble and
repair the hydraulic pump if the
set value belowed
Bleed air and add oil.
Excessive lubricant resistance
caused by the pipeline sunken
6.
Too low oil pressure caused
by the ineffective hydraulic
pump
7.
There has air in the hydraulic
pipeline
8. Malfunction of rotary valve
9. Abrasion or damage of the
power cylinder and damage of
the piston O -ring
10. Too much leakage of the oil
inside the steering gear
housing
1. Improper adjustment of the
wheel alignment (excessive
caster angle)
2. Too little clearance between
the king pin and bushing
3. Inverse installation of the
thrust bearing
4. Inadequate lubrication of the
front axle parts
5. Over tight or loose connection
of the bull
6. Too low tire pressure
7. Excessive abrasion of the tire
C-13
8.
9.
Disassemble and repair rotary
valve.
Disassemble and repair.
10. Disassmeble and repair steering
housing.
1.
Check and adjust the wheel
alignment
2.
Check and adjust the clearance
3.
Adjust the installation
4.
Add the grease to the front axle
5.
Check and lubricate the bulb stud
6.
7.
Inflate to the rated pressure
Replace the tire
Common trouble and elimination
There has oil
spillage in the
steering oil
tank
1.
2.
Clogging of the strainer or the 1.
filter element
There has air in the pipeline
2.
Clean the filter strainer or replace
the filter element
Add the oil and make the
exhaustion
Braking system
Fault
symptom
Possible cause
1.
2.
Unsmooth
of the
wheel
3.
4.
5.
6.
1.
2.
There has
abnormal
sound
when
troddening
the brake
pedal
3.
4.
5.
6.
7.
8.
Eliminating method
There has compressed air inside
the braking chamber
Improper lubrication of the
camshaft or improper return of
the adjusting arm
Brake shoe or chamber return
spring fatigued or broken
The spring braking takes effect
1.
2.
Check and adjust the exhaust valve
of the quick releasing valve
Adjust the faulted parts
3.
Replace the faulted parts
4.
1.
Eliminate causes of the spring
braking unreleased
Disassemble and clean the faulted
parts
Disassemble and clean the braking
valve and replace the faulted parts
as needed
Replace the friction lining
2.
Replace the friction lining
3.
4.
Replace the friction lining
Rivet the rivet or tighten bolt
5.
Adjust or tighten the brake drum
6.
Adjust the clearance between the
brake shoes and
tighten the
supporting pin locknut
Replace the hub bearing
Adjust or replace the brake drum
Clogging of the exhaust port in 5.
the quick release valve
Brake valve primary or 6.
secondary piston return failure
The clincher or the bolt is
projected because of abrasion of
the braking friction lining
Surface hardening of the
friction lining
Deterioration of the friction
lining
Improperly contact between the
brake shoe and the friction
lining
Uneven abrasion of the brake
drum internal surface or weak
installation
Looseness of the brake shoe
supporting
Abrasion of the hub bearing
Deformation of the brake drum
C-14
7.
8.
Common trouble and elimination
Fault
symptom
Possible cause
1.
Tire pressure uneven or tire
dimension different
Improper installation of the
brake shoe or damage of the
return spring
Improper engagement of the
braking friction lining
Improper adjustment of the left
and right brake
Deterioration of the braking
friction lining
Oil on the braking friction
lining
1.
Operate as required
2.
3.
Tighten the locknut of the brake
shoe supporting pin and replace the
return spring
Adjust the friction lining
4.
Adjust the brake
5.
Replace the friction lining
6.
Damage of the brake backing
plate
8. Looseness of the leaf spring
U-bolt
When compressed air pressure is
normal:
1. Too short of the brake valve
travel
2. The camshaft doesn't rotate (the
bushing is lack of lubricant)
3. Improper adjustment of the
braking chamber pusher stroke
4. Improper sliding contact of the
relay valve
5. Overheat or deterioration of the
braking friction lining
6. Improper engagement of the
braking friction lining
7. There has lubricant on the
friction lining or the brake drum
8. Water entering brake drum
7.
8.
Clean with the gasoline to
eliminate the effect of the leakage
at the hub oil seal, oil cylinder
cover and the rubber cap
Replace it
Tighten the U-bolt
2.
3.
4.
Unsteady
braking
Eliminating method
5.
6.
7.
The
braking
can't be
applied
under all
conditions
1.
Check ,and replace the braking
valve if necessary
2.
3.
Check working condition of the
camshaft and replace it as needed
Adjust the travel
4.
Disassemble and repair
5.
Replace the friction lining
6.
Adjust engagement position of the
friction lining
Clean the oil trace with proper
cleanser or replace the friction
lining
Drying out the water by pressing
the pedal gently during the running
7.
8.
C-15
Common trouble and elimination
Fault
symptom
Possible cause
Eliminating method
When compressed air pressure is
abnormal:
1. There has air leakage inside the
air pipeline
2. The air compressor doesn't
work
3. The pressure regulator is
improper adjusted or failured
because of the impurity entering
Air leakage in the brake valve
1.
Repair the leakage point
2.
Disassemble
and
repair
air
compressor
Adjust or wash
Disassemble and repair the brake
valve
3.
4.
Common trouble and troubleshooting of electrical equipment and starting
system
Fault
symptom
There has
abnormal
sound
during the
generator
rotates
The
charging
indicator
light
doesn't go
off during
the running
and the
vehicle is
difficult to
start
The battery
is lack of
power
excessively
and
incapable
of charging
at low
speed
Possible cause
1.
Eliminating method
3.
1.
The belt is of over loose or
excessive abrasion with the
shaking during the running
Adjust the belt and replace the bearing
Bearing failure or oversize
clearance
Too much bearing clearance
The battery is lack of power
1. Charge the battery
2.
The generator is damaged
3.
Check the circuit
4.
Charging indicator lamp loop 3.
short
4.
The belt is slipping
1.
The battery is damaged
1.
Replace the battery
2.
The generator is damaged
2.
Replace the generator
3.
The belt is slipping
3.
Adjust the belt
2.
2.
C-16
Replace the generator
Adjust the belt
Common trouble and elimination
Fault
symptom
Possible cause
1.
2.
Difficult in
starting
3.
1.
Starting
gear of the
starter can
not engage
with the
flywheel
teeth
2.
3.
4.
5.
6.
1.
Starting
gear of the
starter can
not
disengage
completely
2.
3.
4.
5.
Eliminating method
The battery has no power, or is
lack of power or terminal loose
Poor contact of the starter
switch, short circuit of the
connector lug or bad of the
solenoid
Starter pinion is clogged in the
flywheel
ring
gear.
Furthermore, engine bearing is
burnt ,water on external of the
combustion chamber and the
consumption frozen may also
caused the breakdown
Poor contact of the ignition
switch or socket loose
Unsteady connection of the
relay device or the solenoid
switch
Turnoff of the starter solenoid
switch
Damage of the starting gear or
the gear ring of starter
Malfunction of engage switch
Starter armature shaft bent
Starter starting gear sleeve too
tight or stuck
Too little clearance between the
starting gear and the flywheel
ring gear or the starter gear
damage
Magnetic coil dirty
Clogging of the transmission
fork shaft
Locking of the engage switch
C-17
1.
Charge and clean the joint and
screw it
2.
Repair or replace it
3. Repair or replace it
Found out the reason and eliminate it
1.
Clean and tighten
2.
tighten it
3.
4.
Replace it
Repair the teeth or replace it
5.
Found out the reason and eliminate
it
Replace it
6.
1.
2.
Replace the shaft sleeve or clean
and amend it
Adjust the clearance or replace the
starting gear
3.
4.
Clean it
Clean and adjust it
5.
Replace it
Common trouble and elimination
Common trouble and troubleshooting of air conditioner system
The remedy and trouble analysis under abnormal pressure
No.
1
2
Pressure
Description
Analysis
There is bubble in the
inspection glass ; the
cold air in the bus
The refrigerant
insufficient ; high
The high and low
filling is not
pressure pipe a little bit
pressure is lower
enough and the
warm and the low
than normal.
system
is
pressure pipe a little bit
leaking
cold, the temperature
difference is not too
much;
The high and low
The refrigerant is
pressure are higher
too much
Than normal
No liquid flow seen
from the inspection
The high and low
glass;
Air conditioner
pressure are much
Almost no refrigeration system
has
lower
than
Almost no temperature serious leakage
normal .
difference between high
and low pressure pipe
The low pressure
is nearly to zero or
even the negative
value;
The high pressure
is lower than the
normal value
3
The high pressure
and
the
low
pressure
are
abnormal;
The
pressures
are higher than the
normal values
The high pressure
is higher than the
normal value and
the low pressure is
lower than normal
expansion valve
No refrigerate in the blocked;
system
The front or the rear expansion valve
part of the expansion temperature
valve has fog
sensor damaged
or packing error
The temperature of the
sucking pipe is lower
expansion valve
than the normal value
opened too much
and
the
frosting
appeared
The surface for the air
suction pipe of the Expanding valve
compressor has frost or damaged
condensate
C-18
Remedy
Check
the
system for the
leakage and find
out the leaking
point
And make the
maintenance
Fill in refrigerant
Drain some part
of the refrigerant
or refrigerant oil
Check
the
system and find
out the leakage
and
fill
the
enough
refrigerant
Changed
the
expanding valve
Change
the
expanding valve
temperature
sensor
Make
good
package for the
expanding valve
Change
the
expanding valve
Readjust
the
expanding valve
Change
the
expanding valve
Common trouble and elimination
No.
4
5
6
7
8
Pressure
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
and
low
pressure are
higher than the
normal values
The high and low
pressure are
lower than the
normal value
Description
Analysis
The cooling capability
is
Insufficient and the
system has air and the
bubbles seen in the
inspection glass
Air mixed in the
refrigerant The
vacuum is not
good for the first
time
filling
refrigerant
or
after
the
maintenance
The air sent to the
bus sometime cold
and sometimes
warm and the
inspection glass
looks yellow
Too much water
in the system
desiccators
reaching the
saturation
the frosting
water
blocked
the
expanding valve
Change
desiccators
make
vacuum
repeatedly
then re-fill
refrigerant
Cold is in sufficient
The condenser
blower doesn’t
work normally
or
there
is
blockage in the
condenser
radiator
Check
the
electric circuit
diagram
or
cleaning
the
condenser
The
cold
insufficient
air
is Compressor
interior failure
Evaporator
blower
not
running or low
Evaporator wind flow
in efficiently or
is insufficient
the radiator of
the evaporator
blocked
C-19
Remedy
Discharge the
refrigerant in
the system
and change
the desiccators
and also make
the vacuum
repeatedly for
filling the
refrigerant
the
and
the
and
the
Repair or change
the compressor
Check
the
electric circuit
diagram or clean
the evaporator
radiator
Common trouble and elimination
Electric system trouble and remedy
Fault
symptom
the power
lamp on the
control
panel not
light
Possible cause
1. + no power supply;
1.
2. D+ not connected well;
3. harness not tight;
4. control unit failure;
1. system pressure error;
2.
3.
4.
1.
malfunction
light on the 2.
control
3.
panel light
up
4.
5.
1.
6.
1.
pressure switch defective;
pressure switch harness not
connected well;
harness connection not well;
control panel failure;
defrost sensor failure or
connection problem;
temperature control sensor
failure or connection problem;
temperature control sensor
installation
position
not
good ;
temperature control switch
defective;
harness
connection
not
reliable;
Control panel defective
malfunction lamp light up;
2.
sensor failure;
2.
3.
relay failure;
3.
4.
5.
fuse burnt;
battery
not
charge
or
connection loose;
harness connection not tight;
air blower connection loose;
air blower failure;
control panel failure;
4.
5.
2.
refrigerant
lamp is not
lighted up
3.
4.
5.
condenser
fan not
working
Eliminating method
6.
7.
8.
9.
C-20
2.
3.
4.
5.
1.
2.
3.
4.
5.
6.
1.
6.
7.
8.
9.
generator D+ no output, exchange
the generator and repair
reconnect the cable D+;
reconnect the harness;
change the control panel or repair;
to connect the manifold gauge and
eliminate the malfunction;
change the pressure switch and
repair;
reconnect the pressure switch;
harness connection;
change the control panel or repair;
change the defrost sensor or
connect the cable again;
change the temperature control or
connect the harness again;
re-install the temperature control
into the correct position;
change the temperature control
switch or repair;
harness connection again;
change the control panel or repair;
check the problem according to the
item 2;
change sensor or sensor connection
cable;
change the relay or repair the relay
of the connecting harness;
change the fuse;
change the battery or recharge the
battery ,make the connection;
re-connect the harness;
connecting to the venting cable;
change the blower or repair;
change the control panel or repair;
Common trouble and elimination
Fault
symptom
Possible cause
1.
compressor
not working
evaporator
blower not
working
2.
3.
4.
5.
6.
1.
2.
3.
4.
5.
6.
7.
8.
Eliminating method
compressor clutch connecting cable
not connected well;
clutch damaged;
malfunction lamp light up;
refrigerant light not lighting up;
relay out of work;
no harness connection to the battery;
relay not working;
battery no charge;
battery cable confected;
air blower harness not connected
well;
harness connection not good;
venting blower cable not connecting
well;
air blower or blower speed
adjustable resistor failure;
control panel out of work;
C-20
1.
2.
3.
reconnect the cable;
change the clutch or repair;
refer to the above-mentioned items;
1.
change relay or repair or connect the
relay connecting cable;
change the battery or recharge;
reconnect the battery cable;
change the fuse;
reconnect the harness;
reconnect the blower motor connecting
cable;
change the air blower or change the
resistor for repair;
change the control panel or repair
2.
3.
4.
5.
6.
7.
8.
Appendix
Driver tools table(one each)
No.
Part name
1
Tool box
2
Combination wrench
3
No.
Part name
21
Flat-tip screwdriver
6*100MM
8
22
Hammer
Combination wrench
10
23
Slip joint pliers 8”
4
Combination wrench
12
24
Nipper pliers 6”
5
Combination wrench
13
25
Tire pressure gauge 0-1.4MPa
6
Combination wrench
14
26
Valve core wrench
7
Combination wrench
15
27
Filter wrench
8
Combination wrench
16
28
Pry bar also used as rocker lever 55cm
9
Combination wrench
17
29
Pry bar also used as handle 50cm
10
Combination wrench 18
30
Grease gun
11
Combination wrench 19
31
Socket wrench for wheel nut 32(hexagon)
12
Combination wrench 21
32
Torque bar 315 X 25 X 25
13
Combination wrench 22
33
Wrench for front wheel hub bearing nut 70 mm (hexagon)
14
Combination wrench 24
34
Wrench for rear wheel hub bearing nut 110 mm (hexagon)
15
Combination wrench 27
35
Final drive locknut 55mm
16
Combination wrench 30
36
Spare wheel lifter 22X550
17
S-double box wrench 13x15
37
Wrench for drive axle drain plug
18
Adjustable wrench
8”
38
Jack
19
Adjustable wrench
12”
39
Special tool box
20
Cross-head screwdriver 6”
1 pound
400cm3
10x10
16t J1601
The tools above are the state when choose Dongfeng Dena axle, when other axles are applied, driver tools may vary as
below
name
cancel
number
1
Wrench for front wheel
hub bearing nut
Wrench for rear wheel
hub bearing nut
Final drive locknut
Socket wrench for wheel
nut
70mm (hexagon)
1
add
Axle manufacturer
60 X72 mm foursquare
2.25’’or
57
hexagon
mm
ZF Front axle
MeiChi Front axle
1
58 mm
North Benz Front axle
1
115 mm hexagon
DONG FENG DENA13T
(hexagon)
1
4.03’’or102 mm
MeiChi Rear axle
55 mm(hexagon)
1
51 mm hexagon
32 mm(hexagon)
1
41 mm hexagon
1
21 mm foursquare
110
mm
Fangsheng rear axle or Dongfeng
Dena or Hangzhou sanhua 9.5T
Dongfeng Dena or Hangzhou sanhua
9.5T
Dongfeng Dena or Hangzhou sanhua
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
Tightening torque(N·m)
Front tyre nut
412~480
Rear tyre nut
294~421
Bolt, connecting lower knuckle and ball pin
245~304
Steering kingpin lockpin nut
60~70
Fixing nut, upper steering knuckle
274~343
Binding nut, tie rod
90~110
Locked bolt and nut between pitman arm and pitman arm shaft
407~434
Fixing nut, ball pin on both ends of drag rod
240~300
Steering gear fixing bolt
294~333
Steering gear lock nut
137~217
Upper fixing bolt and nut between steering bracket and frame
137~167
Lower fixing bolt and nut between steering bracket and frame
275~330
Final drive bevel gear flange nut
395~539
Fixing nut, Front brake backing plate
160~205
Fixing nut, Rear brake backing plate
196~245
Fixing bolt, between driven gear and differential
588~686
Differential housing nut
216~275
Fixing bolt, Front brake chamber bracket
59~79
Fixing bolt, Front brake chamber
40~59
Fixing bolt, Rear brake chamber
167~196
Fixing bolt, retarder housing
128~157
Fixing bolt, axle shaft
137~176
Drive gear bearing cap bolt
120~137
Rear axle oil level check plug
127~157
Lock bolt, front shoe axle
49~69
U bolt, front axle
196~294
U bolt, rear axle
343~392
Lower slotted nut, damper
134~167
Fixing nut, between damper and damper bracket(M20)
88~118
Leaf spring pin locknut
54~69
Front engine mounting bracket bolt
90~110
Coupling bolt, between flywheel housing and frame bracket
80~100
Fixing bolt, between clutch and flywheel
90~100
Fixing bolt, between flywheel housing and clutch housing
60~75
Fixing bolt, between transmission and clutch housing
142~186
drive shaft coupling bolt
215~240
Fixing nut, transmission output shaft rear connecting panel
333~549
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
M4
3(2)
5(3)
5(4)
M5
6(4)
9(7)
10(7)
M6
10(7)
15(11)
18(13)
M8
25(18)
35(26)
45(33)
M10
50(37)
75(55)
83(61)
M12
88(65)
123(91)
147(108)
M14
137(101)
196(145)
235(173)
M16
211(156)
300(221)
358(264)
M18
290(213)
412(303)
490(361)
M20
412(304)
578(426)
696(513)
M22
560(413)
785(559)
942(695)
M24
711(524)
1000(738)
1200(885)
M27
1050(774)
1480(1092)
1774(1308)
M30
1420(1047)
2010(1482)
2400(1770)
Torques for bolts with metric fine threads
Dimension of bolt
Torques N.m*(ft-lb)
8.8
10.9
12.9
M8×1
26(19)
37(27)
48(35)
M10×1.25
52(38)
76(56)
88(65)
M12×1.25
98(72)
137(101)
126(119)
M12×1.5
93(69)
127(94)
152(112)
M14×1.5
152(112)
216(159)
255(188)
M16×1.5
225(166)
318(235)
383(282)
M18×1.5
324(239)
466(344)
554(409)
M20×1.5
461(340)
628(463)
775(572)
M22×1.5
618(456)
863(636)
1058(780)
M24×2
780(575)
1096(808)
1294(954)
M27×2
1147(846)
1578(1164)
1920(1416)
M30×2
1568(1156)
2254(1662)
2695(1988)
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
Lubricant
Type/table
Level/type
Engine
Diesel engine oil
15W/40
API CH – 4/SG
Transmission
Gear oil
TM-ML02
Ecofluid M
Main reducer
Gear oil
TE-ML12
Ecofluid X
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, recommend Mobile ATF220
3
Others
Oil Site
Oil used
Nominate
Clutch
Synthesize grade oil
Nominate to use HZY4,DOT 4, or Laike 901
etc., can’t mix to use in different type grade oil
Brake system
Synthesize grade oil
DOT3,DOT4,DOT5.1; Laike 901,Laike
901-4,Laike 901-5
Bearing and ball pin
Li - grease
2#
Coolant
Nominate to use SINOPEC brand, YF-2A (upward -45°C centigrade)
coolant, can’t mix to use different type coolant
A-3
Appendix
Air braking schematic diagram
A-4
Appendix
Electric schematic diagram of the complete vehicle (1)
A-4
Appendix
Electric schematic diagram of the complete vehicle (2)
A-5
Appendix
Electric schematic diagram of the complete vehicle (3)
A-5
Appendix
Electric schematic diagram of the complete vehicle (4)
A-5
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