King Long XMQ6900J series, Operating Manual

Page 1: ...OPERATION MANUAL User s Guide King Long XMQ6900J series city bus Xiamen King Long United Automotive Industry Co Ltd...

Page 2: ...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...

Page 3: ...peration Instruction Instrument instruction I 1 Illustration of switch and indicator s SI 1 Air conditioner control panel P A 1 Bus centre controller P B 1 Open or close the passenger door O K 1 Adjus...

Page 4: ...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...

Page 5: ...ing 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...

Page 6: ...em C 11 Braking system C 14 Electrical equipment and the starting system C 16 Air conditioner system C 18 Appendix Driver s tool table A 1 Tightening moment of the bolts and the nuts in major position...

Page 7: ...eight mm 3050 3140 Wheelbase mm 4250 Wheel track front mm 2094 rear mm 1860 Minimum lift off clearance mm 158 Approach angle departure angle 7 8 8 Front overhang rear overhang mm 2175 2750 Rated passe...

Page 8: ...ntification 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 fron...

Page 9: ...kshop manual for product quality assurance and abide by related specification Technical document The instruction book is used combined to the following specification Engine operation instruction or se...

Page 10: ...point safety belt 7 Interior accessory device The vehicle is equipped with electronic clock sunshade safety hammer emergency escaping window curtain destination board inner display screen reversal mon...

Page 11: ...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...

Page 12: ...eporter 4 Rocker switch 5 Light operation handle 6 Combination instrument 7 Steering wheel 8 Horn 9 MP3 player 10 Emergency electric power cut off switch 11 Wiper operation handle 12 A C operation rot...

Page 13: ...ight 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 Rev...

Page 14: ...r 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 foll...

Page 15: ...ror if this symbol still exist after engine starts Coolant temperature high 98 C The bar shows brake circuit 1 pressure Coolant level low The bar shows brake circuit 2 pressure Rear flap open can not...

Page 16: ...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 o...

Page 17: ...e 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 Dia...

Page 18: ...p 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 h...

Page 19: ...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...

Page 20: ...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...

Page 21: ...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...

Page 22: ...h Red Pressed on top to turn on heater Pressed on bottom to turn it off TV overturn switch Green Pressed on top expand the TV Pressed on bottom collapse the TV Fresh air switch Green Pressed on top tu...

Page 23: ...d 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 For articulate plate only Inner guidepost s...

Page 24: ...function Pressed on bottom turning off Side kneeling setting switch Green Pressed on top switching on the side kneeling function Pressed on bottom turning off Engine diagnostic switch Yellow Pressed o...

Page 25: ...dicate 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...

Page 26: ...ling lamp Green Normal height Red Vehicle in abnormality height Red Air chamber trouble warning indicator Red 2nd height indicator Yellow Side kneeling indicator Red Transmission oil temperature warni...

Page 27: ...seconds HA When the command panel shows HA the compressor and the ventilators of the condenser will be off for 3 minutes after that they will restart working again 3 Key turn down or up the desired t...

Page 28: ...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...

Page 29: ...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 30: ...rd If your vehicle is equipped with a safeguard against inadvertent gear engagement this facility must be operated first For that purpose step onto the brake pedal Press button D while the vehicle is...

Page 31: ...2 or 3 pressed will increase fuel consumption Breaking With the DIWA transmission breaking is free of wear Actuating the brake pedal or the manual switch for converter brake will apply the converter b...

Page 32: ...s for activation of ANS accelerator in idling position brake signal driving speed below 1 km h forward gear selected The power flow between engine and transmission is interrupted This results in fuel...

Page 33: ...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 p...

Page 34: ...cy switch is located on right upside 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...

Page 35: ...stment for the back and forth as well as the backrest angle according to requirement of the driver Handle 1 seat angle adjustment Handle 2 back and forth adjustment Note Number of handles varies with...

Page 36: ...utton 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 d...

Page 37: ...the desired position After adjusting press the regulating handle or button down to lock the steering column Note Number of handles varies with vehicle model Attention Adjust the steering wheel only w...

Page 38: ...e 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...

Page 39: ...ely 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 clockwisely rotat...

Page 40: ...rside 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 press...

Page 41: ...Notice If you vehicle is fitted with a retarder but without a dashboard indicator light it is essential to have one fitted Should the indicating light be on without actuation of the retarder this woul...

Page 42: ...uction OI 8 Safety hatch The safety hatch is located on scaffold of the vehicle Please open the safety hatch according to the above diagrammatic representation and illustration for escaping in case of...

Page 43: ...Operation Instruction OI 9 Safety hammer 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...

Page 44: ...Prompt stop switch for get off The stop switch is located at the grab rail see the right picture when the vehicle is going to arrive at bus stop the passenger who need get off press the switch to rem...

Page 45: ...Operation Instruction O E 1 Switch control box Model CQ2025 CQ2025 A wiring diagram Printed on opposite cover of the switch control box...

Page 46: ...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 47: ...t 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 be...

Page 48: ...mulation 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 Work...

Page 49: ...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 50: ...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 51: ...orcibly 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 requiremen...

Page 52: ...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 53: ...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 54: ...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 55: ...hicle speed to avoid engine operating in the danger range red zone When the exhaust brake is operating on down grades select an adequate gearbox speed to keep engine speed within efficient exhaust bra...

Page 56: ...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 57: ...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 58: ...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 59: ...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 60: ...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 61: ...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 i...

Page 62: ...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 63: ...lectrical rearview mirror Check adjust and clean the rearview mirror Rearview mirror control button L adjusting left rearview mirror R adjusting right rearview mirror Mirror button rotate the handle t...

Page 64: ...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 K...

Page 65: ...ke fluid used in the clutch activating system from entering into contact with the vehicle s plastic components or painted surfaces In the case of spilling or accidental dripping immediately clean the...

Page 66: ...e 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 De...

Page 67: ...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 68: ...ction order of input end and control end which is equipped with GK B1250 volts D C converter is connect the input end first then connect the control end To access the battery open the switch control b...

Page 69: ...urn 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 spee...

Page 70: ...ing 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 Pleas...

Page 71: ...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...

Page 72: ...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 73: ...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 74: ...ission 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...

Page 75: ...al 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 w...

Page 76: ...nt 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 resistanc...

Page 77: ...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 78: ...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 79: ...l 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 temper...

Page 80: ...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 tem...

Page 81: ...h different types otherwise it will affect the using effect The original brake fluid should be cleaned out before replacing the compound brake fluid Chassis grease Grease added in each part should use...

Page 82: ...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...

Page 83: ...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 84: ...utes Drive belt 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 d...

Page 85: ...issions as well as fillings during transmission break in for first 7500km only Transmission fix bolt Fasten Transmission air hole Check clean Air hole smooth Transmission and Accessories Check No leak...

Page 86: ...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 head Lubricate Each turning ball head not loosening no c...

Page 87: ...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 Check...

Page 88: ...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 sealing...

Page 89: ...ion Check No 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 fast...

Page 90: ...ore of oil tank N32 which manufactured by Shanghai oi refining factory or ATF or related products which produced IPS series 25 35 40 55 65 Change oil and filter core of oil tank Environment temperatur...

Page 91: ...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 92: ...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 93: ...o 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 operat...

Page 94: ...A131 Oil change 150 000 km 3 years TE ML122RL Rear Axle A 132 New AV 132 Oil change 150 000 km 3 years TE ML 12TE Old model lubricant grease of shaft of wheel hub change include oil seal 250 000KM or...

Page 95: ...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 96: ...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 I I Se...

Page 97: ...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 98: ...I 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 B...

Page 99: ...5 30 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...

Page 100: ...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 101: ...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 102: ...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 103: ...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 104: ...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 105: ...ine 3 Cllogging of the flywheel supporting bearing 4 Pressure spring distorted 5 Impurity in the clutch plate the pressure plate and the flywheel 6 Distortion or breakdown of the diaphragm spring 2 Th...

Page 106: ...hat pushing the clutch cylinder 10 Improper adjustment of push rod on the clutch booster that pushing the clutch 11 Clutch master cylinder oil return port is blocked 12 Abrasion of the clutch plate 1...

Page 107: ...er shaft sliding yoke assembled incorrectly 2 The propeller shaft is distortion or bending 3 The universal joint journal or the needle bearing has been worn out or damaged 4 The propeller shaft loose...

Page 108: ...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 109: ...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 110: ...g 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 111: ...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 112: ...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 113: ...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 114: ...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 115: ...g method 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...

Page 116: ...Common trouble and elimination C 16 Fault symptom Possible cause Eliminating method speed...

Page 117: ...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 118: ...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 119: ...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 120: ...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 121: ...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 122: ...hen open CNG low pressure filter contamination drain mouth to check CNG discharge pressure b Cannot hear s s sound then it is CNG gas feeding system breakdown c Can hear s s sound then ask engine comp...

Page 123: ...ce pressure gauge a Replace or report for repair to Lantianda After refilling for 12 hours pressure gauge display decreased about 2 4Mpa a When vehicle is on the process of gas refilling because CNG g...

Page 124: ...Combination wrench 18 30 Spare wheel lifter 700X22 11 Combination wrench 19 31 Canvas bag 12 Combination wrench 21 13 Combination wrench 22 1 Socket wrench for wheel nut 41x21 14 Combination wrench 2...

Page 125: ...Nut trapeziform arm of Steering left and right 350 450 King pin Cuniform lock nut 25 40 Adjusting nut front wheel hub bearing Min200 Steering knuckle tie rod ball joint nut 250 310 Fixing nut tie rod...

Page 126: ...16 100 120 Bolt bearning cap M22X1 5 440 490 Axle shaft bolt M16X1 5 140 180 Fixing bolt bracket of brake chamber M14X1 5 90 120 Oil level hole plug M24X2 130 150 Fixing nut rear brake chamber M16X1 5...

Page 127: ...bient 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 us...

Page 128: ...Appendix A 4 Air braking schematic diagram...

Page 129: ...Appendix A 4 Electric schematic diagram of the complete vehicle 1...

Page 130: ...Appendix A 4 Electric schematic diagram of the complete vehicle 2...

Page 131: ...Appendix A 4 Electric schematic diagram of the complete vehicle 3...

Page 132: ...Appendix A 4 Electric schematic diagram of the complete vehicle 4...