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This Repair Manual specifies the general repair methods for the chassis, electrical parts and body of
Golden Dragon XML6127J13 、 XML6127J12 buses, providing the data necessary for the repair of
relevant assemblies and standardizing and recommending relevant repair techniques and requirements.
The vehicle models and applicable chassis models are shown in the following table:
Vehicle model Chassis model: Engine Suspension type Mid & rear door
Hongyan leaf spring
CK-6127J13-2TTGD suspension front:10 N/A
rear:12
Hongyan leaf spring
CK-6127J13-2TTGZ suspension front:10 Mid door
XML6127D13 ISLe340 30
rear:12
Jingrui 6 air bag
CK-6127J13-2TTAD N/A
suspension
Jingrui 6 air bag
CK-6127J13-2TTAZ Mid door
suspension
Hongyan leaf spring
CK-6127J12-2PSGD suspension front:10 N/A
rear:12
Hongyan leaf spring
YC6L330-30
CK-6127J12-2PSGZ suspension front:10 Mid door
XML6127D53 (High pressure
rear:12
common rail)
Jinrui 6 air bag
CK-6127J12-2PSAD N/A
suspension
Jinrui 6 air bag
CK-6127J12-2PSAZ Mid door
suspension
All information contained in this cataloge are the latest products information while compiling.this
Catalogue is being compiled. The specifications or procedures in this catalogue may not be in accordance
with specific objects. Golden Dragon has the right to modify them without notification in advance. Any
detail should be subject to the modified parts should there be any modification. specific objects.
Please contact with our After-sales Service Center if you need to know more details about our repair
data and other data or hope to further check the conditions on the repair site.
After-sales Service Center telephone: 0592-5656208
This Manual is exclusively applicable for the Special Repair Stations of Xiamen
Golden Dragon Bus Co., Ltd.
Xiamen Golden Dragon Bus Co., Ltd.
Nov, 2008
Chapter Schedule of Service Manual
The following table shows the numbers of all chapters contained in this Manual in
relation to the repair data of various relevant types of bus systems.
Chapter Model XML6127JLarge passenger bus
GI Foreword and General Descriptions GI-6127J-01
EN Engine and Accessory System EN-6127J-01
CL Clutch CL-6127J-01
CC Clutch operating mechanism CC-6127J-01
TM Transmission TM-6127J-01
TC Transmission operating mechanism TC-6127J-01
PP Transmission shaft PP-6127J-01
FA Front axle FA-6127J-01
RA Rear axle RA-6127J-01
SU Leaf spring suspension system SU-6127J-01
SU Air suspension system SU-6127J-02
SR Steering system SR-6127J-01
BR Brake system BR-6127J-01
EE Electric System EE-6127J-01
AC Air-conditioning and heating system AC-6127J-01
RT Electromagnetic retarder system RT-6127J-01
WT Wheel and tyre WT-6127J-01
BO Body system BO-6127J-01
Golden Dragon
Overview GI
Engine & Accessory
System EN
Repair ManualClutch CL
Clutch Operating
Mechanism CC
Transmission TM
Transmission Operating
Mechanism TC
Transmission shaft PP
Front axle FA
Rear axle RA
Suspension system SU
Steering system SR
Brake system BR
Electric System EE
Air-conditioning and
heating system AC
Xiamen Golden Dragon Bus Co., Ltd. Eddy Current Retarder
All rights reserved. No duplication or photocopy of all or
part of this Manual is allowed without written approvalSystem
of
RT
Xiamen Golden Dragon Bus Co., Ltd.
1st Edition in Sept. 2008
Wheel and Tyre WT
This manual is exclusively used by designated
repair stations of Xiamen Golden Dragon Bus Co.,
Ltd. Body system BO
Geneal Introduction GI-6127J-01 GI-1
Overview
General precautions
This Chapter contains the specifications and requirements to be followed during repair and maintenance of the bus
in order to avoid personal injuries and property losses arising from improper operations or negligence and thus guarantee
repair quality.
Improper or incorrect operations may cause troubles and accidents and thus personal injuries and (or) property
losses. Please consult your local distributor of Golden Dragon if you have any doubts on the repair and maintenance of
the bus.
Please strictly observe the operating requirements specified in column ‘Warnings’ to guarantee operating safety as
the No. 1 priority.
Warnings
Please observe the following requirements in addition to the precautions or warnings in each chapter during operation
of the bus so as to avoid any personal injury and (or) property loss.
Wear a pair of protective goggles to protect your eyes.
Remove all finger rings, watch, tie, loose jewelries and loose clothes before operation is started on the bus.
Tie your long hair reliable behind your head.
Reliably pull up the parking brake, place the gearlever at ‘Neutral’ or ‘N’ position and block each wheel with a
wedge before operation is started on the bus.
The engine shall be shut off normally and the starting switch shall be disconnected unless it needs to run. It is
recommended to remove the key from the switch.
In order to avoid severe scalds, the operator shall avoid touching hot metal parts like engine, exhaust manifold,
radiator, muffler, exhaust pipe and tail pipe.
Do not smoke while working on the bus because the engine’s fuel and the gases discharged from the storage
battery are both inflammables.
Take special care while working on the storage battery because it contains corrosive sulfuric acids.
Take care to avoid short circuits as there are high currents in the cables of storage battery and starter. Otherwise,
personal injuries and (or) property losses may be caused.
Please carefully read and observe the Operating Instructions before using the jack.
Use a safety bracket to support the bus if it is necessary to work underneath the chassis. It is dangerous to work
under the chassis if the bus is merely supported by one jack.
If it is necessary to run the engine with the engine hood opened, please ensure that the parking brake is reliably
actuated, the wheels are properly wedged and the gearlever is placed at the ‘Neutral’ position before startup.
In order to avoid inhalation of carbon monoxide, please run the engine only in a properly ventilated place.
The operator shall keep himself and his clothing and tools far away from various moving parts when the engine is
running, e.g. cooling fan and belt. Please take care not to step on or grip at various types of pipes and hoses with
efforts to avoid damages.
Please take care not to leave any tool in the engine compartment. Otherwise, the tools may collide with the
moving parts to cause personal injury.
Geneal Introduction GI-6127J-01 GI-3
In case the bus is to be towed, please place the gearlever at the neutral position, fully release the parking brake,
eliminate any other potential risks to personal and bus safety, establish proper marks and strictly observe relevant road
safety laws and regulations.
Ensure that the drive shaft of the vehicle under towing is disassembled. In case the differential or rear axle shaft is in
trouble, please remove both left and right rear axle shafts and seal the openings of the wheel hubs to avoid losses of
lubricating oils in the axles and ingress of dusts or foreign matters.
Use heavy-duty cables to tow a vehicle. Fasten the cable securely to the hook of the frame.
Connect the cable to the hook so that the angle between the towing direction and the traveling direction of the
vehicle under towing does not exceed 15 degrees both horizontally and vertically. Avoid pulling the cable
vehemently in case a hook is used to tow a vehicle. For instance, towing any vehicle that sets in mire.
Place the gearlever at the neutral position.
Ensure that the starting switch is kept at the ‘ON’ position.
Ensure that the engine of the vehicle under towing keeps running.
If the engine is shut off, the brake system won't get any compressed air/vacuum. Such a situation is very dangerous
because the brake system can’t work if the engine is not running. In addition, the power steering system won’t work
either so that it would be hard to operate the steering wheel, and thus it is difficult to steer the vehicle. It is
noteworthy that the exhaust brake is disabled because the drive shaft has been removed.
Start up slowly to minimize possible vibrations. The towing speed shall be less than 30km/h.
If the engine of the vehicle under towing is in trouble, the towing work shall be carried out by a special-purpose
towing truck.
Take necessary protective and preventive measures in order to avoid pollutions and damages to other parts of the
bus. Please clean the bus after operation.
Provide a clean environment and observe the cleaning requirements mentioned in the Manual. Dirty components
may cause premature abrasions and unexpected troubles during repairs.
Check and record necessary items and statuses according to the Manual.
Observe the assembly and disassembly regulations specified in the Manual to avoid damaging the components.
GI-4 General Introduction GI-6127J-01
The Repair Manual is compiled to guide the repair work of the bus. Some simple repair methods are not included
herein, e.g. the simple installation and removal of components. Only those important methods that require guidance will
be introduced herein. In some cases, some components as shown in the figures may be slightly different from the ones on
your bus. But these differences don’t matter much. The basic principles and methods specified herein are still applicable.
1. Operating instructions
There is a table of content on the first page of each chapter. It includes further data of the system.
Firstly, check the structure and working principles of the system in the Manual for inspection of the system.
Each chapter includes a section of “troubleshooting”. Please refer to the ‘troubleshooting’ section to acquire
necessary guidance on troubleshooting during operation.
There is a ‘dedicated tools’ section in some chapters. Please use the dedicated tools for repair.
Please confirm the numbers of the dedicated tools as specified in the applicable list of components while
placing an order for such dedicated tools.
2. Definitions of directions
前 Front
后 Rear
左 Left
右 Right
Ex-works number:
Engine model:
Date of ex-works:
Bus VIN:
GI-6 General Introduction GI-6127J-01
Nameplate, chassis
Chassis model:
Ex-works number:
Date of ex-works:
Engine S/N: engine model and S/N are engraved on the engine. Please refer to the Engine Operation Manual for
specific position.
General Introduction GI-6127J-01 GI-7
3. Pipeline Connecting
Washer
Joint pipe
Clip Thread nut
2 . Initial inspection
condition
in a proper running
5.4 Solutions for buses
troubleshooting
scope
5.2 Check beyond the
intermittent troubles
5.3 Diagnosis of
of the
Identify the
6 Recheck the problem trouble
2. Initial inspection: mainly visual inspection. Check the history record of repairs. Check if there is any abnormal noise
or smell. Collect relevant other information for the sake of effective repairs.
3. Routine system inspections: check the system in order to confirm if the system works properly. Then carry out other
diagnosis in orders.
4. Read and check relevant technical documents: fully utilize relevant technical documents and other repair information
and compare with the routine system inspection results.
5-1. The phenomena and causes of troubles can be identified in the User’s Manual or Repair Manual. Please refer to the
corresponding figures for proper treatment.
5-2. It is necessary to carry out troubleshooting on site. Please refer to the Repair Manual, relevant schematic diagrams,
General Introduction GI-6127J-01 GI-11
system descriptions and operation instructions and check if the system is working in certain extreme environmental
conditions (high temperature, humidity and pollution) and special procedures. Please ask for technical support
from relevant organs if necessary.
5-3. Intermittent troubles are troubles that do not occur continuously. They would occur only in some conditions.
Normally, intermittent troubles are caused by electrical, connector and wiring defects, failing parts, additionally
installed equipment or external interferences. In that case, it is necessary to appraise the symptoms and conditions
as described by the user and refer to existing repair information for a diagnosis thereof.
5-4. User reported conditions may fit in with the bus design and therefore are part of the proper working conditions of
the bus. Or the conditions may be caused by the user’s improper operations. In that case, please explain the
identified problems and system operations to the user or compare it to another similar bus that is working properly
in the same conditions.
6. Recheck the problem: if the problem can’t be successfully settled in the foregoing steps, please appraise and check the
problem again. It may be an intermittent trouble or proper working condition.
7. Repair and check repair conditions: after the cause of trouble is identified, repair it and check if the bus works
properly. Check if the trouble is eliminated. The bus may have to undergo a road test.
GI-12 General Introduction GI-6127J-01
1. Bus lubricants
Engine lubricating oil
1) Lubricating oils influence the main working properties of the engine.
a) Viscosity and viscosity-temperature characteristic: viscosity refers to the extent of shearing force between
layers of flowing lubricating oils; viscosity-temperature characteristic refers to the changes of viscosity of
lubricating oils with the changes of temperature.
b) Foaming characteristic of lubricating oils: it refers to the generation of foams because of the difficult
separation of gases infiltrated into the oil due to the surface strains of lubricating oils.
c) Stability of lubricating oils: it refers to the lubricating oil’s ability to keep its physical and chemical
properties stable for a long term, including resistance to vaporization, shearing force, atmospheric
oxidation and high-temperature oxidation.
d) Anticorrosion of lubricating oils: the lubricating oil’s ability to protect the targets from corrosions.
e) Static dispersivity of lubricating oils: lubricating oils are highly capable of dispersing gums, paint films
and other solid substances so that they can be recycled together with the lubricating oils and removed by the
filter.
f) Resistance to abrasion: the lubricating oil’s ability to prevent the oil film from being damaged.
2) Designation and variety of commonly used lubricating oils
Variety Viscosity and designation
SC 5W/20 10W/30 15W/40 30 40
SD、SD/CC 5W/30 10W/30 15W/40 30 40
SE、SE/CC 5W/30 10W/30 15W/40 20/20W 30 40
SF、SF/CD 5W/30 10W/30 15W/40 30 40
CC 5W/30 5W/40 10W/30 10W/40 15W/40 20W/40 30 40 50
CD 5W/30 5W/40 10W/30 10W/40 15W/40 20W/40 30 40
a) In the ‘variety’ column, the first letter ‘s’ indicates lubricating oils for gasoline engine and ‘C’ indicates
lubricating oils for diesel engine; the second letter indicates the grade of the oil in alphabetic order with
C, D, E and F representing a rising grade.
b) In the ‘variety’ column, two letters indicate single-grade lubricating oils that are only applicable to one
type of engine; four or more letters that are separated by a ‘/’(e.g. SE/CD) indicate multi-grade general-
purpose lubricating oils (applicable to both gasoline engine and diesel engine).
c) In the ‘Viscosity and designation’ column, an Arabic number followed by a ‘W’ indicates the viscosity
level that enables engine startup at a certain low temperature in winter; an Arabic number without a ‘W’
indicates lubricating oils not for winter use. The number indicates the highest temperature for the
lubricating oil;
d) For instance: 10W/30 indicates that the lubricating oil can be used in a cold weather (engine that can be
properly started at -25℃) and also be used where there is a high thermal load.
3) Selection of lubricating oils
a) Lubricating oils that fit in with the engine’s working conditions and has a proper viscosity shall be
adopted. It is hard for the pump to feed oils with a high viscosity after the engine is started and thus the
engine abrasion may be increased; the oil film will be easily damaged to dwarf the effects of lubrication
if the viscosity is too low.
b) Lubricating oils with a higher grade can be a substitute of those with a lower grade and it is not cost
effective in this case merely. However, lubricating oils with a lower grade can’t be a substitute of those
with a higher grade. Otherwise, the engine parts may be damaged.
General Introduction GI-6127J-01 GI-13
Hydraulic oils
1) Working conditions and main characteristics of hydraulic oils
A hydraulic system is installed for dump trucks, automobile cranes, loaders and various types of engineering
machineries and the working medium is hydraulic oil. The working conditions of hydraulic oils require that the oils
GI-14 General Introduction GI-6127J-01
must have sound shearing stability, wear resistance, oxidation stability and fluidity. Most importantly, their
incompressibility must be guaranteed. The factor that influences the incompressibility of hydraulic oils most is their
solubility of air. If the air solubility is too high at a certain temperature and pressure but would become lower in
some other working conditions, air bubbles may be created in the hydraulic oils. The compressibility of air bubbles
will spoil the properties of the working medium of the hydraulic system and thus cause the system to malfunction.
For that reason, a certain number of kilfoams shall be added in hydraulic oils to increase their working stability.
2) Types and scope of application of hydraulic oils
a) L-HL hydraulic oil is a type of general-purpose lubricating oil for industrial machine tools and applicable
to the low-pressure hydraulic system and transmission unit of machine tools and other equipment that is
required to resist oxidation and rusting. It works at an environment temperature of over 0 ℃.
b) L-HM hydraulic oil is a type of wear-resistant hydraulic oil applicable to low, medium and high-pressure
hydraulic system. It may also be used to lubricate medium-loaded machinery and equipment. It is
applicable at an environment temperature of -5 to 60℃.
c) L-HV hydraulic oil used to be called engineering hydraulic oil or low-temperature wear-resistant
hydraulic oil and is extensively used on hydraulic equipment in the field and in other rough working
conditions.
d) The various types of hydraulic oils mentioned above are divided into 15, 22, 32, 46, 68 and 100
designations based on viscosity (applicable to different working temperatures). Please see GB11118.1-94
for the value of viscosity corresponding to each designation.
Lubricating grease
Lubricating grease is one stable solid or semisolid product consisting of thickener-containing liquid lubricants. It
has such advantages as good solidity, wide range of working temperatures, easy sealing and storage, etc.
1) Basic makeup and properties of lubricating greases
a) Basic makeup of lubricating greases
Normally, lubricating greases include 80% to 90% lubricating oils as the basic oils and 10% to 20%
thickeners. A small quantity of additives is also added to further improve their properties. Thickeners mainly
consist of various types of soaps generated in saponification of fat and alkali. There are calcium, sodium and
lithium-based thickeners according to different types of metal alkalis. Lubricating greases are also divided into
calcium, sodium and lithium-based greases according to the type of thickeners.
b) Main properties of lubricating greases
The basic properties of lubricating greases required for automobiles mainly include: consistency,
temperature adaptability, wear resistance, water resistance, antirust, etc.
Consistency: it refers to the extent of thickness of the lubricating greases and reflects the ability of
the lubricating greases to maintain on the lubricated parts.
Temperature adaptability: it refers to the ability of lubricating greases to avoid loss at a high
temperature and solidification at a low temperature. It reflects the range of working temperatures to
which the lubricating grease is adaptable.
Wear resistance: it refers to the ability to resist oil film damages on the surfaces of moving parts that
are lubricated with the lubricating grease.
Water resistance: it refers to the ability of the lubricating grease to maintain its physical and chemical
properties when it is in contact with water. It is mainly reflected in the absence of consistency
decrease, emulsification and loss.
Antirust: it is the ability of the lubricating grease to protect the lubricated surface from rusting.
2) Varieties and designations of commonly used automobile lubricating greases
a) Calcium-based lubricating grease
Calcium-based lubricating grease has fat and lime as the raw material and has four consistency
designations of 1, 2, 3 and 4. Calcium-based lubricating grease is applicable within a temperature range of
General Introduction GI-6127J-01 GI-15
-10℃ to 60℃. Its advantage is high water resistance. It is applicable to the parts with a high temperature and
easily get contact with water.
b) Sodium-based lubricating grease
Sodium-based lubricating grease has sodium soaps as the thickeners. It includes two consistency
designations of 2 and 3. Sodium-based lubricating grease is applicable to high working temperatures, over
120℃ at the maximum. It has a good wear resistance but poor water resistance. It will be easily emulsified and
deteriorated when in contact with water. For that reason, it is applicable to the parts with a high working
temperature but out of contact with water.
c) General-purpose lithium-based lubricating grease for automobiles
Lithium-based lubricating grease has lithium soaps as the thickeners and includes only one consistency
designation of 2. Lithium-based lubricating grease has a wide range of applicable temperatures, i.e. from -30℃
to 120℃. In addition, the lubricating grease also has good comprehensive properties, including wear
resistance, water resistance and antirust. It is extensively used for automobiles now.
Unit: N·m
Mechanical property grade
Turnbuckle size
Grade 4.6 Grade 5.6 Grade 8.8 Grade 10.9
Thread Screw pitch
specification (mm)
M6 1 2.5-5.5 3.0-6.0 6-12
M8 1 5.0-11.0 8.0-15.0 17-28
M8 1.25 5.5-11.5 7.0-14.0 16-26
M10 1.5 14.3-24.7 10.0-33.0 37-75 52-90
M10 1.25 16.7-25.8 22.0-34.0 45-79 63-93
M10 1 17.0-26.5 23.0-35.0 46-80 65-95
M12 1.75 28.0-43.3 37.0-53.0 73-111 105-156
M12 1.5 29.0-45.0 38.0-56.0 75-113 106-158
M12 1.25 30.0-48.0 40.0-60.0 78-115 108-161
M14 2 46.8-75.0 62.0-95.0 122-185 141-200
M14 1.5 56.0-92.0 68.0-105.0 146-205 178-235
M16 2 73.0-115.0 98.0-150.0 182-245 200-310
M16 1.5 76.0-133.0 101.0-160.0 199-270 240-335
M18 2.5 107.4-178.0 161.0-220.0 229-298 380-467
M18 1.5 124.5-190.0 165.0-230.0 287-346 397-507
M20 2.5 135.0-230.0 190.0-272.0 389-470 450-568
M20 1.5 149.0-243.0 197.3-285.0 396-480 475-598
Caution:
〇 The fastening torques as mentioned in the foregoing table are applicable where specified turnbuckles are used
for fixation and connection unless otherwise prescribed.