King Long XMQ6900J series, XMQ6120C series Operating Manual

OPERATION MANUAL

User’s Guide

King-Long XMQ6900J series city bus

Xiamen King Long United Automotive Industry Co., Ltd.

Foreword

FOREWORD

King-Long XMQ6900J series city 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 intra-city

transportation, touring affairs, etc.

As for the specifications introduced in relate to information of the driving

and operation, service and maintenance of the XMQ6900J series city 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.

MAY. 2014

Contents

2

Contents

Foreword

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

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

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

Retarder operation-------------------------------------------------------------------------------------------------OI-7

Safety hatch--------------------------------------------------------------------------------------------------------OI-8

Safety hammer-----------------------------------------------------------------------------------------------------OI-9

Prompt stop switch for get off ---------------------------------------------------------------------------------OI-10

Contents

3

Switch control box----------------------------------------------------------------------------------------------O-E-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 Tachograph 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

Clutch actuation system fluid level-----------------------------------------------------------------------------S-21

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

Clutch actuation system fluid level-----------------------------------------------------------------------------S-21

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

Contents

4

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

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

Vehicle maintenance and service

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

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

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

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

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

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

Adjustment of the clutch pedal freeplay------------------------------------------------------------------------M-3

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-22

Common trouble and its eliminating method

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

Clutch---------------------------------------------------------------------------------------------------------------- C-6

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

Contents

5

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

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

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

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

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

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

Appendix

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

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

Air braking schematic diagram -------------------------------------------------------------------------------- A-4

Electrical schematic diagram-------------------------------------------------------------------------------------A-4

Technical parameter and complete vehicle description

6

Technical parameters of the complete vehicle
(Vehicle No.EC600024-25)

Product model

XMQ6900

J

Engine model

ISBE6.7E5 250B

Engine type In-line six-cylinder water-cooling direct-injection diesel engine
Cylinder diameter ×stroke （mm）

107X124

Displacement (ml)

6700

Compression ratio

17.2:1

Rated capacity / rotation speed (kw/rpm)

184/2300

Max. torque / rotation speed (N·m/rpm)

1200 /1200-1600

Dimensions

Overall length （mm）

9175

Overall width (mm) 2450
Overall height（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 passenger (driver included)

(person)

23+4+1

Mass parameter

Kerb weight（kg） 9000
Max. gross mass （kg） 12000

No

load

Front axle （kg） 2700
Rear axle （kg） 6300

Full

load

Front axle （kg） 4000
Rear axle （kg） 8000

Performance

parameter

Max. speed (km/h) ≥90

Fuel consumption (L) --

Maximum gradeability (%) ≥20

Min. turning diameter (m) ≤20

Parking slope (20%)

Parking for 5 minutes

Capacity data

Fuel tank（L） 165
Engine oil（L） 19.5
Transmission lubricant（L） 23
Main retarder lubricant（L） 5
Power steering hydraulic oil（L） 8
clutch lubricant（L） 1.3

Technical parameter and complete vehicle description

7

Introduction to 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.

Technical parameter and complete vehicle description

7

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.

Technical document

The instruction book is used combined to the following specification:

Engine operation instruction or service manual

Transmission operation manual

CAN BUS Instrument system instruction book

ABS anti-braking system instruction book

Air conditioner instruction book

Heater instruction book

Monitor instruction book

VCD/DVD instruction book

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

Technical parameter and complete vehicle description

7

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 without installing

6. Seat
Driver’s seat: adjustable seat with high backrest and three-point belt（E-MARK）.
Passenger seats: FANSA city bus seat, the all seats are equipped with two-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 monitor, Vehicle traveling data recorder ,

reading lamp, disabilities ramp ,guide mike .etc.

8. Air-conditioning system
Cooling system: WEBASTO top mounted dependent air-conditioning system.
Defroster: cooling /heating defrosting device

9. Door
The door adopts the full aluminum remote control inner-swing pneumatic doors.
The inner-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.

Technical parameter and complete vehicle description

8

B. Hint:
a. The door remote control acts only when the parking brake is on the parking gear.

b. The door could only be opened when the external mechanical lock isn't locked up.
c. In order to avoid impact, make sure that the door is completed closed or opened, before you make the

next door switch operation.

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

Technical parameter and complete vehicle description

9

Schematic illustration of the driver zone

1 Rearview mirror heating
2 Rearview mirror control switch
3 Station reporter
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 rotation button
13 Cigar lighter/USB charging socket
14 Door air valve switch
15 Transmission control panel
16 Parking brake shift

1

4

12

6 7 8 9 10

13

14

11

2

3

15

16

5

Operation Instruction

I-1

Instruction of instrument (Siemens Edition）

No. Function Description

1 ABS indicator ABS work/warning

2 High beam indicator When Highbeam 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

Operation Instruction

I-2

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 from

cabin(see 2.1.9)

Fluid fan error

Engine red lamp error

Operation Instruction

I-3

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 wroking

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 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 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.

Operation Instruction

I-4

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 ：ECAS severe error

2.3.9 Service request

：Passenger service request ：Request from cabin

2.2 Error display Page：

Figure -2 text error information

Operation Instruction

I-5

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

Operation Instruction

I-6

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

Operation Instruction

I-7

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.

Operation Instruction

SI-1

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 Function Notes

Retarder Green

Pressed on top: retarder is turned ON

Pressed on bottom: retarder is turned OFF

Retarder turn off

switch

Pressed on top: retarder is turned OFF

Pressed on bottom: retarder is turned ON

Daylight lamp

Green

Pressed on top: interior lighting ON,

Pressed on bottom: interior lighting OFF

Hazard lamp 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

only use this button

when vehicle is stopping

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

only use this button

when vehicle is stopping

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

Operation Instruction

SI-2

Switch Name Color Function Notes

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

adjust engine

speed

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

Disinfect 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

Emergency time-delay

parking

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

Operation Instruction

SI-3

Switch Name Color Function Notes

Exterior guidepost

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

only switch on when

vehicle need park

Vehicle level reset Green Pressed on top: vehicle level reset

Emergency power

Red

Pressed on top: emergency power turned ON

Pressed on bottom: emergency power is

turned OFF

Toilet power switch

Green

Pressed on top: Toilet power is turned ON,

Pressed on bottom: Toilet power is turned

OFF

Heater switch

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: 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.

Electric driver window

defrosting switch

Yellow

Pressed on top: turn on defrosting function;

Pressed on bottom: turn off defrosting

function.

Rearview mirror

defrosting switch

Pressed on top: turn on defrosting function;

Pressed on bottom: turn off the defrosting

function.

Left side bin gate Green

Pressed on top: open the left side bin gate;

Pressed on bottom: close the left side bin

gate.

Operation Instruction

SI-4

Switch Name Color Function Notes

Right side bin gate Green

Pressed on top: open the right side bin gate;

Pressed on bottom: close the right side bin

gate.

Powerful/abstemious

transfer switch

Pressed on top: turn on powerful function;

Pressed on bottom: turn off abstemious

function.

Electric sun blind 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.

For articulate plate

only

Inner guidepost switch Green

Pressed on top: turn on the inner guidepost;

Pressed on bottom: turn off the inner

guidepost.

Changing monitor

video switch

Green

Pressed on bottom: changing the monitor

video from cameras

Spare switch

Pre-heater solenoid

valve switch

Green

Pressed on top: turning on the pre-heater

solenoid valve for water way

Pressed on bottom: turning off

Press the switch while

turning on the

pre-heater ignition

switch

Pre-heater water pump

switch

Green

Pressed on top: turning on the pre-heater

water pump

Pressed on bottom: turning off

Press the switch while

turning on the

pre-heater ignition

switch

Handicapped footplate

switch

Red

Pressed on top: switching on the

handicapped footplate

Pressed on bottom: turning off

Power switch on
dashboard ， control

switch in disable area

Operation Instruction

SI-5

Switch Name Color Function Notes

Height adjusting

switch

Green

Pressed on top: switching on the height

adjusting 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 on top: switching on the engine

self-diagnostic;

Pressed on bottom: turning off

The engine diagnostic

indicator flashing 3 times

for each code

Operation Instruction

SI-6

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

Operation Instruction

SI-7

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

Red Vehicle in abnormality height

Red Air chamber trouble warning indicator

Red 2

nd

height indicator

Yellow Side kneeling indicator

Red Transmission oil temperature warning indicator

Red Transmission trouble warning indicator

Red Engine major trouble

Red Engine small trouble

Yellow Engine maintenance indicator

Yellow Engine diagnostic indicator

Operation Instruction

P-H-1

Spheros A/C Controller Instruction

1. Display

It indicates the internal temperature and the regulated

temperature.

PS: the display will always show the vehicle internal

temperature even when the motor is off.

2. Key

- On/Off

1st touch – turns on the equipment

- the equipment operates in refrigeration at high velocity

PS: If the led light is blinking, it indicates the compressor still has not started operating. If the light is on,

it indicates the compressor has started operating.

2

nd

touch – the equipment starts operating in refrigeration at low velocity.

3

rd

touch – turns off the equipment.

PS: It is always recommended to turn off the equipment before turning off the vehicle motor.

PS: When the air conditioner is activated for the first time, the compressor will be activated at

approximately 10 seconds. After the air conditioner turning off and its subsequent turning on (without

turning off the vehicle motor) the compressor will be activated at about 30 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 temperature.

When you press any of these keys, the (blinking) display will show the selected temperature. For

turning it down or turning it up, keep pressing one of the keys until you get the desired temperature
value (minimum 16 e maximum 32 ). After 5 seconds without pressing one of the keys, the℃℃

temperature will be recorded and the display will once again show the temperature inside the vehicle.

4. Failure code

When the display shows one of the indications related below, it is an indicator of failures in the system.

HA – Indicates low or high pressure in the system. It may be a condenser obstruction or lack of gas.
OP – Sensor of temperature is open. Select one temperature below 24 so that the equipment may ℃
operate in refrigeration and above 24 so that the equipment may operate in ventilation.℃

SC – Sensor of temperature in short circuit. On such a case, the equipment will operate at an internal
refrigeration temperature of 24 .℃

AL – Indicates the alternator is not charging current.

Operation Instruction

P-H-1

Pre-heater Operation (Webasto)

1. General

The standard digital timer enables you to preset the
start of the heater operation up to 7 days in advance.
It is possible to program 3 different starting times,
only one of which can be activated.
The standard digital timer features a wakeup alarm
function.
When the ignition switched on, the timer displays
the current time and the day of the week.
When the heater is switched on, the display and
the buttons are illuminated.
After the power supply has been connected,
all symbols on the display will flash.
The current time and weekday must be set.

2. Operation

The timer can be operated in that all flashing symbols
can be adjusted by means of the 10 and 9 buttons.
If the buttons are not pressed within 5 seconds,
the time displayed will be stored.
If the 10 and 9 buttons are pressed for more than
2 seconds, the fast time-setting mode is activated.
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:

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

11. panel

Operation Instruction

P-A-5

Press the 7 button – the memory location is flashing – using the 9 and 10 buttons set start of the
heater operating time. Day of the week is flashing- set the day of the week. By repeatedly
pressing the 6 button, memory locations 2 and 3 can be programmed or the time display mode
can be reached.

8. Recalling/erasing preset times

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

9. Programming duration of operating time The heater must be switched off. Press the 9

button for 3 seconds – operating time is flashing – and set the desired operating time (10 to 120
minutes) using the 9 and 10 buttons.

10. Setting the remaining operating time

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

11. Setting the wakeup time

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

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

12. Recalling/erasing the wakeup time

Repeatedly press the 7 button until the bell symbol appears on the display – read off

wakeup time. To erase the wakeup time: press the 7 button until the bell symbol is no
longer visible on the display.

13. remote control

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

14. Vehicles with ADR equipment

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

Operation Instruction

P-A-5

Transmission application (Voith)
Starting the engine

First apply the parking brake.

No button of the push-button switch may be depressed

during starting. Bring all buttons into neutral position by

depressing the button marked ’N’: all but-tons are released,

the ’N’-button

is illuminated.

Under certain conditions it may be possible to start the

engine after pressing any button other than the ’N’-button. In

that case, however, no gear will be engaged even if the

push-button switch indicates this. Make sure you only start

the engine after having pressed the ’N’-button.

Driving forward

If your vehicle is equipped with a safeguard against

inadvertent gear engagement this facility must be operated

first. For that purpose step onto the brake pedal.

Press button ’D’ while the vehicle is at standstill and the

engine idling.

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

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

be:

– the accelerator was actuated while selecting a gear,

– the safeguard against inadvertent gear engagement was not

released.

Please also consult the operating instructions of the vehicle.

When moving off on a gradient, step on the accelerator

before releasing the brake in order to prevent the vehicle

rolling back.

Note: Driving in the partial load range rather than at ful

throttle or kickdown mode will have a positive

effect on fuel consumption.

Operation Instruction

0-G-2

Driving in kickdown mode

For higher acceleration, depress the accelerator beyond the

full-throttle pressure point. This causes the transmission to

change gears at a higher speed.

Note: Driving in kickdown mode will increase fuel

consumption.

Driving with buttons

1 , 2 or 3 (if available) pressed:

When the transmission hunts between two gears when

driving uphill, press the button for the lower of the two

gears. This will prevent engagement of the higher gear.

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

Breaking

With the DIWA transmission breaking is free of wear.

Actuating the brake pedal or the manual switch for converter

brake will apply the converter brake.

Depressing the brake pedal further will apply the service

brake.

Please note when braking on a slippery road: the converter

brake only acts on the driven wheels.

On vehicles without ABS the converter brake should therefore

be disabled when road conditions are poor (e. g. in ice or snow)

in order to avoid rear wheel lock-up and a possible loss of

control over the vehicle.

Switch off the converter brake via the converter brake switch,

if available

Hunting between gears Pressing the button

4 - 3 3

3 - 2 2

2 - 1 1

Operation Instruction

0-G-3

In vehicles equipped with ABS the converter brake switch is

mostly not availably. The location of switch and its handling

are described in the operating instructions of the vehicle.

Stopping

During short stops (e.g. traffic lights, bus stops) the selected

button remains depressed and the vehicle is held by the vehicle

wheel brake or the parking brake.

ANS-activation

Automatic Neutral at Standstill:

Conditions for activation of ANS :

– accelerator in idling position,

– brake signal,

– driving speed below 1 km/h,

– forward gear selected.

The power flow between engine and transmission is interrupted.

This results in fuel savings.

Reversing

Press button ’R’ while the vehicle is at standstill and the

engine idling and - if available – the reverse gear inhibiter

button. A change from ’Forward’ to ’Reverse’ or viceversa is

only possible after operation of the ’N’ button.

Never engage reverse gear when moving forward – danger of

accident!

Parking

For longer stops or when switching off the engine, switch the

transmission to neutral (button ’N’) and apply the parking

brake.

Operation Instruction

0-K-1

Open/close the passage door.

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.

Appendix:

The following is door remote controller of King-Long.

Operation Instruction

0-K-2

Door emergency switch

The door emergency 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't rotate the door emergency

switch in driving for fear of danger.

Operation Instruction

0I-1

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:seat angle adjustment

Handle 2: back and forth adjustment

Note: Number of handles varies with vehicle

model

Attention!
The seat should not be adjusted during
driving
to ensure driving safety.

1

2

Operation Instruction

0I-2

Horn button

It is on the steering wheel. The horn is hooting when

pressing the button 1.

The type of steering wheel may vary with vehicle model.

Please use the horn only when strictly necessary to warn

other drivers and pedestrians.

Model 1

1

Operation Instruction

0I-3

Adjustment of the steering wheel

Rotate the loosening button 1. Adjust the height and the inclination of the steering wheel to the desired

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

Note: Number of handles varies with vehicle model

Attention!

Adjust the steering wheel only when the vehicle is

stopped and the parking brake is on.

After adjusting, press the regulating handle or button

down in order to lock the steering column.

1

Operation Instruction

OI-4

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.

1

Operation Instruction

OI-5

Lamplight operating handles

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.

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 clockwisely 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.

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.

Operation Instruction

OI-6

Wiper operating handle

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.

Operation Instruction

OI-7

Retarder operation (for retarder)

The hand lever can be mounted under the steering wheel

or built into the dashboard. This hand-operated control

generally has 5 control positions:

Position 0: off

Position 1: 25%

Position 2: 50%

Position 3:75%

Position 4: maximum braking effect

An indicator light is lit when the retarder is in use.

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 would mean a unfit in the retarder

function.

If the light does not come on when the retarder is

operated, check the bulb.

Don’t forget to return the lever to position 0 once the

vehicle has stopped to prevent unnecessary consumption

of electric current. This can be done in a single

movement, without pausing in the intermediate positions.

Terca & Telma handle

Operation Instruction

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 danger.

Model 1

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.

Operation Instruction

0I-10

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 remind

the driver for stopping.

Operation Instruction

O-E-1

Switch control box (Model: CQ2025)

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

Vehicle Starting and Driving

S-1

Preparatives for vehicle operation start up:

Check daily, before turning engine on:

1. Check oil level of the engine

The warning “Engine oil pressure” is displayed as a signal

item on the combination instrument when the oil pressure

is too low, the alarm buzzer sounds, the warning light

STOP comes on, stop the engine and check engine oil level

at the dipstick. Provide immediately for the oil

replenishment to its correct level.

The oil level should always be checked with the vehicle

parked on level ground, before starting the engine up, or at

least 5 minutes after having shut it down.

Open the engine compartment hood.

Take out the oil dipstick, and clean it with a clean cloth

without loose threads, and put it back into its place fitting it

in completely.

Once again pull out the dipstick and check the oil level.

a. The oil should not exceed the maximum level.. drain

the excess.

b. If the oil is at operational level, do not add more oil to

the crankcase.

c. If the oil is at or below the minimum level, add the

same type and brand of oil to the crankcase as that

already there, until reaching the maximum level..

After the checking, replace and fit the dipstick completely

back into its place.

If the oil level is checked after the engine has been run for

a period of time, then it should take at least five minutes

before the measure to ensure the oil back flow to the oil

sump in full.

Oil level dipstick

Oil inlet

Vehicle Starting and Driving

S-2

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

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

Observe pipe

Vehicle Starting and Driving

S-3

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).

Vehicle Starting and Driving

S-4

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.

Vehicle Starting and Driving

S-5

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.

Vehicle Starting and Driving

S-7

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

(1) 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 alarming lamp 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:

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.

The volume of AdBlue

Vehicle Starting and Driving

S-8

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)

Vehicle Starting and Driving

S-9

Check daily after turning engine on:

1. engine oil pressure

Run the engine.

The information on engine oil pressure can be requested through the driver information digital display.

If the oil pressure is too low, the oil pressure is automatically shown on the combination instrument.

Indication of the oil gauge will show a high value after the cold start of the engine and then it should be

kept within the range of 0.3-0.5Mpa (3- 5kg/cm

2

) along with the increment of the oil temperature as well

as the normal engine speed.

Vehicle Starting and Driving

S-10

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.

Vehicle Starting and Driving

S-11

3. Tachograph 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 and monitor vehicle 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-brake operation （yellow）.

Always avoid engine over revving (red zone), as engine operation in this speed range can end up in

immediate engine damage or 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.

Vehicle Starting and Driving

S-12

4. Steering play

Steering wheel play

Run the engine at idle gear and straighten the front

wheels forwards.

Turn the steering wheel alternatively to the right and

to the left.

The steering play (free movement of the steering

wheel) is measured on the perimeter of the steering

wheel and should be between 20 and 30 mm.

A

Vehicle Starting and Driving

S-13

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.

Vehicle Starting and Driving

S-14

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

The maintenance of the air cleaner is made up of the

substitution of the filtering elements and should be

done only when the maintenance indicator indicates

the saturation of the element.

The cleaning of the main and safety filtering elements

is not recommended. The re-utilization of the filtering

elements can result in deficient filtering of the air and

cause serious damage to the engine.

When washing the engine, conveniently protect the air

inlet with a plastic or similar material to avoid the

infiltration of water to the air filtering element. After

washing the engine, remove the protection from the air

inlet.

Periodically press the dust discharge valve with your

hand, 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.

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.

Model 1

Model II

1 automatic dust discharge valve

Vehicle Starting and Driving

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 vehicle for their leakage.

Vehicle Starting and Driving

S-16

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;

Vehicle Starting and Driving

S-17

5. Check emergency devices and driver’s tools

Such as extinguisher, crosstie for blocking vehicle, emergency hammer, jack and etc..

Fire extinguisher:

The pulse super-micro powder fire extinguisher is fixed

in the engine compartment, when the compartment is on

fire, the fire extinguisher activate automatically or is

active by manual work to eradicate the fire

The fire button is usually located at auxiliary instrument

desk in the driver compartment where people could

operate it easily.

Operation：1. When the engine compartment caught fire,

the driver should stop vehicle and switch off engine

immediately, open the fire button cover, and press the

fire button, start-up fire extinguisher

2.Fire extinguisher may start-up automatically when

it catches fire or its temperature arrives at 170℃.

Important hint:

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

DO NOT press the fire button except for

emergency condition.

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

fire button manually if the vehicle battery is dead or

power turn off.

3. If the vehicle needs to be repaired, you could take

away the anode and the cathode. And put them back

after the reparation completed.

Inner fire extinguisher is fixed under the passenger’s chair, when

vehicle caught fire, stop vehicle and use the fire extinguisher.

Fire extinguisher

Fire button

Extinguisher

Vehicle Starting and Driving

S-18

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

Regularly check the windshield wiper blades for dirt or damage.

Press the lever to activate the windshield washer

Caution: Do not use the windshield wipers when the windshield

is dry. Before activating the wipers, push the head of the wiper

lever inward to spray detergent onto the windshield.

Check surplus of detergent

Stop vehicle on a flat road, open side cover of instrument desk.
Container of detergent is located inside instrument desk. If
detergent is insufficient, add.

Add the clean water into the tank for windshield washer.

There are 2 kinds of water tank.

Model 1

Model 2

Vehicle Starting and Driving

S-19

7. Electrical 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 to adjust

the mirror for 4 directions.

Vehicle Starting and Driving

S-20

Inspection every two weeks before and after driving

1. Power steering

Ensure that all the maintenance service

jobs on the steering system be carried out

at the intervals recommended in the

maintenance manual to guaranty total

efficiency and safety.

If any working abnormality in the

steering is noticed, immediately supply

the necessary repairs.

The habits of forcing the steering too far

against wheel obstacles and of activating

the steering while the vehicle is stopped

are harmful to the steering system and

should be avoided.

In emergencies, in the case of damage to the power steering system, the steering may be used

without hydraulic help,

however, in this condition there will be more steering wheel

play and the steering will become noticeably “heavier”. Drive the vehicle very carefully and

take it to an authorized King-Long Dealer or Workshop to re-establish the correct working

order of the steering system.

Important: In the case of damage to the hydraulic steering pump or of the total loss of fluid

from the hydraulic system, we recommend that the vehicle is not driven further than 50KM in

order to avoid further damage to the steering system components.

Power steering fluid level

The power steering fluid level should be checked while the engine is running at idle and the

fluid is hot. Run the engine at idle gear and turn the steering from side to side various times to

heat the steering system fluid.

Check the level through the inspect window of the container.

Vehicle Starting and Driving

S-21

2. Clutch actuation system fluid level

Clutch

The clutch activating system can present irregular working due to the normal wear of the clutch disc.

When suspecting that the clutch disc has reached the wear limit, take the vehicle to a King-Long

authorized Dealer or Workshop to carry out the necessary repairs.

Clutch fluid level

The clutch oil tank is installed in the instrument desk.

Prevent the brake 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

affected surface with cold water to avoid damage to

these components or to the vehicle paint.

The fluid level in the clutch activating system

container should be between the maximum and

minimum level indications. If there is a need to add

fluid to the container, take the vehicle to check the

impermeability of the hydraulic system. After

eliminating any leaks, fill the container up to the

maximum level and bleed the hydraulic system.

Vehicle Starting and Driving

S-22

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.

Adjusting method of the single belt driving 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 1 and the
fan pulley 2 should be 25 ~ 31mm.

2. Adjust tension of cone belt
Adjust bolt 3 until the tension is proper.
The max offset angle of the fan pully shaft should
not exceed 5°, or else please replace it.

1 2 3

Vehicle Starting and Driving

S-23

Air conditioning compressor drive belt

The pneumatic tensioning system keeps the tension of air conditioning compressor drive belt correctly

adjusted and do not need to be adjusted periodically.

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

1 Check tension of belt

Apply 98N force to belt with finger

Belt crank pulley 3 and middle pulley 2 should lower
10～15mm

2. Adjust tension of cone belt

Adjust nut 1until tension of belt is proper

1

2

3

Vehicle Starting and Driving

S-24

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

Note: The connection 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 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.

1

1

2

Vehicle Starting and Driving

S-25

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.

Vehicle Starting and Driving

S-26

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

Vehicle Starting and Driving

S-27

Engine start up and shut down in the engine compartment

Park the vehicle and activate the parking brake.
Put the gear box lever or the automatic transmission selector in neutral (dead point).
If the transmission is in gear position, the start up with in the engine compartment will not work.
Turn the ignition key to gear position, without activating engine start up.

Engine start up
Press the start up switch (start) and activate the back
cover course end switch bar in the engine compartment.
Loosen the switches immediately the engine begins
running.

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

Engine shut down:
Press the shut down switch (STOP).

To make the engine turn without starting up:
Press the engine start up and shut down buttons
simultaneously.

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

Vehicle Starting and Driving

S-28

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/cm

2

）.

 Pointer of water temperature gauge should be between 83℃ and 95℃.
 Pointer of double-pointer barometer should be between 0.55 and 0.8 Mpa（5.5-8kg/cm

2

）

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

① If abnormal noise or odor occurs, please stop vehicle to check.
② Abrupt acceleration or emergency braking should be avoided as might.
③ Don't put foot on the clutch pedal during the driving.

④ Avoid engine overspeed. When driving long downhill, engine may overspeed easily after gearshift, at

this time, pay attention to apply exhaust brake or retarder and driving brake to ensure engine run at

specified speed.

⑤ During driving downhill, never stop engine, otherwise, resulting in de-pressure in brake pipeline and

power steering gear failure.

During normal running condition，if the pointer of water temperature gauge is under the red sign that indicated

the vehicle is on normal condition. if the pointer is on “H”

Vehicle Starting and Driving

S-29

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.

Maintenance and service

M-1

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. Please cut off ECU control box to avoid the high voltage from outside to make damage to the ECU,

when use the outer power supply to charge the battery.

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

box.

3. Inspect the engine voltage for stabilization periodically.

Maintenance and service

M-2

4. When maintain the brake shoe ,do not damage the ring gear and sensor, clean the ring gear and

sensor at the same time. after maintenance ,do remember to put the sensor to the limited position

along the ring gear direction.

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

components clean and dry.

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

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

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

Note: for details about the working theory of ABS and maintenance, please refer to the ABS instruction

book which is offered by provider.

Because of different allocation requirements, some of the vehicle model may not be equipped with ABS

system, please use correctly according to actual condition of vehicle.

Electrical system maintenance and service:

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

high voltage damage ECU (electric control unit).

(2) When vehicle needs to weld, disconnect ECU. Don’t use multimeter to measure ECU control box.
(3) Monitor voltage stability of generator regularly.
(4) Parts dismantling must be carried out after electric has been shut off and should keep parts’

cleanness and dry.

(5) Don’t change fuse capacity casually or bestride connect fuse.
(6) When indicator doesn’t work, replace it timely.
(7) Don’t use water to scour ECU when doing ECU cleanness.
(8) Don’t use multimeter to measure ECU.

Tire transposition

The tire may appear certain abrasion after period of running. The tire should be made transposition as

the drawing below after every 8000 km to 10000 km running for proper use and prolonged tire life.

Four-wheel locating condition should be checked, dynamic balance and tire transposition be made at

once if there shows early and irregular abrasion of the tire.

Tire transposition diagram (two axles)

Maintenance and service

M-3

Tire transposition diagram(three axles)

Adjustment of the clutch pedal free play

Adjust clearance between push rod and piston of clutch master cylinder to 0.2-0.7mm. Loosen locknut

and rotate push rod along the piston direction until it contacts the piston, and then turn back 1/7-1/2

circle. After adjustment, tighten the locknut and then adjust the length of clutch booster push rod to

ensure 4-6mm empty stroke. At this time, clutch pedal free stroke is 8-12mm

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.

Maintenance and service

M-4

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.

Maintenance and service

M-5

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

Maintenance and service

M-6

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.)

Maintenance and service

M-7

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.

Maintenance and service

M-8

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.

Clutch oil:

 It is compound brake fluid (Laike 901) and must fulfill the standard GB10830-98JG3, GB12981

91H2Y3. It should be paid attention not to mix brake fluid with 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 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 ".

Maintenance and service

M-9

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.

Maintenance and service

M-10

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.

Maintenance and service

M-11

Daily or Refueling Maintenance Check

System Item Operation Technical requirement

Engine

Air cleaner Check

No leakage, damage, and crack.

Clips without looseness.

Fuel-water

separator

Drain

Release the water and fouling

Cooling fan Inspect

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

No crack, looseness, bend or damage.

air inlet/ outlet

piping

Maintenance

check

Pipes without wear and damage, clips without loosenes

s

prevent the air leakage.

Coolant level Check

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 th

e

engine temperature is less than 50℃

Engine oil level Check / correct

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

n

“H”.

Vehicle parking level, check the oil after engine stops for

5

minutes

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 ic

e

blocking.

Engine and

Accessories

Check

No damage and crack

Clutch

Clutch pedal free

stroke

Check / adjust

Clutch release bearing clearance

Free stroke: 30～40 mm

Clutch system Check

Check if clutch separated completely, connection stable an

d

not skidding

Clutch brake flui

d

level

Check / add

Compound brake fluid

Brake chambe

stroke

Check / adjust

Air

suspension

Vehicle body Check Observe the vehicle body whether tilt or not, the air spring (o

piping) of one side is leaky if this side is lower.

The air springs Check If hear the sound of leaking obviously， we can deal with th

e

problem after confirming the specific leaky location

Training

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

2.Correct maintenance: replace oil, oil filter element, diesel filter element , transmission, axle, angl

e

transmission system periodically, clean and replace air filter element periodically

Maintenance and service

M-12

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 Operation Technical requirement

Transmission
(ZF series)

Lubricant oil
surface

Check

Transmission lubricant oil surface within required
range, transmission each part and oil seal without
apparent leakage

Lubricant oil First filling

The lubricant ZF-Ecofluid M 02E is

compulsory for initial fillings of transmissions 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 leakage, operation organization effective, no

abnormal sound, wrong gear engagement.

Propeller shaft

Transmission shaft
cross shaft flex
sleeve

Lubricate

Transmission shaft
bolt and nut

Check and
fasten

7.7－9m: T=180Nm
9m above:T=250-270Nm

Rear axle （ ZF
series）

Oil level Check

TE-ML 12TE，1 time per month

Front axle（DF

& FS series）

Every grease

nuzzle

Filling-up 2# lithium grease

Fastening piece Check &

adjust

Toe-in of front

wheel

Check &

adjust

Radial-ply tire: 0～+2mm （for first 1500km only,

than adjust for every 20000km）

Rear axle（DF &

FS series）

Final drive Filling-up

From injection hole into final drive filling
Parathion-type 90 heavy-duty gear oil (GL-5) to

the face.（for first 1500km, than change for every

24,000km）

Gear oil level Check Axle shell oil

Every grease

nuzzle

Filling-up 2# lithium grease

Maintenance and service

M-13

Maintenance operation and regulation every 5000km

System Item Operation Technical requirement

Rear axle（DF &

FS series）

Check & fasten

Rear axle housing and differential housing, rear

axle housing rear cover half axle bolts and nuts,

No loosen

Fastening

piece

Check &

adjust

Ventilate

stopper

Clean

Front axle &

Rear axle

All wheel nuts Fasten

Screw torque

7.7－9m: front 450 Nm rear 450 Nm
9m above: DF: front 470 Nm, rear 490 Nm

Tire (include

spare Tire)

Check, air

charge, replace

Tire pressure: 0.67 ～ 0.75MPa,clean, no crack,
erosion or distortion, replace Tire if abraded too
much

System Item Operation Technical requirement

Steering system

Working condition

Check

Steering wheel max free rotation at middle

10 degrees
redirector auxiliary
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 head

Lubricate

Each turning ball head not loosening, no

clogging, clearance normal

ZF series

Maintenance Free

GX85, GX 100, ZJ
100C

Change oil

and filter core

of oil tank

For first 5000km only, N32 which

manufactured by Shanghai oil refining

factory or ATF or related products which

produced.

IPS series
25,35,40,55,65

Change oil

and filter core

of oil tank

For first 5000km only, Environment

temperature >10℃, adopt CD level 15W/40

oil;Environment temperature <10℃, adopt

No.8 hydraulic drive fluid.

Transmission
（ ZF series
mechanism
transmission）

Transmission fix
bolt

Fasten

Transmission and
Accessories

Check

No leakage, operation organization effective,

no abnormal sound, wrong gear engagement.

Lubricant oil Change

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

M-14

System Item Operation Technical requirement

Front axle
（ DF & FS
series）

Brake clearance Check &

adjust

Rear axle
（ DF & FS
series）

Brake clearance Check &

adjust

Air

suspension

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

Air
suspension

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.

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 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.

Air
suspension
shock
absorber

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

Maintenance and service

M-15

System Item Operation Technical requirement

Brake
System

The brake pedal
free stroke

Check &
adjust

10－15mm

The braking
condition

Check Shoe drum clearance: 0.30mm ～ 0.50mm, in

complete braking, pedal stroke not surpass 1/2 of the

whole stroke, check dry tin condition
The brake
pressure

Check Check whole vehicle brake pressure as required or

not. Above 0.6MPa
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 ，No leakage

Chassis

Fastening body and
chassis connective
bolts, nuts

Check

The whole vehicle
body butter nozzle

Lubricate

Grease nozzle complete and effective, lubrication

good

Electrical
equipment

The whole
vehicle light and
instrument

Check

The battery fluid
surface

Check Add distilled water,

The wire joint
firmness, no rust

Check No rust

Air-con radiator
filtration net

Clean

Maintenance and service

M-16

Maintenance operation and regulation every 10000km or 3 months

Every 10000km include every 5000km maintenance operation

System Item Operation Technical requirement

Engine

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

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

Water tank without leakage, damage, fouling

Coolant filter Replace Before re-install the coolant filter, daubs the 15W-40

lubricate oil on the interface of the sealing ring.

Fuel pump

installation

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 fasten

Propeller shaft flange fastening bolts not loosening

universal joint

Check
and fasten

Universal joint each bearing no loosening or damage

Front axle

（DF series）

Brake bottom

board

Check No loosening

Hub bear Check No loosening

Brake plate Check /

change

Change the brake plate when plate abrasion more than

limit pit.

Rear axle

（DF series）

Brake bottom

board

Check No loosening

Hub bear Check No loosening

Brake plate Check /

change

Change the brake plate when plate abrasion more than

limit pit.

The leaf
Suspension

Leaf spring

Check

Each fastening bolt not loosening, leaf spring no broken

piece, no apparent change of elasticity

Brake system

Rear braking
system

Check

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

Maintenance and service

M-17

Maintenance operation and regulation every 20000km or 5 months depend on what occurs first.

Every 20000km include every 10000km maintenance operation

System Item Operation Technical requirement

Engine

Fuel filter Replace Replace fuel filter element accordingly

Steering hydraulic

oil

Replace Steering auxiliary oil surface within required range

Coolant system –

anti-freezing

Check Check the density of anti-freezing

Propeller shaft

Dust-proof cover

Check

Dust-proof cover without crack, damage, cli

p

reliable, bracket no loosening
Universal joint
condition

Check

Universal joint without loosening, no bloc

k

abnormal sound

Propeller shaft
bracket

Check

Propeller shaft bracket no loosening, screw torqu

e

120～140Nm
Middle bearing
clearance

Check

Middle bearing clearance no more than 3mm

Lubricate

Lubricate

Lubricate each butter nozzle with 2# lithiu

m

lubricant grease

Steering system

GX85, GX 100, ZJ
100C

Change oil and

filter core of oil

tank

N32 which manufactured by Shanghai o

i

refining factory or ATF or related products whic

h

produced.

IPS series
25,35,40,55,65

Change oil and

filter core of oil

tank

Environment temperature >10℃, adopt CD lev

e

15W/40 oil;

Environment temperature <10 ℃ , adopt No.

8

hydraulic drive fluid

Front axle

Toe-in of front

wheel

Check & adjust

Radial-ply tire: 0～+2mm

Rear axle（DF

& FS series）

Final drive Filling-up

From injection hole into final drive filling

Parathion-type 90 heavy-duty gear oil (GL-5)

to the face.（for first 1500km, than change for

every 24,000km）

The leaf
suspension

Check and
fasten, weld
accordingly

Not loosening, crack, fracture, misplacement,

screw U bolt, front 196～294Nm, rear 343～

392Nm

The air
suspension

The liner bushing of
the rod assembly

Change

The liner bushing is relative sliding with the ba

l

head

Change

The liner bushing is knocked to bend and th

e

tighten bolts of the adjustable rod are becomin

g

invalid which result to the threads of the ball hea

d

and the steel pipe damaged.

The rubber ball
joints

Change

The crack on the surface of the rubber is ver

y

serious. The depth of the crack is up to 2mm an

d

the length of it is up to 8mm

Maintenance and service

M-18

System Item OperationTechnical requirement

The air
suspension

The rubber ba

l

joints

Change

There are gaps on the surface of the rubber

The surface of the rubber become adhesive, brittle and the rubbe

drop off seriously

The connection of the metal and the rubber is damaged. The parti

a

depth is up to 6mm

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

a

will

The heig

h

control valve.

Check
adjust

Check the equilibrium position of the adjustment bar of the heig

h

control valve.

The rubber of
The link rod

Change

Change it if the rubber of link rod becomes ageing, brittle, adhesiv

e

and lose its elasticity

The
connecting
members of
the shock
absorber

Check
change

Check the connecting members of the shock absorber if they ar

e

damaged please adjust or change them.

the rubber

Check
change

If the rubber is crack, brittle, adhesive and loses its elasticity pleas

e

adjust or change them.

The height

Check
adjust

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

k

the wheel base, the height of the vehicle body and the two side’

wheels’ locations which are relative to the frame. If it is necessar

y

please adjust the height of the air springs and the length of the ro

d

in order to arrive to the design request

Brake system

Brake pedal
free stroke

Check Break pedal free stroke 12～15mm

Brake valve
and pipe joint

Check
and
fasten

Break valve and pipe joint connection reliable and without air
leakage

ABS system Check ABS working properly
Auxiliary
brake, stop
brake free
stroke

Check Effective, 20% dual direction stopping at slop reliable

Retarder Check Retarder working properly
Engine
exhaust brake

Check Exhaust brake working properly

Body, frame

door lock
function

Check

Lock function good

Sealing good
cabin door
sustain pole
or air spring

Check

Cabin door lock function good, sustain pole or air spring

effective

inside and
outside mirror

Check

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

reliable

Maintenance and service

M-19

System Item Operation Technical requirement

Body, frame

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

Function reliable, working properly, no distortion,

crack, fracture, welding split, connective bolts and

rivet fix firm and reliable

Inside
establishment

Driver seat Check

Fix firm, front rear up down lock function reliable

Installation firm, backrest angle adjust lock

function reliable

Safety set Check

Safety belt function good, connection reliable, fire

extinguisher, urgency hammer complete and

effective
seat cover, carpet, curtain and
armrest

Check Clean, complete and firm

Compressor,
air reservoir,
safety valve

Compressor, air reservoir,
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

Electrical
equipment

Front lamp, horn, meters and
signal

Check set complete and effective

Wiper generator Check Effective

Wiper connection rod

Check,
adjust

Reliable

Whole vehicle wiring

Check,
adjust

complete, reliable, insulation good

Air-conditioner

Air-con passage and read
lamp control panel

Check

Air-con passage installation reliable, functional

and effective

Air vent set

Check

Installation firm， working properly

Air-con strap tension and
surface condition

Check

Tension proper, strap without crack, scuffing or

distortion

Magnetic clutch, fill lubricant

Check

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

Installation firm, operation normal and reliable

Heating system

Fuel, water heat pipelines

Check

No crack, oil, air or water leakage, joint not

loosening, oil and water pipelines smooth

Heating device

Check

Pipeline connection reliable, operation good

Maintenance and service

M-20

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

Engine

Drive belt, Cooling fan belt tension Check/adjust

Check each belt without loosening or damage

Cooling fan bearing and bolt Check/adjust No damage, fouling, loosening

Belt tension pulley bearing 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

Engine

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 distortio

n

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

Maintenance and service

M-21

Maintenance operation and regulation more than 80000km

ZF Series axle

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

Products
name

Model Maintenance content Maintenance

interval

Oil class Remark

Front

Axle

RL 85A

RL 85E

RL 55E

Filling-up

grease(lubricant point)

80,000-90,000KM or

1 year

NLGI Class 2

check-up oil level and

change oil regularly

every 20000KM

90,000~120,000KM

2 years

TE-ML 02 for front

axle head of

lubricant

only

lubricant grease of

shaft of wheel hub

change

Every 2 years TE-ML 12

Rear Axle

AV132

A80

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 2

years

RENOLIT

LX-PEP

2Rs36/04e

ZF parts
No.： 0671

190 122

Wheel bearings with individual mounts at the

front and rear axles

500.000 km / 2 years

Compact bearings (hub unit) in the wheel

heads at the front and rear

axles

500.000 km / 4 years

System

Application

Oil chang

e

interval

Oil classes

Transmission

- Scheduled routes

- Average speed from 2

0

to 60 km/h

360,000 km

3 years

ZF-Ecofluid M

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

These lubricant classes may generally only be

used in broken-in transmissions

- Long-distance coach

journeys

- Average speed as of 60

km/h

540,000 km

3 years

Maintenance and service

M-22

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

Maintenanc

e

item

Maintenance period

*1000km 2.5 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80

Month 1 3 5 7 8 9 10 11 12

Engine

Engine 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

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

Fixing every bolt and
connection on engine

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

Checking seal of pipe
& connector

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 I R I R I R I R

Air compressor, air
reservoir & pipe

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

Radiator & expand
water tank

I I I I I

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 & exhaust
manifold, muffle,
exhaust pipe

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

Engine suspension
device

I I I I I

Valve clearance I I

Thermostat I I

Maintenance and service

M-23

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

Maintenanc

e

item

Maintenance period

*1000km 2.5 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80

Month 1 3 5 7 8 9 10 11 12

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

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

Selector mechanism I I I I I I I I I I I I I I I I I

Lubricant oil R I I I R I I I R

Venthole C I I I C I I I C I I I C I I I C

Propeller shaft

Drive shaft connecting
parts

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

Add lubricating oil in
drive shaft

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

Universal joint cross
& bearing

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

Driving brake ，
parking brake

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

Brake pipe &
connector seal

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

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

Maintenance and service

M-24

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

Maintenanc

e

item

Maintenance period

*1000km 2.5 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80

Month 1 3 5 7 8 9 10 11 12

Brake system

Brake drum &
wearing plate abrasion

I I I I I I I I I

Brake shoe plate
clearance

I I I I I

FR & RR brake
checking

I I I I I

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 housing , RR
cover half shaft bolt nut

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

Lubricant steering main
pin & brake adjusting
arm & cam shaft

I I I I I I I I I

Fixing wheel nut I I I I I I I I I

Tire transposition I I I

Four-wheel
maintenance , clean
bearing

I I I I I

Checking & fixing front
axle bolts ,nuts, bearings

I I I I I

Checking & fixing rear
axle bolts, nuts, bearings

I I I I I

Clearance final drive
vent hole

C C C C C

Rear axle gear oil R I R I R

Front wheel alignment I I 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

Suspension system

Thrust pole , connecting
pole installation

I I I I I I I I I

Air bag height, seal,
integrality

I

I

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

I

Suspension system
fixing piece

I I I I I

Maintenance and service

M-25

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

Maintenanc

e

item

Maintenance period

*1000km 2.5 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80

Month 1 3 5 7 8 9 10 11 12

Suspension system

Suspension system
lubricate oil

I

I

I I I I I I I I I I 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

Bracket & lifting lug
installation & wearing
state

I I I

Steering system

Checking steering
system working
condition, oil leakage

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

Steering wheel free
stroke & working
condition

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

Checking power steering
hydraulic pressure
system

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 working
condition

I I I

Steering angle checking
& adjusting

I I I

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

I I

Main pin clearance I I

drive steering hydraulic
oil

I

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

Toe-in of front wheel

I I I I I

Common trouble and elimination

M-26

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

Maintenanc

e

item

Maintenance period

*1000km 2.5 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80

Month 1 3 5 7 8 9 10 11 12

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 I I I I I I I I

All wires , circuitry,
connectors

I I I I I I I I I

A/C system & pre-heater system

Air conditioner system
refrigeration working
condition

I I I I I I I I I

A/C compressor belt rate
of tension

I I I I I

A/C system pressure,
compressor freeze oil
quantity

I I I I I

Autonomous water heat
system-fuel supply
system

I I I I I

Autonomous water heat
system-water supply
system

I I I I I

Vehicle body, framework

Luggage bin door air
spring, stay bar

I I I I I

Engine bin door air
spring, stay bar

I I I I I

Rearview mirror fixing I I I I I

Vehicle body,
framework checking

I I I

Common trouble and elimination

C-1

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

Diesel engine can not start

Possible causes Remedies

1

）

Too low starting speed

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

fuel injection or low injection pressure

6) Check the injector atomization situations and replace a new

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

communicator of the starter

Repair or replace the brush and clean the surface of the

communicator with soft sand paper and blow off.

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

necessary.

Piston ring worn-out

9) The fuel cut off solenoid valve joint

is loose, dirty or corroded smudginess

canker

10) Mounting timing incorrect

9) Check the valve clearance, valve spring, valve stem, and

valve seat. Grind the valve seat if necessary.

Tighten and wash or replace.

10) Check and adjust it.