King Long XMQ6127 series, Operating Manual

Page 1: ...1 OPERATION MANUAL User s Guide King Long XMQ6127 series tourist bus Xiamen King Long United Automotive Industry Co Ltd...

Page 2: ...icle 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 mai...

Page 3: ...Instruction Instrument instruction CI 1 Illustration of switch and indicator s SI 1 3 Air conditioner control panel P A 1 Heating Operation P H 1 3 Gearbox operation O G 1 ABS instruction O AB 1 ECAS...

Page 4: ...e 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...

Page 5: ...l specification recommendation of the fuel and the lubricant M 6 Breaking in of a new vehicle M 9 10 Daily Maintenance Operation M 11 Maintenance per 5000km M12 M14 Maintenance per 10000km M 15 Mainte...

Page 6: ...Driver s tool table A 1 Tightening moment of the bolts and the nuts in major position A 2 The table of Lubricant Power steering oil and Grease A 3 Air braking schematic diagram with air suspension A 4...

Page 7: ...lift off clearance mm 240 Approach angle departure angle 10 9 Front overhang rear overhang mm 2380 3270 Rated passenger driver included person 49 1 1 Mass parameter Technically permissible maximum lad...

Page 8: ...cle 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 t...

Page 9: ...ake proper operation and maintenance strictly according to relevant regulations in the instruction book Please refer to workshop manual for product quality assurance and strictly abide by the related...

Page 10: ...electronic clock electric single pieces front windshield sunshade driver side sunshade electric driver window safety hammer double emergency escaping windows curtain and luxury bilateral C type luggag...

Page 11: ...he vehicle may be different with the above description because of different deploying requirement of the clients Schematic illustration of the driver zone 1 Fire extinguisher pushbutton 2 Parking brak...

Page 12: ...Reverse gear N Neutral gear D Drive gear S Safety belt 2 Signal Bar Go to Appendix B 3 Speedometer Display speed of bus Units Km h 4 BarometerI and Barometer II Display air pressure of bus Units 0 1MP...

Page 13: ...not press S1 when flip the screen up or down 3 Instructions 3 1 LCD Display 3 1 1 After power on as shown in Figure 2 Total Mileage Trip Mileage A and Trip Mileage B 2012 08 07 Total TripA TripB 000 0...

Page 14: ...000000 0 L Figure 5 Fuel and Mileage information 3 1 4 The fifth interface display CNG and Catalyst as shown in Figure 6 2012 08 07 C N G CATALYST 0000 Bar 000 Figure 6 CNG and CATALYST 3 1 5 The sixt...

Page 15: ...1 Figure 7 Car and Engine compartment temperature 3 1 6 The seventh eighth ninth tenth and eleventh interface display ECM TCM ABS AIR Retarded information as shown in Figure 8 9 10 11 12 Figure 8 ECM...

Page 16: ...Operation Instruction CI 1 Figure 10 ABS Code Figure 11 AIR Code Figure 12 Retarded Code 3 1 7 The thirteenth interface display online module as shown in Figure 13...

Page 17: ...s S1 go to set interface Second Press S2 and S3 flip the interface up or down Could Set Time Set Backlight Set VehPPK Set MotPPR Clear Trip A Clear Trip B ClearTA Clear Oneway OC as shown in Figure 14...

Page 18: ...Operation Instruction CI 1 Figure 17 Set MotPPR Figure 18 Clear Trip A Figure 19 Clear Trip B...

Page 19: ...ime position as shown in Figure 14 Third press S1 go to Figure 22 Figure 22 Set Year Finally press S2 and S3 could increase or decrease years After set year could press S1 choose Month Day Hour Minute...

Page 20: ...CI 1 Figure 24 Set Day Figure 25 Set Hour Figure 26 Set Minute 3 2 3 Set Backlight First press S1 go to set interface Second press S2 or S3 choose Set Backlight position as shown in Figure 15 Third pr...

Page 21: ...erface Second press S2 or S3 choose Set VehPPK position as shown in Figure 16 Third press S1 go to Figure 28 Set VehPPK VehPPK 0624 Figure 28 Set VehPPK Finally press S2 and S3 could increase or decre...

Page 22: ...eturn main interface 3 2 8 Clear TA First press S1 go to set interface Second press S2 or S3 choose Clear TA position as shown in Figure 20 Third press S1 clear TA and auto return main interface 3 2 9...

Page 23: ...ty 21 Empty Appendix B ZB271M Signal Bar instructions Icon Name Color Left turn light Green Right turn light Green Front fog light Green ABS Yellow Rear fog light Yellow Pre heater Yellow Alarm of oil...

Page 24: ...D Alarm instructions Icon Icon Name Icon Icon Name Front Door Low Power Middle Door Alarm of water level ECAS Fault Concentrate lubrication Engine cabin temperature too high Alarm of oil filter Lack w...

Page 25: ...Operation Instruction CI 1 Brake Light Fault CRUISE Cruise Safety Door Brake Light Break Wear Antifreeze controller...

Page 26: ...p Red Pressed on bottom all turning indication lamps will turn on Luggage compartment lamp White Pressed on top the luggage cabin lamp OFF Pressed on bottom the luggage cabin lamp ON Ventilator White...

Page 27: ...hite Pressed on top the airbags will return to the standard height I height Pressed on bottom the airbags will return to the second height II height The switch should be pressed down only at bad road...

Page 28: ...defrosting is turned off Pressed on bottom the defrosting is turned on Driver window raise lower switch White Pressed on top the window will raise Pressed on bottom the window will descend Front wind...

Page 29: ...e Pressed on top turned off the reversal monitor power Pressed on bottom turned on the reversal monitor power Toilet power switch White Pressed on top turned off the toilet power Pressed on bottom tur...

Page 30: ...llow ECAS alarm indication Red ECAS fault indication White Engine start indication Yellow Exceeding emission standard indication Yellow Engine slight fault alarm White Engine serious fault engine stop...

Page 31: ...Operation Instruction P A 1 Air Conditioner KING LONG A C KL XB3 The introduction of control panel SK 17 1 SK 17 1Y 1 Control panel and functions...

Page 32: ...Operation Instruction P A 1 2 Control panel operation...

Page 33: ...Operation Instruction P A 1...

Page 34: ...Operation Instruction P A 1...

Page 35: ...Operation Instruction P A 1...

Page 36: ...Operation Instruction P A 1...

Page 37: ...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...

Page 38: ...s 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...

Page 39: ...mode the water valve would open automatically and keep heating for room as far as the room temperature is below the temperature value which the system was already pre established in advance once in M...

Page 40: ...Operation Instruction 0 G 1 ZF GEARBOX 6HP604C OPERATION 1 1 Pushbutton 1 1 1 Digital Speed Range Selector 1 1 2 CAN Speed Range Selector 1 1 2 1 Lighting of the CAN Speed Range Selector...

Page 41: ...Operation Instruction 0 G 1 1 1 2 2 Pushbutton Settings...

Page 42: ...Operation Instruction 0 G 1 1 2 Starting the Engine 1 3 Selecting the Gear...

Page 43: ...Operation Instruction 0 G 1 1 4 Setting Off 1 5 Driving Ranges...

Page 44: ...Operation Instruction 0 G 1 1 5 1 Downhill Travel 1 5 2 Downhill Travel 1 5 3 Kickdown...

Page 45: ...Operation Instruction 0 G 1 1 5 4 Retarder Operating Mode Defined in Section 1 9 Defined in Section 1 9 Refer to Section 1 8 or vehicle manufacturer s Operating Instructions...

Page 46: ...Operation Instruction 0 G 1 1 6 Stopping Parking...

Page 47: ...Operation Instruction 0 G 1 1 7 Towing 1 7 1 Towing Away Vehicle with Operational Transmission 1 7 2 Towing a Vehicle with Suspected Transmission Damage...

Page 48: ...Operation Instruction 0 G 1 1 8 Temperature Monitoring 1 9 Limit Values for Oil Temperature 1 9 1 Transmission Oil Temperature Before Heat Exchanger 1 9 2 Oil Temperature in Transmission Oil Sump...

Page 49: ...Operation Instruction 0 G 1 1 9 3 Actions to be Taken When the Relevant Permissible Oil Temperature is Exceeded...

Page 50: ...Operation Instruction 0 G 1 1 10 Status Monitoring Warning Lamps 1 11 Transmission Response to a Malfunction...

Page 51: ...Operation Instruction 0 G 1 1 11 1 Limp Home Mode 1 12 Auxiliary Control Unit...

Page 52: ...Operation Instruction 0 G 1 1 12 1 Operating Instructions for the Auxiliary Control Unit...

Page 53: ...Operation Instruction 0 AB 1 WABCO ABS BASIC INTRODUCTION...

Page 54: ...Operation Instruction 0 AB 1...

Page 55: ...Operation Instruction 0 AB 1...

Page 56: ...Operation Instruction 0 AB 1...

Page 57: ...Operation Instruction 0 AB 1...

Page 58: ...Operation Instruction 0 EC 1 ECAS System Introduction 1 System introduction...

Page 59: ...Operation Instruction 0 EC 1 3 System function...

Page 60: ...Operation Instruction 0 EC 1...

Page 61: ...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 ill be on or will show red light Internal Illu...

Page 62: ...e 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 i...

Page 63: ...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...

Page 64: ...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...

Page 65: ...le 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 9...

Page 66: ...dle switch 3 clockwise up to 90 degree 3 The air valve begin to deflate and next step may pull the door opened accordingly Special attention The door emergency switch is only used in the emergency sta...

Page 67: ...river Handle 1 and Handle 2 cushion height adjustment Handle 4 back and forth adjustment Handle 3 adjustment of the driver s weight Left handle backrest angle adjustment Note Number of handles varies...

Page 68: ...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 driver...

Page 69: ...teering wheel to the desired position After adjusting press the regulating handle or button down to lock the steering column Note Number of handles varies with vehicle model Attention Adjust the steer...

Page 70: ...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 press accelerator modestly to increase the rotational speed of the engine a...

Page 71: ...of this identification Is the Is the headlamp indication The headlamp small lamp meter lamp and width lamp will all be turned on when continuously anti clockwise rotating the handle to position of th...

Page 72: ...INT interval wiper operation step LO Slow wiping HI Quick wiping The wiper may spray water by pressing the end of the handle The shifts of the retarder may be converted by up and down motion of the ha...

Page 73: ...button 3 reading lamp button 4 lamp 5 loudhailer 6 stop button When the passenger require to read something may press the button 3 for turning on the reading lamp may press the cover 1 for cooling ai...

Page 74: ...e safety hatch according to the above diagrammatic representation and illustration for escaping in case of danger When in emergency and dangerous condition should 1 push upward with hands and make the...

Page 75: ...Operation Instruction OI 10 Safety hammer The safety hammer is located on the side window Please take down the safety hammer and break open the side window for escaping in case of danger Model 1...

Page 76: ...ion more compact and function more powerful It improves design of the past central electrical box therefore it avoids weakness such as unreliability and short service life it applies integrated circui...

Page 77: ...Operation Instruction 0 E 1 CAN bus module...

Page 78: ...Operation Instruction 0 E 2 Switch control box Model JKH2025A CQ2025 A wiring diagram Printed on opposite cover of the switch control box...

Page 79: ...n 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 a...

Page 80: ...he 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 sc...

Page 81: ...erior 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 Activa...

Page 82: ...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 tan...

Page 83: ...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...

Page 84: ...Blue 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 da...

Page 85: ...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 evapo...

Page 86: ...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 autom...

Page 87: ...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 co...

Page 88: ...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...

Page 89: ...atio 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 spee...

Page 90: ...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...

Page 91: ...or 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 pressu...

Page 92: ...y 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...

Page 93: ...ving S 15 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 v...

Page 94: ...t 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 Th...

Page 95: ...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 fir...

Page 96: ...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...

Page 97: ...ton Model 1 L adjusting left rearview mirror R adjusting right rearview mirror Mirror button push down the arrow headed button to adjust the mirror for 4 directions Model 2 L adjusting left rearview m...

Page 98: ...raulic 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 Dea...

Page 99: ...r 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...

Page 100: ...essor drive belt correctly adjusted and do not need to be adjusted periodically Adjusting method of the air conditioner belt is shown in the figure 1 Check tension of belt Apply 98N force to belt with...

Page 101: ...of left or right rear side 1 battery 2 switch control box 3 Main power switch To access the battery open the switch control box panel After the vehicle has been parked for the day the main power swit...

Page 102: ...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...

Page 103: ...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 Please a...

Page 104: ...e 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 comp...

Page 105: ...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...

Page 106: ...king 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 acci...

Page 107: ...ransmission 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...

Page 108: ...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 ne...

Page 109: ...es 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 carefu...

Page 110: ...g 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 fi...

Page 111: ...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 ant...

Page 112: ...00 42 48 10 20 105 50 38 52 10 15 105 00 34 56 10 10 104 50 30 60 10 Antifreeze Performance Requirement Item Quality Index Test Way Appearance striking colour clear inclusion free visual inspection od...

Page 113: ...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 perce...

Page 114: ...rt 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 temper...

Page 115: ...s 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 Wate...

Page 116: ...ectrolyte 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...

Page 117: ...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...

Page 118: ...t Check correct No across crack wear or material break off Crankcase breather tube Check Check the breather tube in cold winter cleanup the ice blocking Engine and Accessories Check No damage and crac...

Page 119: ...uxiliary oil and filter element Check Below 10 use DEXRON II above 10 use C 3 10W Fix bolts of each place Fasten Each fastening bolts not loosening steering arm not loosening steering wheel swift Ball...

Page 120: ...ase adjust it in time The air spring surface 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 Ch...

Page 121: ...6MPa The brake nuts Inspect 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 The pipe and joint sealing Check Check brake pipe and joint sealin...

Page 122: ...leakage Air compressor Check No air oil coolant leakage lock nut and bolt no loosen or damage No carbon deposit Brake system Check No leakage Propeller shaft fastening bolt Check and fasten Propeller...

Page 123: ...er core of oil tank N32 which manufactured by Shanghai oi refining factory or ATF or related products which produced IPS40 SB8575D series Change oil and filter core of oil tank Environment temperature...

Page 124: ...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...

Page 125: ...ble no air leakage safety valve normal pressure at 8Mpa check air reservoir if with seeper replace air drier filter element Electrical equipment Front lamp horn meters and signal Check set complete an...

Page 126: ...normal abrasion bush not crack lubrication normal Maintenance operation and regulation every 80000km or 12 months depend on whichever occurs first Every 80000km include every 40000km maintenance opera...

Page 127: ...12 Filling up general greasing point 80 000KM or 1 year ZF Ecofluid 12G TE ML 12 Rear Axle AVE 130 Oil change 60 000 km 1 years ZF Ecofluid 12L TE ML 12 Filling up general greasing point 80 000KM or...

Page 128: ...00 km or 3 3 years ZF Ecofluid M 02B 1 02E 02L Long distance coach journeys Average speed as of 60 km h 540 000 km or 3 3 years Assembly System Name Application Range Oil Change Interval Oil Classes T...

Page 129: ...0km or 3years Automatic Transmission Fluids ATF 14A 14B 14C 14E oil sump temperature below 105 centigrate 150 000km or 3years ZF Ecofluid A PLUS 14E Assembly System Name Application Range Oil Change I...

Page 130: ...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 I I I I I I I I I I I I I I I I I Fixing every bolt...

Page 131: ...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 Clutch cylinder stroke I I I I I I I I I Transmission Transmission if not leaking oil I I I I I I I I I I I I I I I...

Page 132: ...I I I I I Engine exhaust brake I I I I I ABS unit checking I I I Brake valve other valves I I I Axle Tire Tire steel ring I I I I I I I I I I I I I I I I I Checking fixing RR axle housing differential...

Page 133: ...I I I I Absorber working condition I I I Steel plate suspension bush I I I Left right steel plate suspension flexibility I I I Fixing suspension U type bolt I I I I I I I I I Valves function I I I Br...

Page 134: ...35 40 45 50 55 60 65 70 75 80 Month 1 3 5 7 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 I I I I I I I I...

Page 135: ...age in the fuel inlet pipe Clogging of the fuel supply pump filters and fix or replace 6 Insufficient fuel injection without fuel injection or low injection pressure 6 Check the injector atomization s...

Page 136: ...udge in the back of turbine and compressor impellers Clean it 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...

Page 137: ...on 4 Check and adjust the valve timing 5 The driving gear is abrased and get too large gap There is knocking sound at the timing gear box cover 5 Check the gear side clearance and change the gear or n...

Page 138: ...embly 8 middle cooler damaged and leaked 8 Repair or replace it Exhaust with white and blue smoke Possible causes Remedies 1 Poor quality fuel and too much water in fuel 1 Replace the fuel 2 Too low c...

Page 139: ...igh oil pressure Possible causes Remedies 1 Too low ambient temperature and too high oil viscosity 1 Use the required grade engine oil Operate at low speed after starting and then check it when the oi...

Page 140: ...loose or the rubber damp piece material is aging 1 Remove and let the sliding yoke and the fixing yoke on the same plane 2 Adjust or replace the propeller shaft 3 Replace the bearing 4 Tighten propel...

Page 141: ...e 2 Use the lubrication of given grade The transmission gear is off the engaging position Transmission 1 Shift fork distorted or worn 2 Abrasion of lthe lockup ball or the ball on the gear shifter sha...

Page 142: ...rear axle improper sound When the vehicle is running 1 Excessive clearance between the driving and the driven gear 2 Abrasion or damage of the bearing 3 Abrasion or damage of the gear 4 Too low oil le...

Page 143: ...due to malfunction of sealing ring 1 Adjust the pre tightening force 2 Intensify the lubrication or replace the grease 3 Clean and intensify the lubrication 4 Replace the sealing ring Front axle and...

Page 144: ...here has fatigue and damage in the front plate spring 3 Bending of the front axle 4 Unsmooth of the braking 5 Looseness of the front hub bearing nut 6 Inequality of the tire pressure 7 Tires with diff...

Page 145: ...icant to the given level 2 Replace the lubricant 3 Replace the ball stud 4 Overhaul and eliminate trouble 5 Measure the backpressure and repair or replace the pipeline in case of the set value exceede...

Page 146: ...eplace the faulted parts 4 Eliminate causes of the spring braking unreleased 5 Disassemble and clean the faulted parts 6 Disassemble and clean the braking valve and replace the faulted parts as needed...

Page 147: ...l cylinder cover and the rubber cap 7 Replace it 8 Tighten the U bolt The braking can t be applied under all conditions When compressed air pressure is normal 1 Too short of the brake valve travel 2 T...

Page 148: ...ethod There has abnormal sound during the generator rotates 1 The belt is of over loose or excessive abrasion with the shaking during the running 2 Bearing failure or oversize clearance 3 Too much bea...

Page 149: ...contact of the ignition switch or socket loose 2 Unsteady connection of the relay device or the solenoid switch 3 Turnoff of the starter solenoid switch 4 Damage of the starting gear or the gear ring...

Page 150: ...o temperature difference between high and low pressure pipe Air conditioner system has serious leakage Check the system and find out the leakage and fill the enough refrigerant 3 The low pressure is n...

Page 151: ...inspection glass looks yellow Too much water in the system desiccators reaching the saturation the frosting water blocked the expanding valve Change the desiccators and make the vacuum repeatedly and...

Page 152: ...r failure or connection problem 3 temperature control sensor installation position not good 4 temperature control switch defective 5 harness connection not reliable 6 Control panel defective 1 change...

Page 153: ...rator blower not working 1 relay not working 2 battery no charge 3 battery cable confected 4 air blower harness not connected well 5 harness connection not good 6 venting blower cable not connecting w...

Page 154: ...ve locknut 55mm 16 Combination wrench 30 36 Spare wheel lifter 22X550 17 S double box wrench 13x15 37 Wrench for drive axle drain plug 10x10 18 Adjustable wrench 8 38 Jack 16t J1601 19 Adjustable wren...

Page 155: ...45 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...

Page 156: ...7 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 5...

Page 157: ...d 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 Fulfill standard please apply ZF TE ML09 or DEXRON II D III hydraulic fluid to steering...

Page 158: ...Appendix A 4 Air braking schematic diagram...

Page 159: ...A 5 Electric schematic diagram of the complete vehicle 1...

Page 160: ...A 6 Electric schematic diagram of the complete vehicle 2...

Page 161: ...A 7 Electric schematic diagram of the complete vehicle 3...

Page 162: ...A 8 Electric schematic diagram of the complete vehicle 4...