King Long XMQ6900J series User manual

OPERATION MANUAL
User’sGuide
King-Long XMQ6900J series city bus
Xiamen King Long United Automotive Industry Co., Ltd.

Foreword
FOREWORD
King-Long XMQ6900J series city bus keeps features of superior economy,
security and comfort. It has stable performance, strong power, luxury interior
trimming and high speed, which could meet applications of passenger intra-city
transportation, touring affairs, etc.
As for the specifications introduced in relate to information of the driving
and operation, service and maintenance of the XMQ6900J series city bus, please
read them carefully and make proper operation, maintenance and repair so as to
ensure it in good condition. Special hint: without authorization of Xiamen King
Long United Automotive Industry Co., Ltd, never modify the electrical
deployment of the whole vehicle, and should not lap the power supply line in
disorder. Improper usage and repair may have a strong impact on service
performance of the complete vehicle, and thus the manufacturer , Xiamen King
Long United Automotive Industry Co., Ltd. will not takes the responsibility for
the damages caused by them.
Any problem in service, please contact our special maintenance network or
after-sales department. We will ensure timely and complete maintenance as well
as original parts supply.
In order to satisfy all kinds of different demand of the consumers, we strive
to improve the quality of the product continuously to optimize our products. We
should not give any further notice for any modification of the product in advance .
The contents on the instruction book can only be used as reference. If there are
facts not comply with the manual, will be subject to the actual state of the
products because for some device and items, the vehicle will be finally equipped
only if they have been taken as optional configurations.
Final interpretive right of the instruction book belongs to the technical
center of Xiamen King Long United Automotive Industry Co., Ltd.
Xiamen King Long United Automotive Industry Co., Ltd.
MAY. 2014

Contents
2
Contents
Foreword
Foreword---------------------------------------------------------------------------------------------------------------2
Contents
Contents----------------------------------------------------------------------------------------------------------------3
Main overall technical parameters
Technical parameters -------------------------------------------------------------------------------------------------7
Introduction to name plate--------------------------------------------------------------------------------------------8
Product quality assurance --------------------------------------------------------------------------------------------8
Technical document --------------------------------------------------------------------------------------------------8
Vehicle body structure------------------------------------------------------------------------------------------------9
Schematic illustration of the driver zone--------------------------------------------------------------------------10
Operation Instruction
Instrument instruction-----------------------------------------------------------------------------------------------I-1
Illustration of switch and indicator s----------------------------------------------------------------------------SI-1
Air conditioner control panel-----------------------------------------------------------------------------------P-A-1
Bus centre controller---------------------------------------------------------------------------------------------P-B-1
Open or close the passenger door-----------------------------------------------------------------------------O-K-1
Adjustment of the driver's seat----------------------------------------------------------------------------------OI-1
Horn button---------------------------------------------------------------------------------------------------------OI-2
Adjustment of the steering wheel-------------------------------------------------------------------------------OI-3
Ignition switch-----------------------------------------------------------------------------------------------------OI-4
Lamplight operating handles-------------------------------------------------------------------------------------OI-5
Wiper operating handle-------------------------------------------------------------------------------------------OI-6
Retarder operation-------------------------------------------------------------------------------------------------OI-7
Safety hatch--------------------------------------------------------------------------------------------------------OI-8
Safety hammer-----------------------------------------------------------------------------------------------------OI-9
Prompt stop switch for get off ---------------------------------------------------------------------------------OI-10

Contents
3
Switch control box----------------------------------------------------------------------------------------------O-E-1
Vehicle starting and driving
Check oil level of the engine--------------------------------------------------------------------------------------S-1
Check level of the coolant-----------------------------------------------------------------------------------------S-2
Check fuel pre-filter with water separator-----------------------------------------------------------------------S-3
Check fuel level-----------------------------------------------------------------------------------------------------S-4
Check vehicle lighting, intermittent lights and brake lights---------------------------------------------------S-5
Check the level of AdBlue and the daily maintenance of SCR system--------------------------------------S-7
Drain water in air tank---------------------------------------------------------------------------------------------S-8
Check engine oil pressure------------------------------------------------------------------------------------------S-9
Check Pneumatic pressure---------------------------------------------------------------------------------------S-10
Check Tachograph working order-------------------------------------------------------------------------------S-11
Steering wheel play-----------------------------------------------------------------------------------------------S-12
Check tire for abrasion and pressure and tire nut for fixture------------------------------------------------S-13
Air cleaner----------------------------------------------------------------------------------------------------------S-14
General leakages (water, oil, fluids and fuel) -----------------------------------------------------------------S-15
Fastening and state of seat belts---------------------------------------------------------------------------------S-16
Check emergency devices and driver’s tools(fire extinguisher) --------------------------------------------S-17
Windshield wipers and conditions of wiper blades and arms-----------------------------------------------S-18
Electrical rearview mirror----------------------------------------------------------------------------------------S-19
Power steering system--------------------------------------------------------------------------------------------S-20
Clutch actuation system fluid level-----------------------------------------------------------------------------S-21
General state and tension of drive belts------------------------------------------------------------------------S-22
Clutch actuation system fluid level-----------------------------------------------------------------------------S-21
General state and tension of drive belts------------------------------------------------------------------------S-22
Check level of battery electrolyte-------------------------------------------------------------------------------S-24
Procedures for engine start up-----------------------------------------------------------------------------------S-25
Engine shut down-------------------------------------------------------------------------------------------------S-26
Engine start up and shut down in the engine compartment--------------------------------------------------S-27

Contents
4
Starting the vehicle------------------------------------------------------------------------------------------------S-28
Parking the vehicle------------------------------------------------------------------------------------------------S-29
Vehicle maintenance and service
General knowledge------------------------------------------------------------------------------------------------M-1
Maintenance of engine and chassis subassembly--------------------------------------------------------------M-1
Body maintenance ------------------------------------------------------------------------------------------------M-1
ABS system maintenance and service --------------------------------------------------------------------------M-1
Electrical system maintenance and notices --------------------------------------------------------------------M-2
Tire transposition--------------------------------------------------------------------------------------------------M-2
Adjustment of the clutch pedal freeplay------------------------------------------------------------------------M-3
Adjustment of the brake pedal freeplay-------------------------------------------------------------------------M-3
Bus cleaning--------------------------------------------------------------------------------------------------------M-3
Cleaning air filter --------------------------------------------------------------------------------------------------M-4
Cleaning outside of radiator -------------------------------------------------------------------------------------M-5
Coolant specification ---------------------------------------------------------------------------------------------M-5
Oil specification recommendation of the fuel and the lubricant---------------------------------------------M-6
Breaking-in of a new vehicle-------------------------------------------------------------------------------------M-9
Daily or Refueling Maintenance Operation-------------------------------------------------------------------M-11
Maintenance first 2500km --------------------------------------------------------------------------------------M-12
Maintenance per 5000km---------------------------------------------------------------------------------------M-13
Maintenance per 10000km--------------------------------------------------------------------------------------M-16
Maintenance per 20000km--------------------------------------------------------------------------------------M-17
Maintenance per 40000km -----------------------------------------------------------------------------------M-20
Maintenance per 80000km ------------------------------------------------------------------------------M-20
Maintenance more than 80000km------------------------------------------------------------------------------M-21
Maintenance period chart---------------------------------------------------------------------------------------M-22
Common trouble and its eliminating method
Engine Common trouble and elimination ---------------------------------------------------------------C-1
Clutch---------------------------------------------------------------------------------------------------------------- C-6
Propeller shaft-------------------------------------------------------------------------------------------------------C-8

Contents
5
Transmission--------------------------------------------------------------------------------------------------------C-9
Rear axle-----------------------------------------------------------------------------------------------------------C-10
Front axle and steering system----------------------------------------------------------------------------------C-11
Braking system----------------------------------------------------------------------------------------------------C-14
Electrical equipment and the starting system ---------------------------------------------------------------C-16
Air conditioner system-------------------------------------------------------------------------------------------C-18
Appendix
Driver's tool table ---------------------------------------------------------------------------------------------- A-1
Tightening moment of the bolts and the nuts in major position ------------------------------------------A-2
Air braking schematic diagram -------------------------------------------------------------------------------- A-4
Electrical schematic diagram-------------------------------------------------------------------------------------A-4

Technical parameter and complete vehicle description
6
Technical parameters of the complete vehicle
(Vehicle No.EC600024-25)
Product model XMQ6900
J
Engine model ISBE6.7E5 250B
Engine type In-line six-cylinder water-cooling direct-injection diesel engine
Cylinder diameter ×stroke （mm）107X124
Displacement (ml) 6700
Compression ratio 17.2:1
Rated capacity / rotation speed (kw/rpm) 184/2300
Max. torque / rotation speed (N·m/rpm) 1200 /1200-1600
Dimensions
Overall length （mm）9175
Overall width (mm) 2450
Overall height（mm）3050(3140)
Wheelbase （mm）4250
Wheel
track
front （mm）2094
rear （mm）1860
Minimum lift-off clearance（mm）≥158
Approach angle/ departure angle
(°)
7.8/8
Front overhang / rear overhang
（mm）
2175/2750
Rated passenger (driver included)
(person)
23+4+1
Mass parameter
Kerb weight（kg）9000
Max. gross mass （kg）12000
No
load
Front axle （kg）2700
Rear axle （kg）6300
Full
load
Front axle （kg）4000
Rear axle （kg）8000
Performance parameter
Max. speed (km/h) ≥90
Fuel consumption (L) --
Maximum gradeability (%) ≥20
Min. turning diameter (m) ≤20
Parking slope (20%) Parking for 5 minutes
Capacity data
Fuel tank（L）165
Engine oil（L）19.5
Transmission lubricant（L）23
Main retarder lubricant（L）5
Power steering hydraulic oil（L）8
clutch lubricant（L）1.3

Technical parameter and complete vehicle description
7
Introduction to data plate
Bus data plate
The bus data plate may be affixed to either the upside of the front passenger door frame or to the side of the
front passenger door step (the position may vary with vehicle model). There are many parameters on the
plate, such as vehicle model, gross mass, vehicle serial number, vehicle capacity, VIN (short for vehicle
identification number), chassis serial number, engine serial number, engine model, rated power, production
data and etc..
Chassis data plate
The chassis data plate is on right (or left) lateral surface
of the front wheel position of the main sill with vehicle
identification number (VIN) on the frame.
Engine data plate
The engine data plate is on top surface or salient top
position of the engine, whose position may be various
according to different engine manufacturing plant.
The engine number is stamped on the left or right
block of the engine, whose position may be various
according to different engine manufacturing plant.

Technical parameter and complete vehicle description
7
Product quality assurance
We make breaking-in maintenance of the rolling-out new vehicles in their initial driving mileage of
5000 km. Users should make proper operation and maintenance strictly according to relevant
regulations in the instruction book. Please refer to “workshop manual” for product quality assurance
and abide by related specification.
Technical document
The instruction book is used combined to the following specification:
Engine operation instruction or service manual
Transmission operation manual
CAN BUS Instrument system instruction book
ABS anti-braking system instruction book
Air conditioner instruction book
Heater instruction book
Monitor instruction book
VCD/DVD instruction book
Note: the instruction book should be modified according to specific configuration of vehicle.

Technical parameter and complete vehicle description
7
Body Structure
1. Structural style
Semi-integral body structure
2. Structure
The bodywork structure adopts closed girder construction of five major assembly parts, which are
combined welded by rectangle steel pipes with advantages of strong structural stiffness, torsion
resistance and bending resistance as well as relatively simple craftwork. Main components of skeleton
have been performed anticorrosion treatment to ensure steady adhesion of coating and strong capacity
of antirust and corrosion-proof.
3. Interior trim
The interior adopts flexible design and the floor adopts steel plate/wood block composite construction,
and covered with anti-slip and antifriction leather with favorable sound insulation value.
4. Windows
The front windshield is the hyperboloid triplex glass fixed by the gluing; the rear windshields are the
hardened glass fixed by the gluing; the side windows are close cycle window which are made of
hardened glass. The driver’s window is fixed with sliding window.
5. Baggage compartment
The baggage compartment without installing
6. Seat
Driver’s seat: adjustable seat with high backrest and three-point belt（E-MARK）.
Passenger seats: FANSA city bus seat, the all seats are equipped with two-point safety belt.
7. Interior accessory device
The vehicle is equipped with electronic clock, sunshade, safety hammer, emergency escaping window,
curtain，destination board, inner display screen, reversal monitor, Vehicle traveling data recorder ,
reading lamp, disabilities ramp ,guide mike .etc.
8. Air-conditioning system
Cooling system: WEBASTO top mounted dependent air-conditioning system.
Defroster: cooling /heating defrosting device
9. Door
The door adopts the full aluminum remote control inner-swing pneumatic doors.
The inner-swing door adopts the advanced electrically aerodynamic theory design, with the motion of
opening and closing placidly、agile、safe、lock credible and anti-clamp function.
A. Basic function
a. There are two electrically switches, the interior one is trigger touch-tone, which located on the
dashboard of the front right side of the driver, the outside one is a remote control switch. , both switches
can control the door.
b. When the circuit is in OFF position , the emergency switch can be used in the interior, the emergency
switch of the door is located on the lower right side of the entrance of the door , Please rotate the switch
and throw open the door in emergency.
c. Commonly the door is closed, when touch off any electrically switch, the door would move placidly
at a certain velocity, along with it, the step-lamp lights .when touch off the switch again , the door
would return placidly at a certain velocity, after the door returned , the step-lamp goes out.

Technical parameter and complete vehicle description
8
B. Hint:
a. The door remote control acts only when the parking brake is on the parking gear.
b. The door could only be opened when the external mechanical lock isn't locked up.
c. In order to avoid impact, make sure that the door is completed closed or opened, before you make the
next door switch operation.
Note: Deployment on the vehicle may be different with the above description because of different
deploying requirement of the clients.

Technical parameter and complete vehicle description
9
Schematic illustration of the driver zone
1Rearview mirror heating
2Rearview mirror control switch
3Station reporter
4Rocker switch
5Light operation handle
6Combination instrument
7Steering wheel
8Horn
9MP3 player
10 Emergency electric power cut off switch
11 Wiper operation handle
12 A/C operation rotation button
13 Cigar lighter/USB charging socket
14 Door air valve switch
15 Transmission control panel
16 Parking brake shift
1
4
12
6 7 8 9 10
13
14
11
2
3 15
16
5

Operation Instruction
I-1
Instruction of instrument (Siemens Edition）
No. Function Description
1 ABS indicator ABS work/warning
2 High beam indicator When Highbeam is switched on
3 Left turning indicator When Left turning/hazard switch is turned on
4 Severe Error When the electrical system has severe error. (see1.1 )
5 General Error When the electrical system has general warning. (see1.2)
6 Right turning indicator When Right turning/hazard switch is turned on
7 Retarder indicator Retarder work/warning
8 Parking brake
9 DTCO warning communication error or without drivers card
10 Engine Revolution speed too
high
Need to change the gear or slow down the bus
11 Trip distance reset button Set trip distance to 0
12 LCD illumination adjust button Press the button to adjust the illumination of LCD
13 Fuel level gauge The fuel remain
14 Coolant temperature gauge Temperature of engine coolant
15 LCD display
16 Speedometer Current vehicle speed
17 Odometer Current engine speed

Operation Instruction
I-2
1.1 Severe error conditions
EDC red lamp; ECAS red lamp; EBS red lamp; coolant level low; battery not charging (after engine
starts); worn brake shoes; brake circuit 1/2 pressure low; coolant temperature high; catalyst level low;
engine cabin temperature high; oil pressure low (after engine starts).
1.2 General error conditions
Hammer not at right position; ASR error; air filter block; ECAS amber lamp; EBS amber lamp; rear flap
open; toilet water level low; steering oil level low; steering oil pressure low; fuel level low; DM1 error; light
error; communication error.
2 LCD Display
Press the page switch button, the pages will be displayed by the following sequence. Detailed
description is listed as below:
2.3 Driving Information
When the bus is running, this page will show (Figure-1 ):
Figure-1 driving information
pictogram comments pictogram comments
Gear info (see 2.1.1) Acceleration pedal position
Current time (see 2.1.2) System voltage (see 2.1.3)
Front door status (see2.1.7) Preheating indicator
Mid door status (see 2.1.7)
Passenger service/request from
cabin(see 2.1.9)
Fluid fan error Engine red lamp error

Operation Instruction
I-3
pictogram comments pictogram comments
Low beam working Engine amber lamp error
Front fog light working Engine Malfunction
Rear fog light working
Engine wait to start (do not start
the engine until this symbol
disappear)
Brake light wroking EBS red lamp warning
Lift-axle lock EBS amber lamp warning
Steering oil level low ECAS status (see2.1.8)
Steering oil pressure low
Battery not charging (indicate
charging error if this symbol still
exist after engine starts)
Coolant temperature high
(>=98°C)
The bar shows brake circuit 1
pressure
Coolant level low The bar shows brake circuit 2
pressure
Rear flap open (can not start the
engine) The bar shows engine oil pressure
Worn brake shoes The bar shows SCR remain
Hammer not at right position
Function description
2.3.1 Transmission gear Display：
：current gear is "neutral"；
：current gear is "forward"；
：current gear is "reverse"；
2.3.2 Time：
This information comes from DTCO.
2.3.3 System voltage：
This value shows the battery voltage when generator is not working; and shows the voltage by
generator after engine starts.

Operation Instruction
I-4
2.3.4 Acceleration pedal position：
Range: 0 – 100 %。
2.3.5 Oil pressure：
This information comes from engine ECU. Before engine starts, the value is 0.
2.3.6 Brake system pressure:
Brake circuits 1 refers to the front brake system pressure.
Brake circuits 2 refers to the rear brake system pressure.
The symbol becomes red if the pressure is too low or if sensor is open-load.
2.3.7 Door status：
: green; means door is open
: yellow; means the cap on the emergency switch is open (either inside or outside)
: brown; means the knob in the emergency switch is moving
2.3.8 ECAS status
：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

Operation Instruction
I-5
If there is error exists, this page will show after driving information page when you press the page
change button.
Description:
Pictogram ：object name;
Text: detailed description of the error;
Errors can be displayed in this page:
Communication Error: EDC, EBS, TCO, AC, Front node, Top node, Cabin node, Rear node;
Light Error: high-beam, low-beam, reverse light, front fog light, rear fog light, brake light, turning
light
Other Error: brake circuit pressure open-load, fuel-sensor open-load, Engine cabin too hot, worn
brake shoes (1-6), fuel level low, water in toilet level low, air filter block,
2.3 DM1 Diagnosis Information
Figure -3 DM1 display page
This page will show when some ECU sends out DM1 message. The diagnosed ECU must support
CAN diagnosis, and provides SPN-FMI code.
Line1: the object that has error (from SPN).
Line2: Error status (from FMI)
Line ECU: name of the ECU that sends the message (i.e. EDC, EBS, AC)
Line SPN-FMI: the SPN and FMI combination
: means this error is not the last one
Other contents are fixed

Operation Instruction
I-6
2.4 Air conditioner status
This page will appear is air conditioner is working and the communication is right.
A/C mode include: ventilation; heating; cooling; demist/defrost; auto mode; off
Set temp: the temperature currently set to be;
Room temp: the real ambient temperature in the bus;
Outer temp: outside temperature;
Evap_speed: OFF; High; Mid; Low
Fan_speed: OFF; High; Low
2.5 Engine Cabin Temperature high warning page
If engine cabin temperature is higher than 85°C, this page will appear automatically. The temperature
will show on the page. The driver need to press the page change button to switch to the driving page

Operation Instruction
I-7
2.6 Beeper warning conditions
Brake circuit 1 pressure low
Brake circuit 2 pressure low
Coolant level low
Hammer not at right position
Engine cabin temperature high
Oil pressure low (after engine running)
Service request
Left turning
Right turning.

Operation Instruction
SI-1
Illustration of switch and indicator
Number of switches and indicators and position may vary with vehicle model, please consult the flowing
sheet and use correctly according to actual condition of vehicle.
Switch Name Color Function Notes
Retarder Green
Pressed on top: retarder is turned ON
Pressed on bottom: retarder is turned OFF
Retarder turn off
switch Pressed on top: retarder is turned OFF
Pressed on bottom: retarder is turned ON
Daylight lamp Green Pressed on top: interior lighting ON,
Pressed on bottom: interior lighting OFF
Hazard lamp Red when the vehicle have a screw loose, switch
it on, the whole vehicle lamps light
Luggage
compartment lamp Green Pressed on top: lamp lights ,
Pressed on bottom: lamp goes out
Compulsory
radiator Green Pressed on top: radiator working ;
Pressed on bottom: to turn it off
only use this button
when vehicle is stopping
Ventilator Green Pressed on top: ventilator is active,
Pressed on bottom: ventilator is turned off
Front fog lamp Green Pressed on top: front fog lamps ON,
Pressed on bottom: front fog lamps OFF
Rear fog lamp Yellow Pressed on top: rear fog lamps ON,
Pressed on bottom: rear fog lamps OFF
Vehicle raise/lower Green Pressed on top: vehicle raise,
Pressed on bottom: vehicle lower
only use this button
when vehicle is stopping
Defroster Yellow Pressed on top: windscreen heater ON,
windscreen heater OFF
Reading lamp Green Pressed on top: reading lamp ON, Pressed on
bottom: reading lamp OFF