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 serial6540 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 LWH (mm)

538018802285

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. speedkm/h
Fuel
consumptionL/100km

2208
3450

Max. grade ability%

30

Brake system

Front discrear drum/discABS+EBDintelligent 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
contact sales department of our company.

2. Maintenance comments and attention

2.1 VIN position
1 VIN positionLeft side rear part of stringer
2 Engine number positionLeft side middle part of engine
3 Transmission number positionLeft side middle part of transmission box
4 Nameplate positionLeft underpart of front covering
5 Tire pressure logo positionunderpart 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.
2This book introduces the first two steps and bypass the third step.
3This book also bypasses 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 terms
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
Attentionbecause 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 driverco-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.
8Disassembly of electric system
1Disconnection 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.
2Disassembly 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.
9Disassembly 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.
10Disassembly 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.
11Attention 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
1Lift

Car lifting machine

support positioin

Rubber
pads
Shall not be used to support
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.
1Two-pillar lifter

a)
b)
c)
d)

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

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

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

2) Wheel lift tractionPut 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 tractionTraction speed

should be controlled under 30km/h, distance under
80km. When speed and distance surpass the two
numbers, the gearbox may be injured.(As Fig.)

If the vehicle must be pulled with front wheel off the ground or four wheel on ground, it should be
done as follows:
aRelease the parking brake.
bShift the gearbox into neutral.

3 Vehicle service data

3.1 Vehicles bolt torsion table
Intensity

Diametermm

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

Diametermm

Level 8.8

12

Level10.9

14
16
10

12
14
16

Screw
Pitchmm

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
Pitchmm

1.5
1.25
1.5
1.5
1.5
1.25
1
1.5
1.25
1.5
1.5

NormalN.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

NormalN.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 15W-40
CF-4 15W-40
SG 15W-40
GL-5 85W-90
GL-5 85W-90
Liquid drive oil 46#Kunlun6#
DOT4
R134a
Glass waer
Glycol-25

2Highland 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 15W-40
CF-4 15W-40
SG 15W-40
GL-5 85W-90
GL-5 85W-90
Liquid drive oil 32#Kunlun6#
DOT3
R134a
Glycol-45