King Long XMQ6129Y series Operating Manual Download Page 5

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Contents

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

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

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

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

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

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

Bus cleaning--------------------------------------------------------------------------------------------------------M-3

Cleaning air filter --------------------------------------------------------------------------------------------------M-4

Cleaning outside of radiator -------------------------------------------------------------------------------------M-5

Coolant specification ---------------------------------------------------------------------------------------------M-5

Oil specification recommendation of the fuel and the lubricant---------------------------------------------M-6

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

Daily or Refueling Maintenance Operation

-------------------------------------------------------------------M-11

Maintenance first 2500km --------------------------------------------------------------------------------------M-12

Maintenance per 5000km---------------------------------------------------------------------------------------M-13

Maintenance per 10000km--------------------------------------------------------------------------------------M-16

Maintenance per 20000km--------------------------------------------------------------------------------------M-17

Maintenance per 40000km

-----------------------------------------------------------------------------------M-20

Maintenance per 80000km

------------------------------------------------------------------------------M-20

Maintenance more than 80000km

------------------------------------------------------------------------------M-21

Maintenance period chart

---------------------------------------------------------------------------------------M-23

Common trouble and its eliminating method

Engine Common trouble and elimination

---------------------------------------------------------------C-1

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

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

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

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

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

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

Electrical equipment and the starting system

---------------------------------------------------------------C-16

Summary of Contents for XMQ6129Y series

Page 1: ...1 OPERATION MANUAL User s Guide King Long XMQ6129Y series tourist bus Xiamen King Long United Automotive Industry Co Ltd...

Page 2: ...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...

Page 3: ...instruction I 1 7 Illustration of switch and indicator s SI 1 6 Air conditioner control panel P A 1 Pre heater panel P H 1 2 Gearbox operation O K 1 Open or close the passenger door O K 1 2 Adjustmen...

Page 4: ...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 a...

Page 5: ...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 200...

Page 6: ...pendix Driver s tool table A 1 Tightening moment of the bolts and the nuts in major position A 2 Table of lubricant oil power steering oil A 3 Air braking schematic diagram with air suspension A 4 Ele...

Page 7: ...r spring 3870 Leaf spring Wheelbase mm 6000 Wheel track front mm 2064 rear mm 1825 Minimum lift off clearance mm 180 Approach angle departure angle 7 7 4 Front overhang rear overhang mm 2720 3480 Rate...

Page 8: ...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...

Page 9: ...peration instruction or service manual Transmission operation manual CAN BUS Instrument system instruction book ABS anti braking system instruction book Air conditioner instruction book Heater instruc...

Page 10: ...seat belts pedal plate 7 Interior accessory device The vehicle is equipped with electronic clock sunshade safety hammer emergency escaping window curtain and luxury bilateral K 1 type luggage rack gui...

Page 11: ...ment on the vehicle may be different with the above description because of different deploying requirement of the clients Schematic illustration of the driver zone 1 Power charging outlet 2 Air condit...

Page 12: ...ing 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...

Page 13: ...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 displ...

Page 14: ...cate 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 fl...

Page 15: ...its 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 emerge...

Page 16: ...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 bl...

Page 17: ...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 Cab...

Page 18: ...n 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...

Page 19: ...itch 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...

Page 20: ...om 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 preheatin...

Page 21: ...FF 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 Pr...

Page 22: ...eat 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...

Page 23: ...er 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...

Page 24: ...and complete vehicle description SI 6 Indicator lamp Color Function Red Transmission oil temperature too high Red Transmission fault White Start up waiting Yellow Over emission Yellow Kneeling lamp G...

Page 25: ...itch push for one second stop the unit 2 Temperature setting COOLING The system begins to cool if the set temperature is lower than the temperature inside the bus The system stops cooling if the set t...

Page 26: ...15 0 to 40 0 the scope of displayed temperature is from 40 0 to 40 0 4 Flow rate selection 25 25 When starting the switch the wind flowrate will begain from the low level Press four times Press three...

Page 27: ...ds when it s at the first starting after this the interval time is 30 seconds Temperature cycle2 C C Setting temperature25 C 25 C OFF cooling mode 27 C C on cooling mode 8 Strong cooling This function...

Page 28: ...on pressed again to show VF and the setting time Adjust the setting time by pressing the button of and to the setting time within 1 60min Generally the setting time is 10 minutes Press the button for...

Page 29: ...s 14 check and cleanup time Press the for 12 seconds it shows the working time of air conditioner During this procss it isn t operation After 5 seconds it shows the air return inlet temperature When t...

Page 30: ...or 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 displa...

Page 31: ...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 p...

Page 32: ...r and vehicle type Therefore also consult the vehicle manufacturer s operating manual DANGER The driver must not leave the vehicle when the engine is running and a gear is selected 1 1 Starting the en...

Page 33: ...tself the clutch remains separated disengaged Depress accelerator and at the same time release the parking brake DANGER The vehicle may roll away even if the accelerator is not depressed Vehicle sets...

Page 34: ...slow travel Manoeuvring mode is not available in the other gears The system detects manoeuvring mode from the position of the accelerator and the low roadspeed When in manoeuvring mode the vehicle ac...

Page 35: ...ll forwards when in reverse If the vehicle rolls forwards with transmission in neutral once the brake is released and the driver shifts from N to D then the system selects a gear suitable for the road...

Page 36: ...accelerator position road speed engine speed 2 arrows and 4 bars automatic mode 8th gear is selected 1 6 2 Changing gear in manual mode Press tip lever in or direction When a shift is performed manua...

Page 37: ...ing speed being exceeded DANGER The driver may shift to Neutral during travel If the driver does shift to Neutral the driveline is interrupted The engine brake is then no longer effective 1 6 3 Engine...

Page 38: ...s rolling shifts cannot be made into reverse Stop the vehicle immediately 1 8 Changing direction of travel Changing from reverse R to forwards travel D and vice versa DANGER A change in the direction...

Page 39: ...ng the accelerator Before leaving a vehicle with the engine running the transmission must be shifted into neutral and the parking brake engaged Actuating the parking brake during travel may result in...

Page 40: ...should be shifted to neutral if the vehicle stops for long periods of time for more than approx 1 to 2 min for example in traffic jams at railway crossings etc This closes the clutch and relieves the...

Page 41: ...iving vehicle function If only the driving axle is on the roller an AS TRONIC ABS error is detected since the front wheels are not turning Reverse gear cannot be selected when the roller is activated...

Page 42: ...normal display The transmission compressed air system has insufficient pressure NOTE Only set off once there is sufficient pressure in the pneumatic system Due to too low air pressure at vehicle stop...

Page 43: ...clutch wear Proceed to approved workshop to have clutch exchanged at next opportunity HT High temperature too high transmission temperature EE Electronic Error Is displayed when the communication of t...

Page 44: ...nner symbol appear in the display a serious system error has occurred Stop the vehicle Vehicle may no longer be driven refer to chapter 2 16 Error messages and the reactions resulting from these error...

Page 45: ...ure 4 bars and 2 arrows are displayed this means error number 200 only for two digit displays Error number from error memory at call Switch on ignition Turn rotary switch to N and actuate foot brake i...

Page 46: ...must be used to heat the transmission up to a temperature above 30 C before the engine is started The vehicle manufacturer s specifications should always be observed 1 18 1 Using the vehicle when the...

Page 47: ...Technical parameter and complete vehicle description 0 T 1 TPMS OPERATION...

Page 48: ...Technical parameter and complete vehicle description 0 T 1...

Page 49: ...Technical parameter and complete vehicle description 0 T 1...

Page 50: ...Technical parameter and complete vehicle description 0 T 1...

Page 51: ...Technical parameter and complete vehicle description 0 T 1...

Page 52: ...Technical parameter and complete vehicle description 0 T 1...

Page 53: ...Technical parameter and complete vehicle description 0 T 1...

Page 54: ...Technical parameter and complete vehicle description 0 T 1...

Page 55: ...Technical parameter and complete vehicle description 0 T 1...

Page 56: ...Technical parameter and complete vehicle description 0 T 1...

Page 57: ...Technical parameter and complete vehicle description 0 T 1...

Page 58: ...f the status of the toilet If the toilet module is vacant the light indicator will not be on or will show green light if someone is using the toilet the light indicator will be on or will show red lig...

Page 59: ...getting into the bus The toilet module is equipped with a fan a dual fan with inner and outer two different uses the fan will be operated in a low speed to vent the air constantly when the toilet is v...

Page 60: ...the main power is controlled be the driver by operating the switch of power which is on the dashboard In case the toilet is not functioning properly such as malfunction of some components running out...

Page 61: ...f hand wash or toilet flush for several times drain the water in the pump turn on the cover of filter and drain the water in the filter as well to avoid freezing to build up water or damaging electric...

Page 62: ...dle 4 follow press the button 2 after that the door would be opened Specification For the king long city bus the method of open and close the passage door is different to above Details please see the...

Page 63: ...Technical parameter and complete vehicle description 0 K 1 Lock1 Lock 2 Lock 3...

Page 64: ...upside of the door The model 3 door emergency switch is located inside the door pump cover which is on the top of the door Please rotate the switch and throw open the door in emergency Special attenti...

Page 65: ...ll as the backrest angle according to requirement of the driver Handle 1 and Handle 2 cushion angle adjustment Handle 3 back and forth adjustment Handle 4 adjustment of the driver s weight Left handle...

Page 66: ...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 w...

Page 67: ...nation 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 A...

Page 68: ...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...

Page 69: ...sely rotating the handle to position of this identification Is the Is the headlamp indication The headlamp small lamp meter lamp and width lamp will all be turned on when continuously clockwise rotati...

Page 70: ...ring 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 th...

Page 71: ...hicle description OI 8 Passenger control panel instruction 1 air outlet 2 service button 3 reading lamp button 4 lamp 5 loudhailer 6 stop button Model 1 Model 2 1 2 3 4 1 2 5 4 Model 4 1 2 3 4 Model 5...

Page 72: ...e description OI 9 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...

Page 73: ...r and complete vehicle description OI 10 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 dange...

Page 74: ...Central control electric box installed the step wall behind of driver seat 2 Body module 1 installed the step wall behind of driver seat front control unit 3 Body module 2 installed in the air duct ov...

Page 75: ...Body module 3 4 installed in cabin box at the RH RR middle rear control unit 5 Retarder control unit installed the step wall behind of driver seat 6 WABCO ABS control unit installed on the wall of lug...

Page 76: ...in our vehicle It collects input signals of digital and analog and to control the electric devices lights etc Part C Name WABCO ABS ECU Function description ECU receive and deal with the signal from...

Page 77: ...ion 0 E 2 relay ACC electric power relay air condition relay and four UPL system s relay Their names have been marked on the wire The capacity and the name of fuses also could be found on the fuse box...

Page 78: ...Technical parameter and complete vehicle description 0 E 3 Switch control box Model CQ2025 CQ2025 A wiring diagram Printed on opposite cover of the switch control box...

Page 79: ...Technical parameter and complete vehicle description 0 E 4 The hydraulic fan mechanism This system should be made to drive the fan s rotation through pressure yielded from hydraulic oil...

Page 80: ...n the engine compartment hood Take out the oil dipstick and clean it with a clean cloth without loose threads and put it back into its place fitting it in completely Once again pull out the dipstick a...

Page 81: ...he system up until the maximum level indication Only use coolant which is recommended c The compensation tank cover should not be opened when temperature of the coolant is still high to avoid being sc...

Page 82: ...terior 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 Activ...

Page 83: ...time and check fuel pipe for no leakage Ensure sealing performance of fuel tank and before opening fuel tank wipe up clay and dirt Before filling up shut down engine Do not drive vehicle to empty tan...

Page 84: ...the lenses and the quantity of lanterns for each type of vehicle The King Long vehicles leave the factory in strict obeyance of these specifications Traffic safety depends on these factors therefore...

Page 85: ...Blue If the remain volume of AdBlue is less than 6 this lamp will light and the power of engine will be declined forcibly This will cause the emission substandard and it is not good to engine 2 The da...

Page 86: ...the AdBlue spill in skin mild irritation may occur Wash off with soap and water If the AdBlue spill in eye irrigate eyes with large amount of water The AdBlue is Non combustible if heated water evapo...

Page 87: ...Open the water drain valve of air tank to drain oily water fully If too much oily water is bled check to see if desiccant needs to be replaced in air drier This may be avoided when adopting the autom...

Page 88: ...driver information digital display If the oil pressure is too low the oil pressure is automatically shown on the combination instrument Indication of the oil gauge will show a high value after the co...

Page 89: ...STOP warning light comes on in case of low brake pressure in the service brake or parking brake circuits Attention If the driver information indicator displays the warning brake pressure and the STOP...

Page 90: ...speed to avoid engine operating in the danger range red zone When the exhaust brake is being operated on down grades select an adequate gearbox speed ratio to keep engine speed within efficient exhaus...

Page 91: ...the engine at idle gear and straighten the front wheels forwards Turn the steering wheel alternatively to the right and to the left The steering play free movement of the steering wheel is measured on...

Page 92: ...or some time the tires heat and in consequence of the heat the inflation pressure increases Never under any circumstance empty heated tires to reestablish the recommended inflation pressure The pressu...

Page 93: ...y press the dust discharge valve with your hand in order to incomplete the dust which possibly be caught in the internal part maintaining them clear At the same time check clip connecting rubber hose...

Page 94: ...ving S 15 3 General leakages water oil fluids and fuel Check the engine the transmission the driving axle the steering system the cooling system and the oil pipeline the air pipeline of the complete v...

Page 95: ...t belts Check buckle of the safety belt of the driver seat for normal and ensure for its lockup under the following situations when fastening the safety belt The body dashes forward all of a sudden Th...

Page 96: ...should stop vehicle and switch off engine immediately open the fire button cover and press the fire button start up fire extinguisher 2 Fire extinguisher may start up automatically when it catches fir...

Page 97: ...the windshield wipers when the windshield is dry Before activating the wipers push the head of the wiper lever inward to spray detergent onto the windshield Check surplus of detergent Stop vehicle on...

Page 98: ...ton Model 1 L adjusting left rearview mirror R adjusting right rearview mirror Mirror button push down the arrow headed button to adjust the mirror for 4 directions Model 2 L adjusting left rearview m...

Page 99: ...raulic help however in this condition there will be more steering wheel play and the steering will become noticeably heavier Drive the vehicle very carefully and take it to an authorized King Long Dea...

Page 100: ...e 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 carri...

Page 101: ...essor drive belt correctly adjusted and do not need to be adjusted periodically Adjusting method of the air conditioner belt is shown in the figure 1 Check tension of belt Apply 98N force to belt with...

Page 102: ...tment of left or right rear side 1 battery 2 switch control box 3 inverter To access the battery open the switch control box panel After the vehicle has been parked for the day the main power switch s...

Page 103: ...urn the ignition key back to the off position and wait at least 2 minutes After engine start up the vehicle can be put immediately into operation Note a The engine should be running at low middle spee...

Page 104: ...ing The shift should be switched to the neutral position and power supply shut down Please make necessary inspection of engine and then troubleshoot Cautions Cautions during the winter operation Pleas...

Page 105: ...e the back cover course end switch bar in the engine compartment Loosen the switches immediately the engine begins running When the engine is turned on by way of the start up switch in the engine comp...

Page 106: ...should not be released abruptly to impulse the starting when the vehicle is stuck in the mud or can not start on a spoil road The following problems should also be paid attention to during the driving...

Page 107: ...king state Always activate the parking brake when the vehicle is parked Besides activating the parking brake when parking on upward or downward slopes wedge one of the vehicle wheels to avoid the acci...

Page 108: ...ission and front rear axle please refer to relative users guide For use and maintenance of other parts of chassis if without special user s guide or maintenance period please refer to this manual for...

Page 109: ...al system maintenance and service 1 When battery is charged by external power supply disconnect ECU control box to prevent outer high voltage damage ECU electric control unit 2 When vehicle needs to w...

Page 110: ...es apparently when depressing pedal The value should be between 8mm and 12mm After adjustment lock the locknut Bus cleaning Don t pollute the environment when washing vehicle at washing shop Be carefu...

Page 111: ...g the filter 1 Remove butterfly nut on cover cap and take down cover cap and then take out filter element 2 Clean interior of the cover and the housing with a clean and dry napery when cleaning the fi...

Page 112: ...requirement resulting in poor engine cooling and grave damage to components 4 If don t comply with this requirement it may cause poor engine cooling and bad damage to components 5 Anti freeze and ant...

Page 113: ...l oil Suitable for the zone where venture rate is 10 percent and minimum temperature is more than 5 C 4 No 20 light diesel oil Suitable for the zone where venture rate is 10 percent and minimum temper...

Page 114: ...start so the ambient temperature of the engine starting is the main reference for selecting viscosity of the winter engine oil Selecting multifunctional engine oil may avoid oil changing caused by tem...

Page 115: ...s grease Grease added in each part should use 2 lithium base lubricant suitable for temperature within the range of 30 120 Vehicle with centralized lubrication should use 0 lithium base lubricant Wate...

Page 116: ...level 7 Check whether tire pressure has meet requirement 8 Check and see if each transmission gear can engage properly Maintenance during breaking in period 1 Running on smooth and good road surface 2...

Page 117: ...rear suspension carry out when full load 9 Check connections of chassis and driving system according to specified torques Tighten torques please refer to corresponding instructions 10 Check hydraulic...

Page 118: ...utes Drive belt Check correct No across crack wear or material break off Crankcase breather tube Check Check the breather tube in cold winter cleanup the ice blocking Engine and Accessories Check No d...

Page 119: ...issions as well as fillings during transmission break in for first 7500km only Transmission fix bolt Fasten Transmission air hole Check clean Air hole smooth Transmission and Accessories Check No leak...

Page 120: ...II above 10 use C 3 10W Fix bolts of each place Fasten Each fastening bolts not loosening steering arm not loosening steering wheel swift Ball head Lubricate Each turning ball head not loosening no c...

Page 121: ...adjust it in time The air spring surface Check clean Clean the lubricant grease on the surface the dirt on the piston the abnormal things placed between the piston and air spring The air spring Check...

Page 122: ...6MPa The brake nuts Inspect Inspect fastening of rear brake board s nut 7 7 9 m 150 180 Nm 9m above front 160 205 Nm rear 196 245 Nm The pipe and joint sealing Check Check brake pipe and joint sealing...

Page 123: ...ion Check No leakage Air compressor Check No air oil coolant leakage lock nut and bolt no loosen or damage No carbon deposit Brake system Check No leakage Propeller shaft fastening bolt Check and fast...

Page 124: ...ore of oil tank N32 which manufactured by Shanghai oi refining factory or ATF or related products which produced IPS series 25 35 40 55 65 Change oil and filter core of oil tank Environment temperatur...

Page 125: ...elasticity please adjust or change them The height Check adjust Charge the air springs and adjust to the design height then check the wheel base the height of the vehicle body and the two side wheels...

Page 126: ...ble no air leakage safety valve normal pressure at 8Mpa check air reservoir if with seeper replace air drier filter element Electrical equipment Front lamp horn meters and signal Check set complete an...

Page 127: ...o abnormal abrasion bush not crack lubrication normal Maintenance operation and regulation every 80000km or 12 months depend on what occurs first Every 80000km include every 40000km maintenance operat...

Page 128: ...A131 Oil change 150 000 km 3 years TE ML122RL Rear Axle A 132 New AV 132 Oil change 150 000 km 3 years TE ML 12TE Old model lubricant grease of shaft of wheel hub change include oil seal 250 000KM or...

Page 129: ...I R I R I R Air filter element C C C C C C R C C C C C R C C C C Check adjust belt I I I I I I I I I I I I I I I I I Check adjust engine idle speed I I I I I I I I I I I I I I I I I Fixing every bolt...

Page 130: ...I Free stroke of clutch pedal I I I I I I I I I Clutch oil I I I I I I I I R Clutch cylinder stroke I I I I I I I I I Transmission Transmission if not leaking oil I I I I I I I I I I I I I I I I I Se...

Page 131: ...I I I I I Engine exhaust brake I I I I I ABS unit checking I I I Brake valve other valves I I I Axle Tire Tire steel ring I I I I I I I I I I I I I I I I I Checking fixing RR axle housing differential...

Page 132: ...I I I I I Absorber working condition I I I Steel plate suspension bush I I I Left right steel plate suspension flexibility I I I Fixing suspension U type bolt I I I I I I I I I Valves function I I I B...

Page 133: ...5 30 35 40 45 50 55 60 65 70 75 80 Month 1 3 5 7 8 9 10 11 12 Electrical system All lights I I I I I I I I I Battery electrolyte surface connector I I I I I I I I I Wire box installation I I I I I I I...

Page 134: ...age in the fuel inlet pipe Clogging of the fuel supply pump filters and fix or replace 6 Insufficient fuel injection without fuel injection or low injection pressure 6 Check the injector atomization s...

Page 135: ...udge in the back of turbine and compressor impellers Clean it 5 middle cooler mangle leave out 5 Check and replace it 6 Fuel line blocked or leaky 6 Check the seal of fuel line and fuel filter choking...

Page 136: ...on 4 Check and adjust the valve timing 5 The driving gear is abrased and get too large gap There is knocking sound at the timing gear box cover 5 Check the gear side clearance and change the gear or n...

Page 137: ...embly 8 middle cooler damaged and leaked 8 Repair or replace it Exhaust with white and blue smoke Possible causes Remedies 1 Poor quality fuel and too much water in fuel 1 Replace the fuel 2 Too low c...

Page 138: ...igh oil pressure Possible causes Remedies 1 Too low ambient temperature and too high oil viscosity 1 Use the required grade engine oil Operate at low speed after starting and then check it when the oi...

Page 139: ...loose or the rubber damp piece material is aging 1 Remove and let the sliding yoke and the fixing yoke on the same plane 2 Adjust or replace the propeller shaft 3 Replace the bearing 4 Tighten propel...

Page 140: ...e 2 Use the lubrication of given grade The transmission gear is off the engaging position Transmission 1 Shift fork distorted or worn 2 Abrasion of lthe lockup ball or the ball on the gear shifter sha...

Page 141: ...rear axle improper sound When the vehicle is running 1 Excessive clearance between the driving and the driven gear 2 Abrasion or damage of the bearing 3 Abrasion or damage of the gear 4 Too low oil le...

Page 142: ...due to malfunction of sealing ring 1 Adjust the pre tightening force 2 Intensify the lubrication or replace the grease 3 Clean and intensify the lubrication 4 Replace the sealing ring Front axle and s...

Page 143: ...here has fatigue and damage in the front plate spring 3 Bending of the front axle 4 Unsmooth of the braking 5 Looseness of the front hub bearing nut 6 Inequality of the tire pressure 7 Tires with diff...

Page 144: ...icant to the given level 2 Replace the lubricant 3 Replace the ball stud 4 Overhaul and eliminate trouble 5 Measure the backpressure and repair or replace the pipeline in case of the set value exceede...

Page 145: ...eplace the faulted parts 4 Eliminate causes of the spring braking unreleased 5 Disassemble and clean the faulted parts 6 Disassemble and clean the braking valve and replace the faulted parts as needed...

Page 146: ...l cylinder cover and the rubber cap 7 Replace it 8 Tighten the U bolt The braking can t be applied under all conditions When compressed air pressure is normal 1 Too short of the brake valve travel 2 T...

Page 147: ...ethod There has abnormal sound during the generator rotates 1 The belt is of over loose or excessive abrasion with the shaking during the running 2 Bearing failure or oversize clearance 3 Too much bea...

Page 148: ...contact of the ignition switch or socket loose 2 Unsteady connection of the relay device or the solenoid switch 3 Turnoff of the starter solenoid switch 4 Damage of the starting gear or the gear ring...

Page 149: ...o temperature difference between high and low pressure pipe Air conditioner system has serious leakage Check the system and find out the leakage and fill the enough refrigerant 3 The low pressure is n...

Page 150: ...inspection glass looks yellow Too much water in the system desiccators reaching the saturation the frosting water blocked the expanding valve Change the desiccators and make the vacuum repeatedly and...

Page 151: ...r failure or connection problem 3 temperature control sensor installation position not good 4 temperature control switch defective 5 harness connection not reliable 6 Control panel defective 1 change...

Page 152: ...rator blower not working 1 relay not working 2 battery no charge 3 battery cable confected 4 air blower harness not connected well 5 harness connection not good 6 venting blower cable not connecting w...

Page 153: ...ve locknut 55mm 16 Combination wrench 30 36 Spare wheel lifter 22X550 17 S double box wrench 13x15 37 Wrench for drive axle drain plug 10x10 18 Adjustable wrench 8 38 Jack 16t J1601 19 Adjustable wren...

Page 154: ...45 Fixing bolt between driven gear and differential 588 686 Differential housing nut 216 275 Fixing bolt Front brake chamber bracket 59 79 Fixing bolt Front brake chamber 40 59 Fixing bolt Rear brake...

Page 155: ...7 1050 774 1480 1092 1774 1308 M30 1420 1047 2010 1482 2400 1770 Torques for bolts with metric fine threads Dimension of bolt Torques N m ft lb 8 8 10 9 12 9 M8 1 26 19 37 27 48 35 M10 1 25 52 38 76 5...

Page 156: ...be used between 5 20 5W 30 API CH 4 SG be used upwards 25 2 Gear oil could be used between 20 50 2 Power steering oil Oil grade TE ML09 recommend Mobile ATF220 3 Others Oil Site Oil used Nominate Clut...

Page 157: ...Appendix A 4 Air braking schematic diagram...

Page 158: ...Appendix A 4 Electric schematic diagram of the complete vehicle 1...

Page 159: ...Appendix A 5 Electric schematic diagram of the complete vehicle 2...

Page 160: ...Appendix A 5 Electric schematic diagram of the complete vehicle 3...

Page 161: ...Appendix A 5 Electric schematic diagram of the complete vehicle 4...

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King Long XMQ6129Y series, Operating Manual

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