King Long XMQ6127J series User manual

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OPERATION MANUAL
User’sGuide
King-Long XMQ6127J series city bus
Xiamen King Long United Automotive Industry Co., Ltd.

Foreword
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FOREWORD
King-Long XMQ6127J 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 and business affairs, etc.
As for the specifications introduced in relate to information of the driving
and operation, service and maintenance of the XMQ6127J 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.
DEC. 2014

Contents
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Contents
Vehicle picture--------------------------------------------------------------------------------------------------------1
Foreword---------------------------------------------------------------------------------------------------------------2
Contents
Contents----------------------------------------------------------------------------------------------------------------3
Main overall technical parameters
Technical parameters ------------------------------------------------------------------------------------------------7
Introduction to data 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-1-7
Illustration of switch and indicator s--------------------------------------------------------------------------SI-1-6
Pre-heater panel-----------------------------------------------------------------------------------------------P-H-1-2
Gearbox operation -------------------------------------------------------------------------------------------O-G-2-3
ABS instruction-------------------------------------------------------------------------------------------------O-K-1
ECAS operation-------------------------------------------------------------------------------------------------O-K-1
Open or close the passenger door---------------------------------------------------------------------------O-K-1-2
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-----------------------------------------------------------------------------------------------O-R-1
Passenger control panel-------------------------------------------------------------------------------------------OI-8
Safety hatch--------------------------------------------------------------------------------------------------------OI-9
Safety hammer---------------------------------------------------------------------------------------------------OI-10

Contents
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VDO module location & function description------------------------------------------------------------O-E-1-2
Switch control box----------------------------------------------------------------------------------------------O-E-3
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 Tachometer working order-------------------------------------------------------------------------------S-11
Steering wheel play-----------------------------------------------------------------------------------------------S-12
Check tire for abrasion and pressure and tire nut for fixture------------------------------------------------S-13
Air cleaner----------------------------------------------------------------------------------------------------------S-14
General leakages (water, oil, fluids and fuel) -----------------------------------------------------------------S-15
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
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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-9-10
Daily Maintenance Operation-----------------------------------------------------------------------------------M-11
Maintenance per 5000km-----------------------------------------------------------------------------------M-12-14
Maintenance per 10000km--------------------------------------------------------------------------------------M-15
Maintenance per 20000km---------------------------------------------------------------------------------M-16-18
Maintenance per 40000km -----------------------------------------------------------------------------------M-19
Maintenance per 80000km ------------------------------------------------------------------------------M-19
Maintenance more than 80000km------------------------------------------------------------------------------M-20
Maintenance period chart-----------------------------------------------------------------------------------M-21-25
Common trouble and its eliminating method
Engine Common trouble and elimination ---------------------------------------------------------------C-1
Clutch---------------------------------------------------------------------------------------------------------------- C-6
Propeller shaft------------------------------------------------------------------------------------------------------C-8
Transmission--------------------------------------------------------------------------------------------------------C-9

Contents
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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 (with air suspension) ------------------------------------------------------- A-4
Electrical elementary diagram of vehicle --------------------------------------------------------------------A-5

Technical parameter and complete vehicle description
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Technical parameters of the complete vehicle
（vehicle No. EB500806-809）
Parameter item unit Parameter value
Model / XMQ6127J
Engine model / ISL8.9E5 280B
Engine type In-line six-cylinder water-cooling four stroke
electronically controlled common rail direct-injection
diesel engine
Cylinder diameter × stroke mm 114×145
Displacement ml 8900
Compression ratio 16.6：1
Rated capacity / rotation speed
Kw/r/min 206/2100
Max. torque / rotation speed N.m/r/min 1060/1100
Overall length mm 11980
Overall width mm 2550
Overall height mm 3170
Wheel base mm 6000
Wheel track(front) mm 2102
Wheel track(rear) mm 1860
Minimum lift-off clearance mm 160
Min. turning diameter m ≤22
Approach angle ° ≥7
departure angle ° ≥7
Front overhang mm 2670
Rear overhang mm 3310
Rated passenger（driver included）person 63
Number of seats seat 29+1
Kerb weight（standard）
） kg 12600
Max. Gross mass kg 17500
No load
(Standard)
Front axle kg 4000
Rear axle kg 8600
Full load Front axle kg 6500
Rear axle kg 11000
Performance parameter
Max. Speed km/h ≥80
Fuel consumption L --
Maximum gradeability % ≥25
Parking slope（20%）/ Parking for 5 minutes
Braking distance（initial speed
30 km/h）m ≤10

Technical parameter and complete vehicle description
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Capacity
data
Fuel tank L 220
Engine oil L 27.6
Power steering hydraulic oil L 8
Transmission lubricant L 25-27
Main retarder lubricant L 16
Clutch oil L 0
electric parameter
Line system -- Single wire system and negative ground
Line voltage V 24
battery -- 12V、200A·h(2)
generator -- 28V、140A
starter -- 24V、5.5kW

Technical parameter and complete vehicle description
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Introduction to specification 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
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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
Note: the instruction book should be modified according to specific configuration of vehicle.

Technical parameter and complete vehicle description
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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
Without installing the baggage cabin.
6. Seat
Driver’s seat: Q15-2 adjustable seat with high backrest and three-point belt（E-MARK）.
Passenger seats: FAINSA type, high backrest, the all seats are equipped with three-point safety belt.
7. Interior accessory device
The vehicle is equipped with electronic clock, sunshade, safety hammer, emergency escaping window,
curtain，reversal monitor, destination board, guide mike .etc.
8. Air-conditioning system
Defroster: WEBASTO cooling /heating defrosting device
Heating: WEBASTO system
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、agilely、safely , further, keeping credible locking 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 of the door on the left/right side panel 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.

Technical parameter and complete vehicle description
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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.
Schematic illustration of the driver zone
1Power charging rocket
2VOITH gearbox operation panel
3Parking brake handle
4Door emergency valve switch
5Emergency power switch
6Extinguisher switch pushbutton
7Wiper operation handle
8WEBASTO heating control panel
9MP3 player
10 Rocker switch
11 Steering wheel
12 horn
13 Combination instrument panel
14 Light control handle
15 Rocker switch
16 Mirrors control button
1
2
3
4
5
6
8
9
7
10
11
131415 1216

Technical parameter and complete vehicle description
I-1
Instruction of instrument (Siemens 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. (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 Tachometer Current engine speed

Technical parameter and complete vehicle description
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

Technical parameter and complete vehicle description
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 working 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.

Technical parameter and complete vehicle description
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
：ECASlift ：kneeling
：ECASgeneralerror ：ECAS severe error
2.3.9 Service request
：Passenger service request ：Request from cabin
2.2 Error display Page：
Figure -2 text error information

Technical parameter and complete vehicle description
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

Technical parameter and complete vehicle description
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

Technical parameter and complete vehicle description
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.

Technical parameter and complete vehicle description
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 white
Pressed on top: retarder foot control function
is turned OFF
Pressed on bottom: the function is turned
ON
Daylight lamp white Pressed on top: interior lighting OFF
Pressed on bottom: interior lighting ON
Hazard lamp Red when the vehicle have a screw loose, switch
it on, the whole vehicle lamps light
Luggage
compartment lamp white Pressed on top: lamp goes out
Pressed on bottom: lamp lights
Fresh air switch white
Pressed on top: turn off the changing fresh
air function;
Pressed on bottom: turn on the changing
fresh air function.
Ventilator white Pressed on top: ventilator is turned off
Pressed on bottom: ventilator is turned on
Front fog lamp white Pressed on top: front fog lamps OFF
Pressed on bottom: front fog lamps ON
Rear fog lamp white Pressed on top: rear fog lamps OFF
Pressed on bottom: rear fog lamps ON
Vehicle raise/lower white Pressed on top: vehicle raise,
Pressed on bottom: vehicle lower only use this button when vehicle is stopping
Defroster white Pressed on top: windscreen heater OFF,
windscreen heater ON
Reading lamp white Pressed on top: reading lamp OFF, Pressed
on bottom: reading lamp ON.