1.overview 2lr2

Overview 1. Vehicle main parameter 1.1 Introduction 1.2 Main parameter

2. Maintenance comments and attentions 2.1 VIN positon 2.2 Comments on type editing 2.3 Maintenance comments and attentions

3. Service data 3.1 Vehicles’ bolt torque table 3.2 Amount of various oil and coolant

1.Vehicle main parameter 1.1 Introduction 1.1.1This service manual gives the introduction of maintenance of chassis, body and electrical equipment of A9 commercial bus. 1.1.2 Chassis suitable type: JS6520 JS6470 JS6580 1.1.3 Body suitable type: HKL serial（6540 6480 6600） 1.1.4 All information in this manual is compiled according to the latest products. When specifications and steps change, it shall be prevailed as the new one. 1.2 Parameter 1.2.1 HKL6540

Type Project Name

HKL6540

Overall L×W×H (mm)

5380×1880×2285

Wheel Tread(mm)

1655/1650

Wheelbase(mm) Type Rated Output(kw) Max. Torque(N. m) Displacement(L) Transmission type Engin e

Fuel Approach/Departure angle Min. turning radius (m) Bodywork mass (kg) Max. mass (kg)

3110 4G69S4N 100/5250 217/2600-3200 2.378 ZM001AD 93#

4RB2 102/4600-5000 217/2600-3200 2.438 ZM001AG 93# ≥14°/ ≥14.5° ≤6.25 2130 3300 70

DK4B1 75/3600 235/1600-2400 2.498 038T 0#

≥125

≥125

≥125

10/12.3

10.2/12.7

9.3/10.9

2105 3300

Fuel tank (L) Max. speed（km/h） Fuel consumption（L/100km）

2208 3450

Max. grade ability（%）

30

Brake system

Front disc＆rear drum/disc、ABS+EBD、intelligent brake assistance system

Steering system Suspension system Tire

Power steering, steering pillar energy absorbing equipment Front double wishbone independent suspension+ torsion spring/rear variable rate leaf spring 195R15C radial tire

Atten. ： this manual only introduces the parameter of HKL6540. For the information of other types, please sales department of our company.

2. Maintenance comments and attention 2.1 VIN position （1） VIN position——Left side rear part of stringer （2） Engine number position——Left side middle part of engine （3） Transmission number position——Left side middle part of transmission box （4） Nameplate position——Left underpart of front covering （5） Tire pressure logo position——underpart of left door/upside of tire

Name plate

Engine number

Transmission number

Frame

Tire pressure identification

2.2Opinion about edit vehicle model 2.2.1General item （ 1 ） Maintenance process is generally divided into three steps: diagnose, maintenance, (dismantle, replace, install, inspect, adjust) final inspect. （2）This book introduces the first two steps and by the third step. （3）This book also byes the introduction of following situation （a） Operation of jack and lefter （b） Clean of dismantled parts （c） Eyesight inspection of process （4） Operation instruction （a） Name of spare parts marked on assembly illustration （b） Scrapped parts, lubricated parts and torque of standard parts. （c） Order of installation and disassembly of spare parts. （d） Operation position and content in assembly illustration; Operation method and attention in literal parts. （e） Assembly illustration is same to similar models while different in certain parts. （5） Mark of standard value （a） Standard value is showed in bold face （6） Definition of Standard value Limit value

Allowed range during inspection and adjustment Low limit during inspection and adjustment Data measured through simple method when standard value Reference cannot be evaluated. 2.2.2 Attention on SRS airbag （1） Cut off power supply Turn ignition switch on LOCK; disconnect cathode pillar of accumulator for ninety seconds, then conduct the maintenance Attention：because airbag is equipped with reserve power supply, airbag may be opened if it is not disconnected for ninety seconds. （2） Attention before maintenance （a） Use special tool to inspect circuit of airbag system （b） Comply with attention marked around airbag system （c） Operator should not break down airbag （d） Operator should not measure resistance （3） Attention when airbag is scrapped (before operation) （a） Airbag cannot be scrapped before opening (use special tool) （b） Because loud noise during operation, operator should notice around beforehand. （c） Operation should be done outside and avoid operating around residence. （d） When opening airbag, operator shall keep special tool away from airbag for five meter. （4） Attention when airbag is scrapped (after operation) Because the temperature of airbag after exploding may increase over 100℃, operator shall leave it alone for thirty minutes.

（5） Airbag assembly of driver＆co-driver （a） After taking down airbag, leave the opening side upwards. （b） Do not put things on airbag as well as overlap the airbag. （6） Attention on wiring connector All connectors in engine cabin are yellow; operator should take care during installation and

disassembly. （7） Dealing method after vehicle collided （a） When using electrical welder, operation should be conducted after airbag strainer is dismantled. （b） Under the condition that airbag may be collided, operator should dismantle airbag sensor first, then airbag. 2.2.3 Basic items （1） Maintenance attention 1 Cloth requirement  Keep cloth clean, wear helmet and safety shoes  Install fence hood, anti-dirt hood, seat covering and 2 Body protection carpet covering before maintenance  Fix vehicle with block before maintenance  When there are two or more operators, they should confirm safety each other before next operation  Keep air ventilating when operation is conducted with 3 Safe operation engine running.  Take care for those positions of high temperature, rotation and vibration.  Take measure to confirm safety when vehicle is lefted  Project tool, special tool, measuring equipments, 4 Maintenance tool lubrication oil, dish cloth and new parts.  Diagnose after error is confirmed, then repair according to realistic condition  Confirm the deformation of error part and record. Maintenance 5  Record and mark the complex parts on condition that it operation will not influence the performance of vehicle  Reinstall the dismantled parts after cleaning and inspected to be qualified.  Array the dismantled parts in order in case of polluted again.  Replace gasket, o-type ring and bolts according to 6 Error part requirements.  Notice customer in time after package error parts in box. （2） Glued bolts （a） Glued bolts mean those bolts painted sealing glue on bolt trace （b） Paint new sealing glue when screw bolts again （c） After screwing glued bolts, leave it until harden the glue. （3） Gasket （a） When install gasket, use sealing glue to avoid leaking if necessary （4） Bolt and sleeve （a） Confirm the torque of bolts and sleeves and use wrench with the same specification. （5） Replace fuse （a） Use fuse with the same capacity; if use different fuse, the current of new one should be lower than old one. （6） Claw （a） Old claws cannot be used again. （7） Vacuum pipe （a） Hold the end of vacuum pipe and pull it out （b） Show how to connect with label after pulling vacuum pipe out.

（c） When use vacuum inspector, do not connect hose if pipe is relatively big. （8）Disassembly of electric system 1）Disconnection of accumulator cathode wire （a） During maintenance of electric system, operator should disconnect cathode wire of accumulator in case of short circuit. （b） Turn the key to OFF. （c） After cathode wire of accumulator is disconnected, operator should confirm the content of some memory parts for it may get lose. 2）Disassembly and installation of electric parts （a） Do not dismantle ECU （b） Do not hit computer, sensor, relay and so on. Replace these parts when they are hit. （c） Avoid high temperature and water （d） Electric unit, air filter and exhaust relevant parts shall not get water when clean engine with steam. （9）Disassembly of fuel system 1) Operation place of fuel system （a） Good air ventilating, no welder, grinding wheel and drilling machine around （b） Cannot fill with fuel gas 2) Disassembly of fuel system parts （a） Prepare fire existing equipment （b） Leak out the fuel in pipe （c） Connect the ground wire and watering （d） Do not use electric pump and operation lamp. （e） Separate fueled rags from other rags. （10）Disassembly and installation of engine intake system （1） The metal sheet in intake system will influence engine and turbine. （2） When dismantle intake system, operator shall protect the connecting part with plastic bag. （3） When install intake system parts, operator shall confirm no metal sheet mixed in. （11）Attention about hoops （1） In order for convenient operation, the position of hoops must be confirmed before hose is dismantled （2） Replace the deformed hoops （3） Install the hoop on the same place （4） Intensify hoop after installation （12） Vehicle with catalytic converter It will get lose to catalytic converter once large amount of gasoline get through catalytic converter. （a） Only use gasoline without lead. (gasoline vehicle) （b） When inspect spark plug, operator should dismantle injector connecting wire in case of fuel injecting. （c） When measure compression pressure of engine, operator should dismantle injector connecting wire in case of fuel injecting. （d） Do not run engine when fuel tank is empty. 2.2.4 Lift of vehicle （1）Lift

Car lifting machine positioin

Rubber pads Shall not be used to here

Centre –of –gravity

positiion Explanation ： if dismantle very heavy parts from rear of vehicle, for example, suspension or fuel tank, operator should first locate the front part of vehicle on safety bracket, for the center of gravity will change and vehicle will incline forwards. 1）Two-pillar lifter

a) b) c) d)

Put rubber block or safety bracket of lifter under the ing points of vehicle Lift up a little, then shake the vehicle to confirm whether it is steady. Lift the vehicle and inspect the ing point to confirm whether it is fixed. Put ing bracket under the vehicle.

2）Four-pillar lifter Drive vehicle on the bracket of lifter, fix four wheels with block.

（2）Traction 1) Carrying truck traction——Place the vehicle on a flatbed trailer. Adopt this kind of traction when chassis and drive wheel fail to work.（As Fig.）

2) Wheel lift traction——Put two rotating arms under the tire(front wheel or rear wheel), then lift off the ground with other two on the ground or enhance four wheels. （As Fig.）

3) Four wheel on ground traction——Traction speed should be controlled under 30km/h, distance under 80km. When speed and distance sur the two numbers, the gearbox may be injured.(As Fig.)

注：如果不能用平板拖车运送，则应当 If the vehicle must be pulled with front wheel off the ground or four wheel on ground, it should be done as follows: （a）Release the parking brake. （b）Shift the gearbox into neutral.

3 Vehicle service data 3.1 Vehicles’ bolt torsion table Intensity

Diameter（mm ） 6 8 8 10

Level 4.6

12 14 16 6 8 8 10

Level 5.6

12 14 16 6 8 8

Level 8.8

10 Intensity

Diameter（mm ）

Level 8.8

12

Level10.9

14 16 10

12 14 16

Screw Pitch（mm ） 1 1.25 1 1.5 1.25 1 1.5 1.25 1.5 1.5 1 1.25 1 1.5 1.25 1 1.5 1.25 1.5 1.5 1 1.25 1 1.5 1.25 1 Screw Pitch（mm ） 1.5 1.25 1.5 1.5 1.5 1.25 1 1.5 1.25 1.5 1.5

Normal（N.m）

Max.（N.m）

Min.（N.m）

4 8 8.5 19.7 20.8 21.8 38.5 39.6 74.6 105 4.5 10.6 11 26 28 29 47 50 90 132 9 23 25 59 63 64

5.5 11 11.5 24.7 25.8 26.5 45 48 92 133 6 14 15 33 34 35 56 60 105 160 12 26 28 75 79 80

2.5 5 5.5 14.3 16.7 17 29 30 56 76 3 7 8 19 22 23 38 40 68 101 6 16 16 37 45 46

Normal（N.m）

Max.（N.m）

Min.（N.m）

97 99 180 240 74 78 80 142 145 210 305

113 115 205 270 90 93 95 158 161 235 335

75 78 146 199 52 63 65 106 108 178 240

3.2 Amount of various of oil and coolant 1) Ordinary Region gasoline

93#

diesel 4RB2 engine oil DK4 engine oil 4G69 engine oil Transmission box oil Rear axle gear oil Booster steering oil Braking oil refrigerant Washing liquid coolant

0# SG 级 15W-40 CF-4 15W-40 SG 级 15W-40 GL-5 85W-90 GL-5 85W-90 Liquid drive oil 46#（Kunlun6#） DOT4 R134a Glass waer Glycol-25°

2）Highland and cold region gasoline diesel 4RB2 engine oil DK4 engine oil 4G69 engine oil Transmission box oil Rear axle gear oil Booster steering oil Braking oil refrigerant Washing liquid coolant

93# 0# SG 级 15W-40 CF-4 15W-40 SG 级 15W-40 GL-5 85W-90 GL-5 85W-90 Liquid drive oil 32#（Kunlun6#） DOT3 R134a Glycol-45°