King Long XMQ6127DYW Series 2019 User manual

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OPERATION MANUAL
Vehicle Model: XMQ6127DYW (C12HD)
Vehicle No.: KDM00001
Country: UK
File Version: NO.1
Editor: Ms Lin
Date: 21.06.2019
Xiamen King Long United Automotive Industry Co., Ltd.

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Foreword
King-Long XMQ6127DYW (C12HD) series tourist bus keeps features of superior economy,
security and comfort. It has stable performance, strong power, luxury interior trimming and high
speed, which could meet applications of passenger inter-city transportation, touring and business
affairs, etc.
As for the specifications introduced in relate to information of the driving and operation, service
and maintenance of the XMQ6127DYW (C12HD) series tourist 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.

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Contents
Foreword............................................................................................................................................................... 2
Contents................................................................................................................................................................ 3
Chapter I Technical Parameters and Vehicle Description.................................................................................. 6
1. Technical parameters................................................................................................................................. 6
2. Introduction to data plate...........................................................................................................................7
3. Product quality assurance.......................................................................................................................... 8
4. Technical documents................................................................................................................................. 8
5. Body Structure...........................................................................................................................................8
Chapter II Operation Instruction...................................................................................................................... 10
1. Schematic illustration of the driver zone.................................................................................................10
2. Multi-function steering wheel button function........................................................................................11
3. Instruction of instrument (VDO EDITION)............................................................................................13
4. Illustration of switch and indicator..........................................................................................................19
5. DPF switches (diesel particulate filter)................................................................................................... 24
6. Lane departure warning system (LDWS)................................................................................................27
7. Gearbox Operation.................................................................................................................................. 28
8. Introduction of KING LONG integrated A/C system............................................................................. 33
9. AEBS driving system operation instruction............................................................................................ 44
10. Tire pressure monitoring system introduction (TPMS).........................................................................49
11. ECAS introduction................................................................................................................................ 57
12. Open/close the passage door................................................................................................................. 59
13. Door emergency switch.........................................................................................................................60
14. Adjustment of the driver's seat.............................................................................................................. 60
15. Horn button............................................................................................................................................61
16. Adjustment of the steering wheel.......................................................................................................... 61
17. Ignition switch.......................................................................................................................................62
18. Lamplight operating handles................................................................................................................. 63
19. Wiper operating handle..........................................................................................................................63
20. Retarder operation................................................................................................................................. 64
21. Passenger control panel instruction....................................................................................................... 64
22. Safety hatch........................................................................................................................................... 65
23. Safety hammer.......................................................................................................................................65
24. VDO Module function description........................................................................................................66

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25. VDO CAN module................................................................................................................................ 67
26. Switch control box (Model: JKH2028)................................................................................................. 67
27. Engine compartment fire extinguisher operation.................................................................................. 68
Chapter III Vehicle Starting and Driving......................................................................................................... 70
1. Check daily, before turning engine on.....................................................................................................70
1.1 Check oil level of the engine......................................................................................................... 70
1.2 Check level of the coolant............................................................................................................. 71
1.3 Fuel pre-filter with water separator (drain accumulated water).................................................... 72
1.4 Check fuel level............................................................................................................................. 73
1.5 Check vehicle lighting, intermittent lights and brake lights.......................................................... 73
1.6 Check the level of AdBlue and the daily maintenance of SCR system......................................... 74
2. Check daily after turning engine on:....................................................................................................... 75
2.1 Check engine oil pressure.............................................................................................................. 75
2.2 Check pneumatic pressure............................................................................................................. 75
2.3 Check tachometer working order...................................................................................................75
2.4 Check steering play........................................................................................................................76
3. Control periodically, at least once a week............................................................................................... 76
3.1 Check tire for abrasion and pressure and tire nut for fixture......................................................... 76
3.2 Check air cleaner (activate the dust discharge valve to loosen accumulated dust)....................... 77
3.3 Check general leakages (water, oil, fluids and fuel)...................................................................... 78
3.4 Check fastening and state of seat belts.......................................................................................... 78
3.5 Working order of windshield wipers and conditions of wiper blades and arms............................78
3.6 Electrical rearview mirror..............................................................................................................78
4. Inspection every two weeks before and after driving..............................................................................79
4.1 Power steering................................................................................................................................79
4.2 General state and tension of all drive belts.................................................................................... 80
4.3 Check level of battery electrolyte.................................................................................................. 83
5. Engine start up and shut down.................................................................................................................84
5.1 Procedures for engine start up....................................................................................................... 84
5.2 Engine shut down...........................................................................................................................84
5.3 Engine start up and shut down in the engine compartment........................................................... 85
5.4 Starting the vehicle........................................................................................................................ 85
5.5 Parking the vehicle.........................................................................................................................86
Chapter IV Vehicle Maintenance and Service.................................................................................................87

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1. General knowledge..................................................................................................................................87
2. King-long Bus General Maintenance...................................................................................................... 87
3. Maintenance of engine and chassis assembly......................................................................................... 87
4. Body maintenance................................................................................................................................... 87
5. ABS system maintenance and service.....................................................................................................87
6. Electrical system maintenance and service............................................................................................. 88
7. Tire transposition.....................................................................................................................................88
8. Adjustment of the brake pedal free play..................................................................................................89
9. Bus cleaning............................................................................................................................................ 89
10. Cleaning the air filter.............................................................................................................................90
11. Cleaning outside of the radiator............................................................................................................ 91
12. Charging-up the coolant........................................................................................................................ 91
13. Fuel recommendation............................................................................................................................ 92
14. Oil/lubricant quality and specification recommendation...................................................................... 92
15. Introduction about the lubricate points in KL bus.................................................................................94
16. Breaking-in of new vehicle maintenance.............................................................................................. 97
17. Daily Maintenance Operation................................................................................................................98
18. Maintenance period chart...................................................................................................................... 98
Chapter V Common Trouble and Its Elimination.......................................................................................... 104
1. Engine common trouble and its elimination (suitable for diesel engine)..............................................104
2. Propeller shaft common trouble and its elimination..............................................................................109
3. Transmission common trouble and its elimination................................................................................110
4. Rear axle common trouble and its elimination...................................................................................... 111
5. Front axle and steering system common trouble and its elimination.................................................... 112
6. Braking system common trouble and its elimination............................................................................ 115
7. Common trouble and troubleshooting of electrical equipment and starting system............................. 117
8. Common trouble and troubleshooting of air conditioner system.......................................................... 118
9. Electric system trouble and remedy.......................................................................................................119
Chapter VI Appendix..................................................................................................................................... 121
1. Driver tools table（one each)................................................................................................................121
2. Tightening torque of main bolts and nuts..............................................................................................123
3. Bolts torque table...................................................................................................................................125

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Chapter I Technical Parameters and Vehicle Description
1. Technical parameters
(vehicle No: KDM00001)
Product model
XMQ6127DYW(C12HD)
Engine model
ISL9E6C 400
Engine type
In-line six-cylinder water-cooling direct-injection diesel
engine
Cylinder bore ×stroke (mm)
114X145
Displacement (ml)
8900
Compression ratio
16.6:1
Rated power / rotational speed (kw/rpm)
298/2100
Max. torque / rotational speed (N·m/rpm)
1695/1400
Dimensions
Overall length (mm)
12000
Overall width (mm)
2550
Overall height (mm)
Air spring
3695
Wheelbase (mm)
6050
Wheel track
front (mm)
2105
rear (mm)
1881
Minimum ground clearance (mm)
180
Approach angle/ departure angle (°)
9/9
Front overhang / rear overhang (mm)
2600/3350
Rated Seats Number (driver included)
51+1+1
Mass parameter
Kerb mass (kg)
13900
Max.gross mass (kg)
19000
No load
Front axle (kg)
4700
Rear axle (kg)
9200
Full load
Front axle (kg)
6500
Rear axle (kg)
12500
Performance
parameter
Max. speed (km/h)
100
Maximum gradeability (%)
30
Min. turning diameter (m)
≤24
Parking slope (20%)
Parking for 5 minutes
Capacity data
Fuel tank (L)
420
Engine oil (L)
(Engine model :ISL9E6C 400)
20
Transmission lubricant (L)
(Transmission model: ZF ECOLIFE 6AP1700B)
42(first oil fill); 24(service oil change)
Final reduction gear lubricant (L)
14
Power steering hydraulic oil (L)
7.2
Tire size
295/80R22.5

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2. Introduction to data plate
Bus data plate for reference
Chassis data plate for reference
Engine data plate for reference
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.
Note: The right side identification plate is an example for
reference only.
The chassis data plate with vehicle identification number (VIN)
is upon the front door.
Note: The right side identification plate is an example for
reference only.
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.
Note: The right side identification plate is an example for
reference only.

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3. Product quality assurance
We insisted that the end user should make breaking-in maintenance of the rolling-out new vehicles in their
initial driving mileage of 5000 km. Users must 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.
4. Technical documents
An operation manual (paper version)
A general maintenance manual (PDF version on CD)
Other maintenance data (PDF version on CD)
Bus harness diagrams (paper version)
5. Body Structure
5.1 Structural style
full-integral load body structure.
5.2 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.
5.3 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.
5.4 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 or sliding style which are made of
hardened glass. The driver’s window is electric driver windows.
5.5 Baggage compartment
The baggage compartment adopts transverse run-through design, the outer materials of are all made of
aluminum, and the inner materials are used of something waterproof as well as fire prevention.
5.6 Seat
Driver’s seat: adjustable seat with high backrest and three-point belt.
Passenger seats: adjustable style, equipped with armrest, foot pedal and with transverse movement function,
and with three-point seat belts.
5.7 Interior accessory device
The vehicle is equipped with electronic clock, electric mirrors, automatic front windshield sunshade, driver
side sunshade, electric driver window, safety hammer, emergency escaping windows, curtain and luxury
bilateral luggage rack, middle door, reversal monitor, vehicle traveling data recorder, reading lamp, flip color
TV, guide seat, etc.
5.8 Air-conditioning system
Cooling system: KING-LONG top mounted dependent air-conditioning system.
Heating system: heater, and natural heat sink.
Defroster: King Long cooling/heating defrosting device.

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5.9 Door
The door adopts the full aluminum remote control out-swing pneumatic doors.
The out-swing door adopts the advanced electrically aerodynamic theory design, with the motion of opening
and closing placidly, agile, safe, lock credible and anti-clamp function.
A. Basic function
a. There are two electrically switches, the interior one is trigger touch-tone, which located on the dashboard
of the front right side of the driver, the outside one is a remote control switch, both switches can control the
door.
b. When the circuit is in OFF position, the emergency switch can be used in the interior and exterior, the
emergency switch of the door is located inwardly upon the entrance of the door and outwardly behind the
passenger door respectively, 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.
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.

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15
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Chapter II Operation Instruction
1. Schematic illustration of the driver zone
1．Reversal rearview mirrors button
2．Parking brake handle
3．Low-voltage system cut off switch
4．Engine cabin extinguisher operation button
5．Wiper control handle
6．Combination instrument
7．Horn button
8．Steering wheel
9．Light operation handle
10．Reversal monitor
11．Tire Pressure Monitoring System (TPMS)
12．VDO travelling data recorder
13．DVD player
14．KING LONG A/C operation panel
15．Variable speed operation control panel
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10
9
8
7
6
5
4
3
2
1

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2. Multi-function steering wheel button function
2.1 Feature overview
Multi-function steering wheel buttons are distributed on the left and right sides, 7 keys on the left and 7 keys
on the right, as shown below.
Multi-function steering wheel main functions:
(1) Operation control player volume, anthem, sound source;
(2) operation control Bluetooth phone answering and hanging up;
(3) operation control instrument display, menu;
(4) operate control engine cruise;
2.2 Feature details
(1) Left buttons
The left buttons have a total of 7 keys for operating the control player and instrument.Some keys are
multiplexed keys, different functions when operating the player and instrument, pressing the key in
long time is used to switch key control objects for the player or instrument. The key function is defined as
follows:

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No
Icon
Function
Control of the player's features
Function when controlling the
instrument
Remarks
L1
Arrow key - Right/
Next song
Press it in short time to switch
the next song or channel +
Press it in short time, the instrument
display flipping pages, next page
L2
Direction key-Left/
Last song
Press it in short time to switch
the last song or channel-
Press it in short time, the instrument
display flipping pages, last page
L3
Direction key-Up/
Volume+
Press it in short time, increase
the volume(volume+)
Press it in short time, display the last
content
L4
-Direction
key-Down/ Volume -
Press it in short time, decrease
the volume(volume-)
Press it in short time, display the next
content
L5
Confirmation
Pause/Continue playback
Press it in short time to confirm
L6
Turn back
Press it in short time to turn back; Press
and hold 2S exit instrument control
and enter player control
L7
Function switching
Press it in short time circularly
to switch audio sources:
Radio/DVD/USB
Press it in short time displaying the
menu
Press and hold 2S to
switch the control object
between the player and
instrument; After entering
the instrument control, if
there is no operation in
the 8S, automatically exit
the instrument control and
enter the player control
Note: Some features in the italic section of the table above is the planning reservation feature.
(2) Right buttons
The right buttons have a total of 7 keys for operating control Bluetooth phones and engine cruises. The keys
function are defined as follows:
No.
Icon
Function
Feature description
Note
R1
Phone connection
Turn on the Bluetooth call
R2
Phone hang up
Hang up or reject Bluetooth calls
R3
Adjustable speed limit
Adjustable speed limit function on
Features to be developed (reserved)
R4
Cruise
Cruise on
R5
Set/Speed +
Set the cruise/limit speed,
Increased cruise/limit speed.
R6
Recovery/Speed -
Recovery cruise/limit speed,
Reduce cruise/limit speed.
R7
Cruise/adjustable speed
limit off
Cruise/adjustable speed limit function off

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3. Instruction of instrument (VDO EDITION)
No.
Function
Description
1
ABS indicator
ABS work/warning
2
High beam indicator
When High beam is switched on
3
Left turning indicator
When Left turning/hazard switch is turned on
4
Severe error
When the electrical system has severe error
5
General error
When the electrical system has general warning
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
Tachometer
Current engine speed

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3.1 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).
3.2 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.
3.3 LCD Display
Press the page switch button, the pages will be displayed by the following sequence. Detailed description is
listed as below:
(1) Driving Information
When the bus is running, this page will show (Figure-1):
Figure-1 driving information
pictogram
comments
pictogram
comments
Gear info
Acceleration pedal position
Current time
System voltage
Front door status
Preheating indicator
Mid door status
Passenger service/request from cabin
Fluid fan error
Engine red lamp error
Low beam working
Engine amber lamp error
Front fog light working
Engine Malfunction

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Rear fog light working
Engine wait to start (do not start the engine
until this symbol disappear)
Brake light working
EBS red lamp warning
Lift-axle lock
EBS amber lamp warning
Steering oil level low
ECAS status
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
/
/
lamp
status description
the driver required
After treatment outlet temperatures
higher than normal operation.
Nothing
The soot load of DPF had reached the
first stage of plugging.
Fault Code 2639 occurred.
Take active regeneration as conditions permit, increase the
load of vehicle. Stationary regeneration available.
The soot load of DPF was moderately
severe.
The engine torque reduced.
Fault Code 1921
Stationary regeneration required.

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①Transmission gear Display
: current gear is "neutral";
: current gear is "forward";
: current gear is "reverse";
②Time
This information comes from DTCO.
③System voltage
This value shows the battery voltage when generator is not working; and shows the voltage by generator
after engine starts.
④Acceleration pedal position
Range: 0 – 100 %.
⑤Oil pressure
This information comes from engine ECU. Before engine starts, the value is 0.
⑥Brake 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.
⑦Door 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
⑧ECAS status
: ECAS lift : kneeling
: ECAS general error : ECAS severe error
⑨Service request
: Passenger service request : Request from cabin

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(2) Error display Page
Figure -2 text error
If there is error exists, this page will show after driving information page when you press the page change
button.
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.
(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.

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(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
(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.
(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.

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4. Illustration of switch and indicator
Number of switches, indicators and each own position may vary with the vehicle model and configuration
state, please refer to the flowing sheet:
Switch
Name
Function
Notes
Rearview mirror
defrosting switch
Pressed on top: turn off defrosting function.
Pressed on bottom: turn on the defrosting
function.
Driver window
raise/lower
switch
Pressed on top: the window will raise.
Pressed on bottom: the window will
descend.
Driver window
defrosting
switch
Pressed on top: the defrosting is turned off.
Pressed on bottom: the defrosting is turned
on.
Electric parking
brake function
release switch
Pressed on top: parking brake function is
restored.
Pressed on bottom: parking brake function
is released, permit the vehicle move while
the passenger door is opened.
STOP
Its function is only useful of
release-interlock between passenger door
and parking brake.
Hazard alarm
lamp switch
Pressed on bottom: all turning indication
lamps will turn on and flash.
LDWS (Lane
Departure
Warning System)
mode switch
Pressed on bottom: turn on the LDWS
function.
Pressed on bottom again: turn of the LDWS
function.
MODE LDWS

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Automatic
headlamp
switch
Pressed on top: headlamp OFF.
Pressed on bottom: headlamp ON.
Front windshield
sunshade switch
Pressed on top: the sunshade will be raised
up.
Pressed on bottom: the sunshade will be
descended down.
Electric horn/air
horn change
switch
Pressed on top: the electric horn is turned
on.
Pressed on bottom: the air horn is turned
on.
Daylight lamp
switch
Pressed on top: interior lighting OFF.
Pressed on bottom: interior lighting ON.
Reading lamp
switch
Pressed on top: the reading lamp OFF.
Pressed on bottom: the reading lamp ON.
Luggage
compartment
lamp switch
Pressed on top: the luggage cabin lamp
OFF.
Pressed on bottom: the luggage cabin lamp
ON.
Disinfection
function switch
Pressed on top: turn off the disinfection
function.
Pressed on bottom: turn on the disinfection
function.
STERIL
Front fog lamp
switch
Pressed on top: the front fog lamp OFF.
Pressed on bottom: the front fog lamp ON.