operation manual

OPERATION MANUAL
Dear customers:
Many thanks for choosing HOWO trucks! Please read this manual carefully before the new vehicles run into operation.
And hope you could enjoy your driving experience.
This manual is about operation and maintenance of HOWO series heavy duty trucks. It contains the technical
information of HOWO trucks such as operation/performance and structure/maintenance/adjustment and so on. You can
find the related assembly information and attentions according to the specific configuration of your vehicles.
To ensure the normal life of vehicles and obtain the good economic benefit, all the instructions of the operation and
maintenance requirements mentioned in this manual need strictly to be followed.
Pure fuel in accordance with the quality requirement is required to be used during the vehicle’s running. All chosen oil,
lubricating oil, hydraulic oil etc. for vehicles shall be consistent with the provided grades of this manual.
When the vehicles break down, please contact the authorized service station by SINOTRUK immediately, and we will
supply the timely and effective services to you.
This manual is the latest edition for vehicle’s operation and maintenance and we reserve the rights of technical
alteration and upgrades for better improvement without prior notice.
CHINA NATIONAL HEAVY DUTY TRUCK GROUP CO., LTD
OPERATION MANUAL
Vehicle No.
In order to maintain your vehicle conveniently, please fill the Vehicle No. accurately and completely:
Vehicle Model:
VIN:
Engine Code:
Purchasing Date:
ATTENTION:
1. Nameplate marked with vehicle model is on the first footplate on the co-driver’s side (Open the door.)
2. VIN code is punched on the ventral shield of the frame right stringer which stands in the centerline of the
front-axle.
3. Engine No. is punched on the left block of the engine (Check it along the direction of driving).
VIN CODE
Engine No.
OPERATION MANUAL
ATTENTIONS:
1. When driving downhill, do not sliding out of gear, use the main brake, in the meantime use the exhaust brake as
much as possible to assist deceleration, also open the exhaust brake to assist deceleration when heavy loaded.
2. Turn off the engine, main power switch and use the parking brake service in order to avoid accident, when parking
the vehicle for a long time.
3. Unauthorized modification and installation of various devices is prohibited, especially for electronics, brakes, steering
and other systems related to the safety of the vehicle, or it may affect the service and safety performance of the
vehicle and result in accident, fire or damage to vehicle, and our company will not be responsible for the
consequences. Disassembling or replacing the ECU of the engine is strictly prohibited, or the vehicle may break
down.
4. The radiator mask must be opened before tilting the cab.
5. When there is welding work in or near the vehicle, it is a must to cut the battery power and unplug all electronic
components (Main-control, driving, instrument panel, engine, and ECU of ABS etc.) connectors.
6. Regular inspection and maintenance is important to the vehicle. We supply maintenance of different periods for our
company’s vehicle, and it’s free for the first–time maintenance. Maintenance above mentioned is very essential for
the safe use of your vehicle and to keep the vehicle in good condition. If the specified maintenance in this manual
is not executed, our company will not assume warranty obligations.
7. Do It Yourself of this manual is to introduce the user which they can do, please use the parts CNHTC provided (Short
for: original parts) and go to dealers authorized by CNHTC to buy original parts. CNHTC will not be responsible for
any direct or indirect losses caused by the use of unoriginal parts.
OPERATION MANUAL
Before starting to read this manual, please pay attention to the following symbols:
Specification:
Content with this symbol is additional information.
Notice:
This symbol is for instructing the important information how to operate the vehicle correctly or
which may damage the vehicle.
Warning:
This symbol is for instructing the risks of accident or injury that may happen.
OPERATION MANUAL
Content
It will show you the content of this manual with the list of all the titles on the next page.
Directions Explanation
All the directions (left/right/front/behind) applied in the manual are referring to the forwarding direction of the
vehicle. (Exception: Other directions explained by the content.)
Pictures Explanation
The pictures in the manual are used to supportive explain in order to help the customers understood. Some
pictures are only for illustration, not the real photos of the vehicle.
Contents
OPERATION
Cab
Light and View
Driving and Control
Overview----------------------------------1
Combination Instrument CMIC--------3
Tilting Switch symbols----------------42
Tilting Switch symbols----------------43
Steering Indicators and Alarm-------54
High Beam------------------------------55
Fog Lamp and Inside Lamp----------56
Sun Visor--------------------------------58
Windscreen wiper and Cleaner------58
Rearview Mirror------------------------59
New Vehicle Running-in--------------66
Preparation before Driving----------67
Start the Engine-----------------------72
Turn off the Engine-------------------74
Parking Brake Release---------------75
Start and Shift-------------------------76
Cruise Driving and EVB control-----78
Differential Lock Control-------------80
PTO Control----------------------------83
Start and Close
Main Switch-----------------------------44
Key---------------------------------------44
Unlock/Lock the Vehicle with Key---45
Manual Glass Lifter--------------------46
Radio with USB Connection----------46
Tachograph-----------------------------49
Air Conditioner
Air Conditioner ------------------------51
Riding and Adjusting
Seat--------------------------------------60
Adjusting Steering Wheel-------------62
Sleeper----------------------------------63
Pedal-------------------------------------63
Cup Bracket-----------------------------64
Ashtray----------------------------------64
Cigar Lighter----------------------------65
Glovebox--------------------------------65
CATALOGUE
Security
Maintenance
Braking System:
Vehicle Service Conditions------------------------------99
Cycle of Maintenance----------------------------------100
Maintenance Items-------------------------------------101
Mandatory Maintenance-------------------------------105
Engine----------------------------------------------------106
Transmission--------------------------------------------114
Front Axle------------------------------------------------118
Rear Axle------------------------------------------------119
Steering System----------------------------------------121
Clutch----------------------------------------------------123
Air Conditioner------------------------------------------126
Battery---------------------------------------------------127
Changing and Replacing Parts------------------------128
Service Brake-------------------------------------------------85
Auxiliary Brake------------------------------------------------86
Emergency and Parking Brake-----------------------------88
Trailer Brake and ABS Operation---------------------------89
Brake Cautions------------------------------------------------90
Influencing Factors
Driver’s Sitting Position--------------------------------------91
Headrest-------------------------------------------------------93
Safety Belt-----------------------------------------------------94
Pedal Area-----------------------------------------------------96
Sundries & Articles Storage---------------------------------98
CATALOGUE
Do It Yourself
Driver's Tools and Spare Wheel------------------------130
Changing wheels-----------------------------------------131
Trailer------------------------------------------------------132
Cab Tilting System---------------------------------------134
Common Errors and Solutions-------------------------139
Technical Data
Frequently-Used Vehicle Data ---------------------------149
Logo----------------------------------------------------------151
VIN-----------------------------------------------------------151
Operation
Overview
-1-
Operation
Overview
The general overview helps you to know instrument panels and control equipments.
Item
Description
Item
Description
1
Warm air outlet
8
Transmission shift handle
2
Horn button
9
Button switch control panel
3
Steering wheel
10
Ashtray
4
Combination instrument
11
Air conditioner control panel and LCD
5
Cruise control switch
12
Cigar lighter
6
Handle of hand brake valve
13
Cup seat
7
Handle of trailer hand brake valve
-2-
Operation
Combination Instrument CMIC
Item
1
2
3
4
5
Description
Speedometer
Engine tachometer
Engine water temperature gauge
Fuel gauge
Subsection mileage/Subsection mileage fuel
consumption reset button
Page No.
4
4
4
5
5
-3-
Item
6
7
8
9
Description
Air pressure gauge of brake circuit 1
Air pressure gauge of brake circuit 2
LCD
Alarm indicator
Page No.
5
34
34
35
Operation
Combination Instrument CMIC
Combination Instrument Function Instruction
1. Speedometer
The speedometer displays vehicle‟s running speed.
The speed will be zero if error occurs in the communication between tachograph and CPU, meanwhile the error indicating
massage will be displayed on the combination instrument screen.
The vehicle odometer and phase mileage information will be displayed on the lower right corner of screen.
2. Engine Tachometer
The engine tachometer displays engine rotating speed.
The needle will stay at the position which is +5° exceeding maximum when engine rotating speed is over scale range.
3. Engine Water Temperature Gauge
It displays the temperature of engine cooling water.
The alarm indicator of engine cooling water temperature will light up when temperature is over 95℃, meanwhile the serious
alarm indicator flashes and buzzer gives an alarm.
Notice:
In this case, stop and check the vehicle at once, otherwise it will cause loss of life and property!
-4-
Operation
Combination Instrument CMIC
4. Fuel Gauge
The fuel gauge displays fuel quantity in the fuel tank.
The fuel alarm indicator will light up when the fuel quantity is less than 1/8 of total fuel capacity in the fuel tank.
5. Subsection Mileage Fuel Consumption Reset Button
When vehicle is parking, press the button continuouslly more than 2 seconds, which is used to
reset subsection mileage/subsection mileage fuel consumption.
6. LCD
It displays many kinds of information, such as accumulative total mileage, subsection mileage,
time and so on. All the information is dispatched from CPU to combination instrument through
data bus and displayed on LCD.
According to display sequence and detail functions on LCD, the displaying contents of each
page is introduced as follows:
6.1. Logo
The logo “SINOTRUK” will be displayed within 1.5 second after key switch turns on. Please
refer to picture 6.1.
-5-
Picture 6.1
Operation
Combination Instrument CMIC
6.2. Normal Driving Information
Display vehicle information under normal driving, refer to picture 6.2
The contents are displayed as follows:
 Electric Source Voltage (Item 1, Item 2 in Picture 6.2)
Display electric source voltage in the form of figure on LCD, range: 0–32 V.
 Oil Pressure of Engine (Item 3, item 4 in Picture 6.2)
Display oil pressure in the form of figure on LCD as well.
Picture 6.2
 Transmission Gears Information (Item 5 and item 6 in Picture 6.2 )
When installed manual transmission, it shows N, R and blank on the Item 6 position which means neutral, reverse gear and
forward gear.
 Cruise Working Indicator (Item 10 in Picture 6.2)
When vehicle comes into cruise driving, it displays “CC”.
-6-
Operation
Combination Instrument CMIC
 Time (Item 11 in Picture 6.2)
Time displaying: The time will show tachograph‟s time if system connects with tachograph of VDO which connects chassis CPU
through CAN bus.
If tachograph of VDO is not equipped, the displayed time will be set by the customer after system electrifying.
 Accumulative Total Mileage of Vehicle (Item 13 in Pic. 6.2)
Display range: 0~9999999km.
 Subsection mileage (Item 14 in Picture 6.2)
Display range: 0~9999.9km.
If accumulative mileage exceeds displaying range or press subsection mileage/subsection mileage fuel consumption reset button
for 2 seconds, subsection mileage and subsection mileage fuel consumption will be reset.
Notice:
It is prohibited to disconnect battery with chassis CPU directly without turning off the key, otherwise the
data of single mileage will be lost.
-7-
Operation
Combination Instrument CMIC
6.3. Displaying Page of Working Information
It is used for displaying some system working information of vehicle, such as working indication of differential lock, lifting axle,
PTO and EVB, ect.
There are seven indication symbols displaying on the LCD, which is divided to display on two screens.
Displaying pages refer to picture 6.3 and picture 6.4:
Pic. 6.3
Pic. 6.4
-8-
Operation
Combination Instrument CMIC
Indicators Description in Illustration:
Item 1:Working indicator of interwheel differential lock
When interwheel differential lock is at the right place, the indicator symbol hushes on the LCD; otherwise, the
indicator symbol will flash.
Item 2:Working indicator of interaxle differential lock
When interaxle differential lock is at the right place, the indicator symbol hushes on the LCD. Otherwise, the indicator
symbol will flash.
Item 3: Working indicator of all-wheel driving
When all-wheel driving differential lock is at the right place, the indicator symbol hushes on the LCD. Otherwise, the
indicator symbol will flash.
Note:
When any indicator of Item 1-3 displaying on LCD, that shows, when switches of interwheel, interaxle
differential locks or all-wheel driving are off, the LCD will stay on this page.
Item 4: Working indicator symbol of lifting axle
When lifting axle works, the indicator will display on LCD.
Item 5: Working indicator of PTO magnetic valve
After PTO starts to work, the indicator symbol hushes on the LCD. Otherwise, the indicator symbol will flash.
Item 6: Working indicator of PTO on neutral
When PTO works on neutral gear, the indicator symbol hushes on the LCD.
-9-
Operation
Combination Instrument CMIC
Item 7: Working information indicator
It will display
, when differential lock, all-wheel driving, PTO, PTO neutral work and exhaust valve brake work.
Item 8: When the information could not display on one screen, the indicator of page down/page up will be
displayed on the LCD, it can be browsed by turning menu button.
When the current page is shown as picture 3.3 and some information is needed to display on picture 3.4, the indicator
will flash. Press down menu button and come to next screen.
When the current page is shown as picture 3.4 and some information is needed to be displayed on picture 3.3, the
indicator will appear and keep hushing. Press menu button and return to the first screen.
Item 9: Alarm indicator of oil-water separator.
When oil-water separator alarms, the indicator symbol begins to indicate.
Item 10: Working indicator of exhaust valve brake (EVB)
When exhaust valve brake works, the indicator symbol will display on LCD.
- 10 -
Operation
Combination Instrument CMIC
6.4. Vehicle Status Adjustment/ Checking the Page
It is used for entering into vehicle status adjustment/ checking page layout, as picture 6.5:
Picture 6.5 Vehicle status adjustment/ checking the page
Procedure:
1. Press the menu button and enter (as item 1 of picture 6.5):
2. Brightness adjustment of LCD (as item 2 of picture 6.5)
3. Fuel consumption situation (Refer to item 3 of picture 6.5) (It is only restricted to the vehicle with common rail engine).
4. Time adjustment (Refer to item 4 of picture 6.5)
- 11 -
Operation
Combination Instrument CMIC
 Brightness Adjustment of LCD
Turn menu knob until the background of Brightness adjustment of LCD turns to yellow, and then press menu button to enter
page shown as picture 6.6: Brightness adjustment of LCD (Item 1).
Pic. 6.6 Brightness Adjustment of LCD
The Brightness and columniation bar (Item 2) will increase or decrease as long as turning menu button to left or right, the
brightness reach maximum when the columniation bar is full.
- 12 -
Operation
Combination Instrument CMIC
When adjust to the brightness meets requirement, press menu button for one time (Item 3) to quit brightness adjustment. In
this case, the interface comes back to the page shown in picture 6.5, and the chosen brightness will be saved in the CBCU.
Before adjusting the brightness of LCD next time, the brightness saved before will be shown on the background.
When the small lamp is lights up, adjust the brightness of LCD, the background brightness of combination instrument and
brightness of tilting switch head lamp are adjusted in the same time.
Brightness adjustment mode would be cancelled if any switch of interaxle differential, interwheel differential or
all-wheel driving turns off, and the current brightness will be saved in CBCU.
 Fuel Consumption Situation (Picture 6.7)
It is used for displaying fuel consumption situation of vehicle with common rail engine only.
It will not display this interface if the vehicle is not equiped with common rail engine.
Item 1: Subsection mileage fuel consumption (Qtrip) display:
Press down reset button of subsection mileage /subsection mileage fuel
consumption on the combination instrument and keep two seconds, the
subsection mileage fuel consumption (Qtrip) will be reset.
Item 2: Engine total fuel consumption (Qtotal) display:
- 13 -
Pic. 6.7
Operation
Combination Instrument CMIC
Item 3: Hour fuel consumption display (Qinst)
Item 4: Fuel consumption (per 100km) display (Q100km):
When the value of Q100km is beyond 150 L/100 km, cancel display of fuel consumption (1/100km), hour fuel
consumption will display only.
 Time Adjustment
When system disconnects with VDO tachograph, enter time setting through operating menu knob.
Turn the menu knob to right until the background of time adjustment turns yellow, press down menu knob/switch and enter
time adjustment interface (Refer to picture 6.8).
Pic. 6.8
- 14 -
Operation
Combination Instrument CMIC
Press down the menu knob one time, enter into hour adjustment, and the hour position is flashing. Turn left to decrease, turn
right to increase; the adjustment range is displayed circularly within 0-23.
Press down menu knob one time as soon as the hour meets requirement, it will enter minute adjustment mode which is as same
as hour‟s. It is circled within 0-59. After adjusting in the right place, save it through pressing down menu knob referring to
showing, and exit. (Picture 6.9)
Pic. 6.9
Exit method:The adjustment mode will exit if any switch of interaxle differential, interwheel differential or all-wheel driving
turns off in this process, and the current time will be saved in the system.
The time setting interface will not be displayed if the VDO tachograph is installed and connected with CAN bus.
- 15 -
Operation
Combination Instrument CMIC
6.5. System Errors Information
The errors information will be displayed on the LCD when the system errors occur, such as sensor connecting error, lower brake
air pressure and overtime of CAN communication of engine, ABS (Refer to picture 6.10).
When new error occurs, it will displayed on LCD automatically.
Pic. 6.10 System error information
- 16 -
Operation
Combination Instrument CMIC
 Code Display Mode
For the system in support of CAN-DMI diagnosis function, the SPN code and FMI code of error information of AMT and ABS
systems will be displayed on the interface.
For the error information shown on the LCD, find out error source according to annex A ABS (WABCO) errors code table.
Pic. 6.11 ABS Error Code Display
Above picture 6.11 is the interface displaying ABS errors, when ABS errors occur.
- 17 -
Operation
Combination Instrument CMIC
Take the case of ABS, above displayed information shows that:
Item 1 ----ABS error: error source is ABS system;
Item 2 ----789: SPN code, error position will be sensor of left front wheel as per Agreement J1939;
Item 3 ---- 5: FMI code, error position will be lower electricity than requirement or open circuit as per Agreement.
 Words Displaying Mode (Picture 6.12)
The error information excepting getting by DMI diagnosis of CAN system will be displayed on the interface in the form of words.
All displayig error information will be ranked as per priority level, if many errors happen, the errors with high priority will be
displayed firstly such as the errors of brake, body safety and engine safety.
As per the error information shown on the LCD, find out error source and removing methods according to annex B System error
information and exit methods.
Pic. 6.12 Words displaying Mode
- 18 -
Operation
Combination Instrument CMIC
Item 1: The first error symbol;
Item 2: The text description of the first error. And it will be displaying on two rows if the information more than one row.
Item 3: The arrowhead of page up;
Item 4: The second error symbol;
Item 5: The text description of the second error. And it will be displaying on two rows if the information more than one row.
Item 6: The arrowhead of page down;
Item 3 will be displayed on the interface if the error information can not displayed on one page fully and not displayed on the
first page as well;
Item 6 will be displayed on the interface if the error information can not displayed on one page fully and not displayed on the
last page as well;
Item 3 and Item 6 will be displayed on the interface at one time if the error information displays on many pages and not
displayed on the first page or last page;
If error occurred is very serious, the serious error alarm indicator STOP will light up, and the buzzer alarms continuously when
engine is working.
Notice:
For this case, please stop and check the vehicle at once! Restart to drive after errords are sloved, or it will
cause loss of life and property!
- 19 -
Operation
Combination Instrument CMIC
Press down menu knob, the buzzer alarm sound will close for a while, but it will restart to alarm one minute later or new serous
error happened within one minute later on.
When common error happens, the alarm indicator lights up. Meanwhile, if the following error happens with engine operating,
the buzzer alarm ten times in the form of one time per second.
After removing all errors, the buzzer will be silent, and symbols of all error information will disappear.
The alarm interface will return back to normal driving interface.
6.6. System Operation
Sleep mode means that the CBCU is under power saving status, and system does not work.
Operating mode means that CBCU is under working status, the program and all connectors are working.
There are three waken methods, different signal with different waken object, details as following:
Signals
Key switch
Emergency alarm switch
Lighting switch
Waking objects
CBCU
CMIC
VDR/MTCO
MCU
√
√
√
√
√
√
√
X
X
√
X
X
- 20 -
Operation
Combination Instrument CMIC
 Key Switch Wake-up
In this case, all the system willl be activated, electrify to self-check and LCD lights up.
All the system starts to work, the communication connections between them will be established and the vehicle enters driving
status if connected with ABS or common rail engine.
 Emergency Alarm Switch Wake-up
Under the condition that the key switch close and the emergency alarm switch turn on only, body central computer will be
waken up partly and the LCD of instrument does not work, in this case, the emergency alarm, that is, steering lamps light up.
 Lighting Switch Wake-up
When the key switch is off and lighting switch is on, function of CBCU will be wakened partly, and the lamps controlled by
lighting switch are working such as position lamp, height lamp, side indicator, instrument backlighting and switch indicator.
Turn-on and turn-off voltages of emergency alarm switch wake-up and lighting switch wake-up can be defined by program.
Key switch delays 1 second after closed, the system will return to sleeping status which makes sure all systems exit working
status safely.
- 21 -
Operation
Combination Instrument CMIC
6.7. System Electrify and Self-checking
When the key switch is at the ON position, that is, bus system will self-check after KL15 turning on. After that, all parts will
operate as following:
All instruments: Every instrument finger starts from mechanism terminal, and rotate to scale span within 2 seconds. Later on,
the odometer and engine tachometer return to zero position, and air pressure gauge, fuel gauge and water temperature gauge
show the real value of current system.
All indicators: All indicators will light up for one second, and then return to real condition.
LCD: Interval of two seconds, it displays SINOTRUK logo firstly and then displays normal driving interface (displays voltage and
oil pressure).
After self-checking, if any switch of interaxle differential, interwheel differential lock switch and all-wheel driving switch is on, the
differential lock indicator interface will be displayed;
If above mentioned differential locks are not engaged and error happenes, the interface will enter into error information page;
If the two situations above mentioned do not exist, but the working indicator symbols of other indicator interface is working, the
system will switch to indicator interface.
If above mentioned three situations do not appear, the system will stay on normal driving interface.
- 22 -
Operation
Combination Instrument CMIC
6.8. System Turn-off
If the system is activated by emergency alarm switch or lighting switch, it will return to sleeping status after switch is off.
Disconnect switch, the system will delay for one second to return to sleeping status.
In this case, all working loads are off, and the instrument fingers go back to zero position, the instrument backlighting will be
off.
Notice:
It is strictly prohibited to cut off electric circuit connection between battery and body center computer under
unclosing key switch or other input power with wake-up function!
Otherwise, all components including the system control units, wire harness and electronic components of whole vehicle may be
damaged, and system data may be lost and down to cause vehicle unavailable!
- 23 -
Operation
Combination Instrument CMIC
6.9. LCD Menu and Interface Operation
Only one menu is displayed on the LCD every time. But the needed content is more than one item, so it is needed to switch
between them.
Turn the menu knob to right to browse downwards;
Turn the menu knob to left to browse upwards;
When the displayed differential lock information is more than one screen, press down menu knob to display next information, all
information can be displayed in turns.
If the screen is not enough to display needed error information, turn menu knob to right or left to display more information.
Notice:
When entering error information interface and other information interfaces, it will display from the very
beginning every time.
After system electrifying and self-checking, interface displays in priority order.
1. Display differential lock information as long as differential lock starts to work, and other interface will exit immediately
including error information, backlighting adjustment, time adjustment mode and so on;
2. If it is not under the first status, and new error happened, the error information will be displayed on the interface immediately
after ending of lighting adjustment or time adjustment (if it is under this status);
- 24 -
Operation
Combination Instrument CMIC
3. If it is not under the first and second statuses, and new working information happened, the working information will display
on the interface immediately after ending of lighting adjustment or time adjustment (if it is under this status);
4. If the second and third happens simultaneously, it will display 3 one minute after 2 is displayed.
5. If above mentioned does not exist, it will display normal driving information;
6. Excepting description mentioned in item 1 and 4 and under no any operation, all interfaces will return to normal driving
interface after delaying one minute.
- 25 -
Operation
Combination Instrument CMIC
Annex B Displayed Error Information and Failure Recovery Methods
Error Source
Display Content on LCD
Symbol
Wording Information
Brake Circuit 1
Air pressure in brake circuit 1 is low
Brake Circuit 2
Air pressure in brake circuit 2 is low
Assistant Air
Air pressure in auxliary air is low
Error Cause and Failure Recovery Methods
The air pressure of air reservoir is lower than 5.5x 0.1Mpa
(5.5bar).
When engine is working, the temperature of cooling water
is higher than 95℃.
Please check engine cooling system.
When engine is working, the engine oil circuit pressure is
less than 0.6 x 0.1Mpa (0.6bar).
Engine Water
Temperature
Engine water temperature is high
Engine Oil Pressure
Engine oil pressure of is low
Engine Overspeed
Engine overspeed
The engine speed is over 2600 rpm for five seconds.
Fuel Height
Low fuel level in fuel tank
The rest of
capacity.
Oil Filter
Oil filter is jammed
Oil filter is jammed, please check and maintain oil fuel filter.
Fuel Filter Jam
Fuel filter is jammed
Fuel filter is jammed, please check and maintain fuel filter.
Air Filter
Air filter is jammed
Air filter is jammed, please check and maintain air filter.
- 26 -
fuel of fuel tank is less than 1/8 of total
Operation
Combination Instrument CMIC
Battery And Generator
Generator can not charge.
The voltage at end of “D+” is lower than 24V after generator operation.
Failure reasons: generator error or connection error.
Cab
Cab is unlocked
Cab is unlocked. The cause is that cab is unlocked or wire harness error.
Cab Unlocking
Cab door is unlocked
Cab door is not locked well on running.
Air Pressure Sensor
(Brake Circuit 1)
Air pressure sensor error
in brake circuit 1
Air Pressure Sensor
(Brake Circuit 2)
Air pressure sensor error
in brake circuit 2
Water Temperature Sensor
Engine water temperature
sensor error
Oil Pressure Sensor
Engine oil pressure sensor
error
Oil Level Sensor
Fuel level sensor error
Engine Communication Error
Engine communication
error
ABS Communication Error
ABS communication error
Tachograph
Tachograph error
The numerical value of resistance of sensor installed on brake circuit 1 is
over normal range (open circuit of sensor) or connection error. Please
measure sensor and check connection.
The numerical value of resistance of sensor installed on brake circuit 2 is
over normal range (open circuit of sensor) or connection error. Please
measure sensor and check connection.
The numerical value of resistance of water temperature sensor installed on
engine is over normal range (open circuit of sensor) or connection error.
Please measure sensor and check connection.
The numerical value of resistance of oil pressure sensor installed on engine
isover normal range (open circuit of sensor) or connection error. Please
measure sensor and check connection.
The numerical value of resistance of water temperature sensor installed on
fuel tank over normal range (open circuit of sensor) or connection error.
Please measure sensor and check connection.
If disconnect communication between engine and center computer, this
error will display the information. Check CAN line and ECU of engine.
If disconnect communication between ABS and center computer, this error
will display. Check CAN line and ECU of ABS.
If disconnect communication between tachograph and center computer,
this error will be displayed. Check CAN line and tachograph.
- 27 -
Operation
Combination Instrument CMIC
System Voltage
of Whole
Vehicle
voltage is high
Voltage is low
Voltage Error of
the Sixth Group
G6 power error
(CBCU power)
Voltage Error
Of The Fifth
Group
G5 power error
(CBCU power)
Voltage Error of
The Forth Group
G4 power error and
menu knob disabled
Voltage Error of
The Third Group
G3 power error
(CBCU power)
Voltage Error of
The Second
Group
G2 power error
(CBCU power)
Voltage Error of
The First Group
G1 power error
(CBCU power)
The voltage is higher than 31.5 V which is over normal permitted working voltage of electric
system. It maybe damage electricity components. Please check generator, charging circuit and
battery.
The voltage is lower than 20 V which maybe cause some system can not work normally. And
maybe damage electricity components. Please check generator, charging circuit and battery.
The voltage of the sixth group is lower than system voltage. The circuit and fuse connected the
second hole of plug-in 1 (total nine holes) of body center computer and power.
Note: when error occurs, the load connected with this group power will be affected and
unavailable.
The voltage of the fifth group is lower than system voltage. The circuit and fuse connected the
eighth hole of plug-in 1 (total nine holes) of body center computer and power.
Note: when error occurs, the load connected with this group power will be affected and
unavailable.
The voltage of the fourth group is lower than system voltage. The circuit and fuse connected the
eighth hole of plug-in 5 (total nine holes) of body center computer and power. In this case,
menu knob disabled, please press menu knob instead of ratating.
Note: when error occurs, the load connected with this group power will be affected and
unavailable.
The voltage of the third group is lower than system voltage. The circuit and fuse connected the
second hole of plug-in 5 (total nine holes) of body center computer and power.
Note: when error occurs, the load connected with this group power will be affected and
unavailable.
The voltage of the second group is lower than system voltage. The circuit and fuse connected
the sixth hole of plug-in 6 (total fifteen holes) of body center computer and power.
Note: when error occurs, the load connected with this group power will be affected and
unavailable.
The voltage of the first group is lower than system voltage. The circuit and fuse connected the
tenth hole of plug-in 6 (total fifteen holes) of body center computer and power.
Note: when error occurs, the load connected with this group power will be affected and
unavailable.
- 28 -
Operation
Combination Instrument CMIC
Washing Motor
Washing motor error
Conducting wire from center computer to washing motor is short circuit to the ground,
please check the circuit.
Braking lamp is short circuit Press down brake pedal, if the lamp does not light and displays the error information, it
to the ground
means short circuit. Check the circuit connected this lamp.
Tractor Truck
Braking Lamp
Braking lamp overload
Braking lamp is open circuit.
Press down brake pedal, if the braking lamp light up and display the error, it means the
power of the lamp over permitted power range(30-54w). Check the lamp and examine
whether the power meets the requirement or not.
Press down brake pedal, if displays the error, it means that the power of lamp is not in
permitted range. Check lamp and circuit, examine whether the power meets the
requirement and connection good or not.
Braking lamp is short circuit After connecting trailer, press down brake pedal, if the lamp does not light and display
to the ground
the error information, it means short circuit. Check the circuit connected this lamp.
Trailer Braking
Lamp
Braking lamp overload
Braking lamp is open circuit.
Tractor Truck
Left-front And
Left-rear Steering
Lamps
Left-front and left-rear
steering lamps are short
circuit to the ground.
Left-front and left-rear
steering lamps overload
After connecting trailer, press down brake pedal, if the braking lamp light up and display
the error, it means the power of the lamp over permitted power range (30-54w). Check
the lamp and examine whether the power meets the requirement or not.
After connecting trailer, press down brake pedal, if display the error, it means that the
power of lamp is not in permitted range. Check the lamp and circuit, examine whether
the power meets the requirement and connection good or not.
If turn on left steering switch or emergency alarm switch and display error information
on the LCD, it means short circuit. Please check circuit and lamp.
Turn on left steering switch or emergency alarm switch, if steering lamp light up, but
display error information on LCD, it means the power of the lamp over permitted power
range (30-54w). Examine whether the power meets the requirement or not.
- 29 -
Operation
Combination Instrument CMIC
Left-front And
Left-rear Steering
Lamps
Left-middle
Steering Lamp Of
Main Vehicle
Left-front and left-rear
steering lamps are
open circuit.
Turn on the left steering switch or emergency alarm switch, if steering lamp lights up, but
displays error information on LCD, it means that the power of lamp connected is lower than
permitted power range (30-54w). Check the lamp power and connections whether they meet
requirement or not.
Left-middle steering
lamp is short circuit to
the ground.
If turn on left steering switch or emergency alarm switch and displays error information on LCD,
it means short circuit. Please check the circuit and lamp.
Left-middle steering
lamp overloads
Left-middle steering
lamp is open circuit
Left-side Steering
Lamp Of Trailer
Trailer left-side
steering lamp is short
circuit to the ground.
Trailer left-side
steering lamp
overloads
Trailer left-side
steering lamp is open
circuit.
Right-front And
Right-rear
Steering Lamp
Right-front and
right-rear steering
lamps are short circuit
to the ground.
Right-front and
right-rear steering
lamps overload.
Turn on the left steering or emergency alarm switch, if steering lamp lights up, but displays error
information on LCD, it means that the power of lamp connected exceeds the permitted power
range (15-27w). Check the lamp power whether it meets regulated power or not.
Turn on the left steering switch or emergency alarm switch, if steering lamp lights up, but
displays error information on LCD, it means that the power of lamp connected is lower than the
permitted power range (15-27w). Check the lamp and circuit, examine the power and
connections whether the power meets regulated power and connections are good or not.
If turn on left steering switch or emergency alarm switch and displays error information on LCD,
it means short circuit. Please check the circuit and lamp.
Turn on the left steering switch or emergency alarm switch, if steering lamp lights up, but
displays error information on LCD, it means the power of lamp connected exceeds the permitted
power range (15-180w). Check the lamp power whether it meets regulated power or not.
Turn on the left steering switch or emergency alarm switch, if steering lamp lights up, but
displays error information on LCD, it means that the power of lamp connected is lower than the
permitted power range (15-180w). Check the lamp and circuit, examine the power and
connections whether the power meets regulated power and connections are good or not.
If turn on left steering switch or emergency alarm switch and displays error information on LCD,
it means short circuit. Please check the circuit and lamp.
Turn on the left steering switch or emergency alarm switch, if steering lamp lights up, but
displays error information on LCD, it means the power of lamp connected exceeds the permitted
power range (30-54w). Check the lamp power whether it meets regulated power or not.
- 30 -
Operation
Combination Instrument CMIC
Tractor Truck
Right-front And
Right-rear
Steering Lamps
Right-front and
right-rear steering
lamps are open circuit.
Right-middle steering
lamp is short circuit to
the ground.
Tractor Truck
Right-middle
Steering Lamp
Right-middle steering
lamp overloads
Right-middle steering
lamp is open circuit
Trailer Right-side
Steering Lamp
Trailer right-side
steering lamp is short
circuit to the ground.
Trailer right-side
steering lamp
overloads
Trailer right-side
steering lamp is open
circuit.
Rear fog lamp is short
circuit to the ground
Tractor Truck
Rear Fog Lamp
Rear fog lamp overload
Turn on the right steering switch or emergency alarm switch, if steering lamp lights up, but
displays error information on LCD, it means the power of lamp connected is lower than permitted
power range (30-54w). Check the lamp power and connections whether they meet requirement
or not.
If turn on right steering switch or emergency alarm switch and displays error information on LCD,
it means short circuit. Please check the circuit and lamp.
Turn on the right steering switch or emergency alarm switch, if steering lamp lights up, but
displays error information on LCD, it means the power of lamp connected exceeds the permitted
power range (15-27w). Check the lamp power whether it meets regulated power or not.
Turn on the right steering switch or emergency alarm switch, if steering lamp lights up, but
displays error information on LCD, it means that the power of lamp connected is lower than the
permitted power range (15-27w). Check the lamp and circuit, examine the power and connections
whether the power meets regulated power and connections are good or not.
If turn on right steering switch or emergency alarm switch and displays error information on LCD,
it means short circuit. Please check the circuit and lamp.
Turn on the right steering switch or emergency alarm switch, if steering lamp lights up, but
displays error information on LCD, it means the power of lamp connected exceeds the permitted
power range (15-180w). Check the lamp power whether it meets regulated power or not.
Turn on the right steering switch or emergency alarm switch, if steering lamp lights up, but
displays error information on LCD, it means that the power of lamp connected is less than the
permitted power range (15-180w). Check the lamp and circuit, examine the power and
connections whether the power meets regulated power and connections are good or not.
Turn on the switch of small lamp, front and rear fog lamp, if the lamps can not light up and
displays the error information on LCD, it means short circuit. Check the circuit connected to the
lamp.
Turn on the switch of small lamp, front and rear fog lamp, if the lamps light up and displays the
error information on LCD, it means that the power of lamp connected goes beyond the permitted
power range (30-54 w).
Check the lamp and examine the power whether it meets requirement or not.
- 31 -
Operation
Combination Instrument CMIC
Tractor Truck
Rear Fog Lamp
Tractor Truck
Front Fog Lamp
Rear fog lamp is open
circuit.
Turn on the switch of small lamp, front and rear fog lamps, if displays the error information, it
means that the power of lamp is not in the permitted power range. Check the lamps and
connections, examine whether the power meets requirement and connections are good or not.
Front fog lamp is
short circuit to the
ground.
Turn on the switch of small lamp and front fog lamp, if the lamp can not light up and displays
the error information, it means short circuit. Check the circuit connected to the lamp.
Front fog lamp
overloads.
Front fog lamp is
open circuit.
Rear fog lamp of
trailer is short circuit
to the ground.
Trailer Rear Fog
Lamp
Trailer rear fog lamp
overloads.
Trailer rear fog lamp
is open circuit.
Distance
Headlamp
Dipped
Headlamp
Relay of distance
headlamp is short
lamp to the ground.
Dipped headlamp is
short circuit to the
ground.
Dipped headlamp
overloads.
Turn on the switch of small lamp and front fog lamps; if the lamp lights up and displays error
information, it means that the power of the connected lamp is beyond the permitted power
range (98-182w). Check the lamp and examine whether the power meets requirement or not.
Turn on the switch of small lamp and front fog lamp, if displays the error information, it means
that the power of lamp is not in the permitted power range. Check the lamp and connections,
examine whether the power meets the requirement and connections are good or not.
Turn on the switch of small lamp, front and rear fog lamps, if the lamp can not light up and
displays the error information, it means short circuit. Check the circuit connected to the lamp.
Turn on the switch of small lamp, front and rear fog lamps, if the lamp lights up and displays
error information, it means the power of the connected lamp is beyond the permitted power
range (30-54w). Check the lamp and examine whether the power meets requirement or not.
Turn on the switch of small lamp, front and rear fog lamps, if displays the error information, it
means that the power of lamp is not in the permitted power range. Check the lamp and
connections, examine whether the power meets the requirement and connections are good or
not.
Turn on the switch of distance headlamp, if displays the error information, it means short circuit
between center computer and relay. Check the circuit and relay.
Turn on the light switch with II gear and the light locates dipped light position, the lamp can not
light up and display the error information, it means short circuit. Check circuit connected to
lamp and lamp.
Turn on the light switch with II gear and the light locate dipped light position, the lamp lights up
and displays the error information, it means the power of lamp is beyond the permitted power
range (126-234w). Check the lamp, examine whether the power meets the requirement or not.
- 32 -
Operation
Combination Instrument CMIC
Dipped Headlamp
Dipped headlamp is open
circuit.
Reversing lamp is short
lamp to the ground.
Tractor Truck
Reversing Lamp
Reversing lamp overloads.
The lamp is open circuit.
Trailer reversing lamp is
short circuit to the ground.
Trailer Reversing
Lamp
Trailer reversing lamp
overloads.
Trailer lamp is open circuit
Lamp Switch
Switch lamp is short lamp
to the ground.
Turn on the light switch with II gear and the switch locates dipped light position, and
displays the error information, it means the power of lamp is not in the permitted power
range. Check the lamp and circuit, examine whether the power meets the requirement
and connections are good or not.
Turn on with the key located on reversing gear position, the reversing lamp can not light
up and display the error information, it means short circuit. Check the lamp and circuit
connected the lamp.
Turn on with the key located on reversing gear position, the reversing lamp light up and
displays the error information, it means that the power of lamp is beyond the permitted
power range (30-54w). Check the lamp, examine whether the power meets requirement
or not.
Turn on with the key located on reversing gear position, and displays the error
information, it means that the power of lamp is not in the permitted power range. Check
the lamp and circuit, examine whether the power meets the requirement and connections
are good or not.
Turn on with the key located on reversing gear position, when the trailer connected, the
trailer reversing lamp can not light up and displays the error information, it means short
circuit. Check the lamp and circuit connected the lamp.
Turn on with the key located on reversing gear position, when the trailer connected, the
reversing lamp light up and display the error information, it means that the power of lamp
is beyond the permitted power range (30-54w). Check the lamp, examine whether the
power meets requirement or not.
Turn on with the key located on reversing gear position, when the trailer connected, if
displays the error information, it means that the power of lamp is not in the permitted
power range. Check the lamp and circuit, examine whether the power meets the
requirement and connections are good or not.
Turn on the key and when turn on the switch of small lamp, switch lamp can not light up
and displays the error information, it means short circuit. Check the lamp and circuit
connected the lamp.
- 33 -
Operation
Combination Instrument CMIC
Left-side position is
short circuit to the
ground.
Tractor Truck
Left Position
Lamp
Left-side position
overloads.
Left-side position lamp
is open circuit.
Right-side position
lamp is short circuit to
the ground
Tractor Truck
Right Position
Lamp
Right-side position
overloads.
Right-side position
lamp is open circuit.
Trailer Position
Lamp Reply
Trailer position lamp
relay is short circuit to
the ground.
Turn on the key and when turn on the switch of small lamp, left-side position lamp
(including flank lamp, height lamp, position lamp and license plate lamp) can not light up
and display the error information, it means short circuit. Check the lamp and circuit
connected the lamp.
Turn on the key and when turn on the switch of small lamp, left-side position lamp
(including flank lamp, height lamp, position lamp and license plate lamp) light up and
displays the error information, it means that the power of lamp is beyond the permitted
power range. Check the lamp, examine whether the power meets requirement or not.
Turn on the key and when turn on the switch of small lamp, if displays the error
information, it means that the power of lamp is not in the permitted power range. Check
the lamp and circuit, examine whether the power meets the requirement and
connections are good or not.
Turn on the key and when turn on the switch of small lamp, right-side position lamp
(including flank lamp, height lamp, position lamp and license plate lamp) can not light up
and displays the error information, it means short circuit. Check the lamp and circuit
connected the lamp.
Turn on the key and when turn on the switch of small lamp, left-side position lamp
(including flank lamp, height lamp, position lamp and license plate lamp) light up and
displays the error information, it means that the power of lamp is beyond the permitted
power range (35-60w). Check the lamp, examine whether the power meets requirement
or not.
Turn on the key and when turn on the switch of small lamp, if displays the error
information, it means that the power of lamp is not in the permitted power range. Check
the lamp and circuit, examine whether the power meets the requirement and
connections are in good condition.
When displaying the error, please check the circuit and relay.
- 34 -
Operation
Combination Instrument CMIC
Other Error Analysis of Bus System Between Instrument or CBCU:
a) When connection is disconnected, and error already exists, the contents will display three seconds on the LCD of instrument,
STOP will flash three minutes and backlight is up.
b) If error already exists before starting the key switch, instrument can not light up, while lamps work, it means that the CBCU is
normal, please check instrument or circuit connections.
c) Under normal connections, if all in-out does not work, please check CBCU.
7. Air pressure gauge of brake circle 1
8. Air pressure gauge of brake circle 2
It is used for display air pressure value of brake circle 1 and brake circle 2.
When any alarm switch of air pressure circles connects (the air pressure of brake circle less than 5.5x0.1 MPa), the lower air
pressure alarm indicator will light up, in the meanwhile, the serious alarm indicator lights up as well, and the buzzer will alarm
during running.
Notice:
In this case, stop and check the vehicle at once, otherwise it will cause loss of life and property!
- 35 -
Operation
Combination Instrument CMIC
9. Indicators
Signal lamp symbol and function:
Code
Description
Color
Code
1
2
3
4
5
6
7
8
9
10
11
12
Left steering indicator
Right steering indicator
Oil pressure alarm indicator
Low air pressure alarm indicator
Parking brake indicator
Trailer steering indicator
Safety belt alarm indicator
High water temperature alarm indicator
Charging indicator
High beam indicator
Front fog lamp indicator
Rear fog lamp indicator
Green
Green
Red
Red
Red
Green
Red
Red
Red
blue
Green
Yellow
13
14
15
16
17
18
19
20
21
22
23
- 36 -
Description
Serous alarm indicator
Preheat working indicator
Fuel lower level alarm indicator
Air filter plug alarm indicator
Cab unlocking alarm indicator
Engine error indicator
Transmission lower gear range indicator
Common alarm indicator
Tractor truck ABS indicator
Trailer ABS indicator
ASR indicator
Color
Red
Yellow
Yellow
Yellow
Red
Yellow
Green
Yellow
Yellow
Yellow
Yellow
Operation
Combination Instrument CMIC
1. Left steering indicator
2. Right steering indicator
Left-side or right-side steering indicator will flash according to steering signal, the flash frequency of indicator will be around two
times than normal situation if one of steering lamp meets errors. All the steering lamps and left/right side indicators will flash
when press down alarm indicator switch.
3. Lower oil pressure alarm indicator
This lamp will light up when the engine oil pressure is low. In this case, stop the vehicle and engine, check immediately or
contact with local service station to maintain if it is necessary.
4. Lower air pressure alarm indicator
This lamp will light up when the brake air pressure is lower. Contact with local service station to maintain if it is necessary.
5. Parking brake indicator
This lamp will light up when the vehicle stops and turn on the hand brake switch.
6. Trailer steering indicator
The green lamp will light up when turn on trailer steering indicator; this lamp will display with continuouslly flash as long as the
lamp meets errors.
7. Safety belt alarm indicator
This lamp will light up with alarm, if driver does not fasten safety belt after starting.
- 37 -
Operation
Combination Instrument CMIC
8. Higher water temperature alarm indicator
This lamp will light up when the water temperature is high, for the time being, stop the vehicle and check water level of engine.
Contact with local service station to maintain if it is necessary.
9. Charging indicator
When the generator works with normal situation, the lamp is off; when the generator meets errors, the lamp will light up.
10. High beam indicator
This lamp will light up when turn on the headlamp switch and distance lamp switch.
11. Front fog lamp indicator
The green lamp will flash when turn on the front fog lamp indicator; this lamp will display with continuouslly flash as long as the
lamps meet errors.
12. Rear fog lamp indicator
The yellow lamp will flash when turn on the front fog lamp indicator; this lamp will display with continuouslly flash as long as the
lamps meet errors.
13. Serious alarm indicator
This lamp will light up when the vehicle meets serious errors. For the time being, stop vehicle and check, contact with local
service station to maintain if it is necessary.
- 38 -
Operation
Combination Instrument CMIC
14. Preheating indicator
When turn on starting switch to start the engine, the lamp will light up to preheat the engine; and the lamp will be off after
engine starting.
15. Low fuel level alarm indicator
This lamp will light up when the fuel level of fuel tank is low. In this case, supply the fuel to fuel tank.
16. Air filter plug alarm indicator
The lamp will light up when much dust on filter lead to air intake blocked. Clean the filter or change it.
17. Cab unlocking alarm indicator
This lamp will light up when the door unlock. In this case, lock the door again.
18. Engine error indicator
This lamp will light up when engine meets errors. In this case, stop the vehicle and check, contact with the local service station
to maintain if it is necessary.
19. Transmission lower speed range indicator
This lamp will light up when the transmission is on lower speed range (1~4 gear).
20. Common alarm indicator
This lamp will light up when the vehicle meets common errors. In this case, stop the vehicle and check, contact with the local
service station to maintain if it is necessary.
- 39 -
Operation
Combination Instrument CMIC
21. Tractor truck ABS indicator
The ABS system will operate when the tractor truck brakes. This lamp will light up when the ABS system meets errors.
22. Trailer ABS indicator
The ABS system will operate when the trailer brake. This lamp will light up when the ABS system meets errors.
23. ASR indicator
The ASR system will operate when the vehicle slide during starting or accelerating. This lamp will light up when the ABS system
meets errors.
- 40 -
Operation
Combination Instrument CMIC
- 41 -
Operation
Tilting Switch Symbol
Roller switches and function illumination
(Including indicators. It is invalid when the key switch is on 1 gear, unless specified description)
Item
1
Description
Distance Lamp
Switch
Status Function
0
1
Off
On
0
Off
2
Interwheel
Differential
1
On
3
Front Fog Lamp
Switch
0
1
Off
On
0
Off
1
On
0
Off
1
On
0
Off
1
On
0
Off
1
On
4
Interaxle
Differential
5
Rear Fog Lamp
Switch
6
Working Lamp
Switch
7
Serious Alarm
Switch
Remarks
Interwheel differential magnetic valve will be driven, and the indicator will be
flash until interwheel differential switch put in right place, the indicator light up
completely.
Precondition: Shift 1 of lighting switch have been turned on.
Interaxle differential magnetic valve will be driven, and the indicator will be flash
until interwheel differential switch put in right place when the indicator light up
fully.
Precondition: 1) Shift 1 of lighting switch have been turned on, front fog lamp
have been turned on also; or 2) Shift 2 of lighting switch have been turned on.
Working lamp driven
1,2,3,4 shifts of key switch are available.
- 42 -
Operation
Tilting Switch Symbols
8
ECU diagnostic
switch
9
Horn transferring
switch
10
ABS Checking
switch
11
Screen
adjustment
button
0
Off
1
0
On
Electric horn
Press horn button on the steering wheel
1
Air horn
Press horn button on the steering wheel
0
1
Notice:
After pushing the interaxle diff-lock switch, the lamp will flash, if there is feedback signal from
interaxlediff-lock switch within 5 seconds, the lamp for interaxle diff-lock will be on; if there is no
feedback signal, check driving output of interaxle diff-lock magnetic valve, and if the output is normal,
the lamp will be on.
- 43 -
Operation
Main Switch
Key
The main switch is at outside of battery box on right side
member.
Notice:
Switch off if out of using for long time to avoid
accident.
The key is on the steering pillar.
Position
Purpose
1(ACC)
Launch the facilities of parking
2 (LOCK)
Power cut
3 (ON)
4 (START)
1- Main switch
- 44 -
Remarks
Key may be removed
Driving
Start engine
Return to position 3
automatically
Operation
Unlock/Lock the Vehicle with Key
Operation on Door
Warning:
Driving without door locked is forbidden!
Use the Door Lock from Outside
Open the door: When the door is not locked, pull down the handle to open the
door; if the door is locked, insert the key and turn 180°anticlockwise, then pull
the handle to open.
Lock the door: Insert the key and turn 180°clockwise.
① Lock
Use the Door Lock from Inside
② Unlock
Open the door: Turn the handle and push the door to open.
Lock the door: Close the door. If push the lock switch, door can not be opened from outside.
- 45 -
① Locking handle
② Locking switch
Operation
Manual Glass Lifter
Radio with USB Connection
Manual Glass Lift:
Turn the handle to lift or decline the glass.
Radio with USB Connection
Notice:
1. Adjust volume not to disturb your hearing others’
horn.
2. To avoid short circuit, please connect cathode of
battery after connecting the equipment.
- 46 -
Operation
Radio with USB Connection
Panel Instruction
Sound Adjustment
1 Power supply switch
○
2 ,○
3 Channel search, USB playing chooser
○
4 SEL button, sound mode
○
5 ,○
6 ,○
7 ,○
9 ,○
10 ,○
11 Settings
○
○8 USB socket
12 DSP sound resource setting
○
13 AUX button
○
14 Reset
○
15 AST auto searching and saving
○
16 SRC USB/AUX shifting
○
17 BND change to FM/AM
○
18 LCD screen
○
On/Off
Volume
Sound and EQ mode
Button 1
Button 1
Button 4
Notice:
Operate within 2 seconds after chosen the mode, or
it will turn back to volume control.
Radio
BND, button 14, shift between FM and AM
Auto searching: Press button 2 or 3 till channel received. Press
again for next searching.
- 47 -
Operation
Radio with USB Connection
Auto searching-pressing button 2 or 3 more than 2 seconds ( at least two seconds) will shift to manual searching. Change one
frequency point with one press, and it will change to short pressing mode with no operation during 3 seconds.
Auto channel saving (AST)-Button 15. Channels will be saved by setting button 1-6.
Settings buttons (1-6)-Turn to the wanted channel and press relevant setting button at least two seconds to save the channel.
USB Playing
Connection-Insert flash memory and press SRC 16 button to shift to USB mode.
File Type -Sound file is *.mp3; Storage type is FAT16 and FAT32 in segments; bit speed is 8-320kbps.
Quick choosing-Press one combination of 1-6 or any one of them quickly, it will play automatically after 3 seconds;
shortly press any one of 1-6, for instance 2, it will play the second song; press channel button 2 or 3, you can
choose previous or next song.
Notice:
Please remove the flash memory after turning off.
- 48 -
Operation
Tachograph
Operation Method
The tachograph will be on automatically when the voltage
between power line and ground is above 9V and applicable
voltage scope is 9~36V.
Operation and Displaying
Generally, the tachograph shows time and speed.
There 4 buttons: menu, upward, downward and print. Menu button is for page down of the screen. 'Upward' and 'downward'
buttons are to show the information which is out of one screen. 'Print' button is for printing the information.
Press „menu‟ button, the screen will show the average speed within 15 mins before parking, press upward and downward, you
can check suscessively:
1. Real Time and Speed
2. Average Speed Within 15 Mins Before Parking
3. Fatigue Driving Record
4. Driver‟S Code
5. Driving License Number
6. Excessive Alarm Speed
7. Vehicle Character Coefficient
8. Total Mileage And Subsection Mileage
9. Record Index and Parking Index
10. Serial No. Of Tachograph and Software Version.
- 49 -
Operation
Tachograph
Printing
When under parking, press „print‟ button to print data according to operation shown on screen.
Notice:
1. No printing when driving.
2. It always prints data of current driver and no recognition of drivers.
Specification Settings
IC card is for recognizing drivers and position of tachograph.
Notes: when inserting the IC card, make the CMOS chip upward and quickly insert or remove.
Vehicle character coefficient settings: insert the IC card and the screen will show „vehicle coefficient settings: 624‟, then press
„upward‟ and „downward‟ to adjust the value. Remove the IC card when comes to the needed value and the settings will be
saved. Excessive speed and time can be set as well in the time way.
- 50 -
Operation
Air Conditioner
1. Controller
1.1 Panel:
① Screen
② Wind power adjuster
③ Defrost wind directions:
head, foot, foot defrost and defrost.
④ Air inlet mode select: circulatory selecting
⑤ Power off
⑥ Auto
⑦ Wind mode select:
head, foot, foot defrost and defrost.
⑧ Cooling
⑨ Temperature settings
1.2 Screen Showing
① Wind power
② Air inlet
③ Wind mode
④ Set temperature and real temperature
⑤ Aeration
⑥ Cooling
- 51 -
Operation
Air Conditioner
2. Instruction
2.1 Set Needed Inside Temperature
Adjust the button to your needed temperature with scope „LO‟, „18℃--29℃‟ and „HI‟. „LO‟ to make cooler and „HI‟ to make warmer.
Notes: Normally 22℃~26℃ is better.
2.2 Wind Power Setting
Wind power can be set manually or automatically.
Notice:
Totally nine (9) grades of wind power and changes slowly after you pressing the button.
2.3 Night Vision Function
Turn on small lamp, the buttons‟ symbol can be shown as other symbols.
2.4 Wind Mode Selecting
Four (4) modes can be selected by wind mode button and defrost button.
- 52 -
Operation
Air Conditioner
2.5 Air inlet mode selecting
Inside circulation can be adopted within short time in following cases:
 In hot weather, quickly reduces temperature inside.
 In cold weather, quickly rises temperature inside.
 Bad air outside, for instance dusty or smelly.
3. Notice
3.1 Termly maintain A/C.
3.2 Clean the panel with soft and dry cloth. Wet and hard cloth may cause damages to panel, buttons and screen.
3.3 Do not touch the screen with finger, hard or grease things to cause the screen displays unclearly.
3.4 Refrigerant filling port is on compressor and pipe. Please contact technician if the refrigerant is insufficient. When refrigerant is
insufficient, white foam can be seen from window; when refrigerant is sufficient, colorless liquid can be seen.
3.5 If defect occurs to the system, please contact with technician.
- 53 -
Operation
Steering Indicator and Alarm
1. Steering Indicator:
①
②
Turn right
Turn left
Notice:
When the steering lights on, the indicating lamp on the instrument panel also flashes (indicators on trailers
also will flash). If some bulb of indicating lamp is damaged, the flash and indicating lamp will be more
frequent (frequent doubling); defect notice will be shown on information screen at the same time.
2. Alarm
Power on and press alarm switch, then all the steering indicators and indicating lamps will be on.
- 54 -
Operation
High Beam
Operation of Front Lamp:
① Front lamp
② Assist high beam
Combination switch handle is at middle. When the key is at position 3 and lamp switch is at shift 2, the low or high beam will be on.
Then shift the handle to 4, the low and high beam will be both on. Lift the handle to 10 degree, the low or high beam will change to
the other. The handle can reposition itself.
When overtaking/passing or meeting vehicles at day time, lift the handle by 4 degrees to turn on high beam, then the handle will
reposition after your action.
- 55 -
Operation
Fog Lamp and Inside Lamp
① Front fog lamp
Notice:
Fog lamps can only be operated when the lamp switch is on.
1. Front fog lamp
Lamp switch is at position 1;
Press front fog lamp switch, the front fog lamp will be on and also indicator on the instrument panel.
2. Rear fog lamp
Lamp switch is at position 2, or the front fog lamp is on;
Press rear fog lamp switch, the rear fog lamp will be on and also indicator on the instrument panel.
- 56 -
Operation
Fog Lamp and Inside Lamp
Inside Lamp
Sleeper lamp
① Reading lamp ② Illuminating
3.1 Turn on or off inside lamp
Press left of inside lamp switch, then when the door opens, inside lamp system will automatically be on.
3.2 Continuous illuminating
Press right side of inside lamp switch.
3.3 Turn off the switch
Turn the switch to the middle.
- 57 -
Operation
Sun Visor
Windscreen Wiper and Cleaner
Operation of Wiper
0
Off
J
Intermission
I
Low
II
High
Press
Windscreen cleaner
Operation of windscreen cleaner: press left arrowhead
to start the windscreen cleaner.
- 58 -
Operation
Rearview Mirror
- 59 -
Operation
Seat
1. Instruction
① Forward and backward adjustment
Lift the handle and adjust the seat position.
② Waist support
Press lower end of controlling valve, the air charging begins; press higher
end of the valve, the deflation begins.
③ Heating
Press higher end of switch, the temperature will rise up to the set on; press
lower end of switch, the temperature will be kept; press the middle to cut.
- 60 -
Operation
Seat
④ Front height adjustment
Lightly lift the handle and force the front of the seat upward or
downward to adjust the front of the seat. Free the handle when the
position is all right.
⑤ Rear height adjustment
Lightly lift the handle and force the rear of the seat upward or
downward to adjust the rear of the seat. Free the handle when the
position is all right.
⑥ Backrest adjustable handle
Turn the handle to adjust the backrest to right position。
⑦ Backrest elevation adjustment
List the handle to adjust the elevation of backrest.
- 61 -
Operation
Adjusting Steering Wheel
The steering wheel is adjustable in the scope of ± 25 mm
in height and ± 5°in degree.
Instruction: Free the adjustment handle 8 and make the
steering wheel to the needed position, then fasten the handle.
- 62 -
Operation
Sleeper
Pedal
Long cab and high roof cab have sleepers. For high roof cab,
there are 2 sleepers and the upper one can be folded to any
position.
- 63 -
Operation
Cup Bracket
Ashtray
- 64 -
Operation
Cigar Lighter
Glovebox
For high-roof cab, one portable cooling and heating
box can be placed. (for customer‟s option)
- 65 -
Operation
New Vehicle Running-in
The distance of running-in is 2000~4000Km. Check the vehicle before running-in, and make sure the vehicle be in the normal
working conditions.
Running-in notice:
1. After the engine starting, do not accelerate immediately; increase the engine speed when reaching the normal using
temperature.
2. Drive the vehicle on the flat road in breaking-in period.
3. Change the gear timely, make the clutch smooth engagement, and avoid to sudden accelerate or brake.
4. Change into the low-grade before uphill; do not let the engine work at a very low speed.
5. The new vehicle is not driven at high speed when full-loading. Pay attention to every indicating signal and warning light!
6. Exam and control the normal temperature of cooling fluid and grease pressure. Pay attention to the temperature of gearbox,
front and rear axle, wheel-hub and brake drum. If serious heating, find the reason, adjust and repair it immediately.
7. In the first 50 km road and after changing the wheels tighten the wheel nuts according to the set torque.
After running-in, check and maintain the vehicle according to the content of maintenance requirements „First Examination‟.
- 66 -
Operation
Preparation before Driving
Warning:
Make sure no defect before driving!
Preparation includes: duty check before driving, ignition and flameout.
Duty Check before Driving
1. Turn on the main electric source switch.
2. Check electric system (system check automatically)
Please refer to content 6.7 of „electric instruments and controlling system‟
3. Check coolant level. Fill coolant if it insufficient.
Open the mask and check coolant level in extension tank. Fill the specified coolant to scale if it is insufficient.
- 67 -
Operation
Preparation before Driving
Notice:
1. Tilt the cab to fill coolant.
2. Open the mask of radiator before tilting the cab.
Relief valve can raise boiling point of coolant by keeping higher pressure than outside. It is especially important on tableland.
When the temperature of engine is still high, fill the coolant by two steps: first, relief high pressure from the filling port;
second, open the filling port cover, and then fill the coolant during idle speed.
Warning:
Filling coolant in high engine temperature is forbidden!
3.1 Check fuel quantity
Turn on the key switch to check fuel. If it shows incorrectly, please
check fuel gauge and sensor.
① Engine oil filling port
② Oil Gauge
3.2 Check the engine oil
Park the truck on horizontal road. After the engine cools down, pull out the oil gauge, the level should be between upper and
lower scales (around 3L). Fill specified engine oil if it is insufficient with the stipulated oil.
- 68 -
Operation
Preparation before Driving
3.3 Fill cleaning liquid
The fill port of cleaning liquid is at second left foot pedal of cab. After removing the tap, pull out the port and fill.
4. Check and remove the water in brake air reservoir
When the vehicle is stopped, pull or push the drain valve 1 to remove water from air reservoir. If liquid mixed by water and oil, the
drier is invalid and it is necessary to change a new one.
- 69 -
Operation
Preparation before Driving
5. Check air pressure of tires.
6. Check leakage of lubricant, coolant and air.
7. Check the air cleaner.
In winter or dusty condition, the 3 dust bags should be cleared everyday. Damaged dust bag might cause early damage to engine
and turbo-charger.
① Dust bag
Signal lamp is on if the air cleaner is blocked. Air cleaner should be changed if blocking signal lamp is on.
- 70 -
Operation
Preparation before Diving
8. Check if the cab is locked
Warning: Cab must be locked during driving.
Indicating lamp will be on if the cab is not locked.
After the cab is locked, check if the cab lifting cylinder is in initial position by watching the piston rod in initial position or not, or the
cab may be damaged.
Make sure that no person or other obstacles near the vehicle before starting the vehicle.
- 71 -
Operation
Start the Engine
Start the engine
1. Switch on and turn the key to position 4 (STRAT).
Notice: When driving, do not turn off the key switch. The key is at position 3 (ON) when driving.
2. Starting
Launch hand brake. Shift to neutral and turn the key to start. After started, the charging indicator lamp will be off.
Notice: 1. If failed to start for first time, turn the key to position 2 and start again.
2. Every start should be least than 15 seconds and at least 30 seconds between two times of starting.
3. Engine oil pressure
After engine started, watch the engine oil pressure value. The signal lamp for oil pressure should be off if the value is normal.
Notice: The engine should never work with high speed in cold condition! Check and repair immediately if no
pressure value shown after starting the engine.
4. Turbo-charger
Turbo-charger is at top-back of the engine, composed with turbo parts and pump wheel parts. The exhaust gas goes into the turbo
and makes the pump wheel rotate with high speed, then press the compressed air into the air inlet pipe of the
- 72 -
Operation
Start the Engine
engine to enlarge air pressure and enhance the engine power. .
The rotor of turbo-charger has very high speed (7000~10000 rpm). The rotor bearing is lubricated by enforcement and the
lubricant is supplied by engine main oil pipeline. Lubricant is cut with flameout.
Notice:
1. The engine should work in idle speed for 3~5 mins after started without hard accelerating before the oil
pressure and temperature is normal (especially in cold weather), or the bearing and sealing ring of turbo-charger
will be damaged in advance.
2. The engine should work in idle speed for 3~5 mins before flameout. Flameout after the speed of turbo-charger goes
down. No hard accelerating before flameout because it will cause high speed and lubricant pump will stop immediately after
flameout, the rotor axis, bearing and sealing ring will be damaged in advance.
3. Pre-lubricate the turbo-charger before starting the engine which has not been started for a long time. You may
remove the oil inlet pipe of the turbo-charger and fill some clean lubricant to avoid the turbo-charger from being damaged.
- 73 -
Operation
Turn Off the Engine
Flameout
Turn the key to „LOCK‟ position and the engine will stop, then turn off the main electric switch and remove the key for the
switch.
Warning: After working with heavy loading, the engine should stop after 3~5 mins working in idle speed.
- 74 -
Operation
Parking Brake Release
Hand Brake Valve (Parking brake of power-storing with spring)
The hand brake valve is at right side of instrument panel. (The picture is at „without brake‟)
Only when the hand brake signal lamp is off and the air pressure is over 0.65 Mpa (6.5 bar),
the hand brake can release completely, then the vehicle can start.
Specification: Trailer hand brake valve is added on tractors. The trailer hand brake valve will reposition
automaticlly and can not be used for parking brake.
Warning: Do not drive the vehicle before the signal lamp is off!
After the signal lamp is off, operate power-assist systems (clutch, shifting and so on). After the air pressure in air reservoir is
more than 0.7 Mpa (7 bar), the brake system will reach the standard performance and the vehicle is suitable for driving. Only
when the pressure of air reservior reaches 0.7 Mpa (7 bar), the brake system can reach its standard performance.
- 75 -
Operation
Starting and Shift
Starting
After starting the engine, the vehicle can not be started if low air pressure warning lamp and alarm is on. After the air pressure
reaches 0.55 Mpa (5.5 bar) and lamp or alarm is off, release the hand brake to start the vehicle.
① Clutch pedal
②
③ Accelerating pedal ④
Brake pedal
⑤ Hand brake valve
Exhaust brake button
- 76 -
⑥ Trailer hand brake valve
Operation
Start and Shift
Gears and Operation of Gearbox
Operation System
Picture 1 and 2 are shifting handle and shifts. When the switch is at L, 1-2-3-4–5–6 and R1 gears are available; when the
pre-selecting valve switch is at H, 5-6-7-8-9-10 and R2 gears are available.
Gears
Shifting rod
To move vehicle smoothly, turn the pre-switch to L and shift to 1 or 2 to drive forward or R1 to reverse.
- 77 -
Operation
Cruise Driving and EVB Control
Use of Cruise Combination Switch
Functions: cruise and exhaust brake (when engine is equipped with exhaust brake).
1. Cruise
There are 3 cruise switches: CC, RES/+ and SET/-:
„CC‟ is main cruise switch and can reposition. Switch on and enter cruise function. Now the symbol of CC on instrument will flash
by frequency of 90HZ. Change the accelerating to reach needed speed, stop accelerating and press SET/- to enter cruise mode.
The symbol of CC is always on.
- 78 -
Operation
Cruise Driving and EVB Control
During cruise, step brake or clutch pedal will cancel cruise mode and symbol of CC again flashes by frequency of 90HZ. Press
RES/+ for exit temporarily and re-enter cruise mode.
Raise needed speed: accelerate to the new target speed and press SET/- or repetitive operation on pressing RES/+ (1 km faster
by one press).
Reduce needed speed: brake to the new speed and press SET/- or repetitive operation on pressing SET/- (1 km slower by one
press).
Cautions:
1) The cruise mode is available between 35km to 105km, otherwise it will be cancelled automatically.
2) Duration of pressing RES/+ and SET/- button should not excess 559 ms, or engine error 26 and 43 will occur. Error 43 only
can be released by stopping the engine; Error 26 can be released by releasing the button.
2. Engine Exhaust Valve Brake
Engine exhaust valve brake (EVB) can be use to gain better braking performance. Switch the cruise switch to VEB1 or VEB2, and
then step the exhaust valve brake switch to brake.
- 79 -
Operation
Differential Lock Control
Operation of Diff-lock
The driving axles are equipped with diff-locks. When the wheels are sliding of trapped in mud, use the diff-lock to gain more
trafficability. Diff-lock includes inter-wheels and inter-axles and only inter-wheels for single axle.
Notice:
No inter-wheels diff-lock for single reduction driving axle.
- 80 -
Operation
1. Operation for single driving axle vehicle
Differential Lock Control
1.
Operation of Single Driving Inter-wheel Diff-lock
Warning: Inter-wheel diff-lock can only be used when vehicle is going straightly.
1.1 Engage: only when the vehicle is in halted state or going straightly under low speed.
Press the switch for inter-wheels diff-lock and the indicating lamp will be on after engaged.
Warning: When driving, release the clutch before engaging!
1.2 Release: stop accelerating and release the clutch, then press top of the switch. The indicating lamp will be off after the lock
is released.
2. Operation for Multiple Driving Axles Vehicle
Operation Principle: First engage inter-axles diff-lock, then for inter wheels.
2.1 Inter-axles diff-lock: Inter-axle diff-lock is for locking the differential between the first and second driving axles.
2.1.1 Engage: When the vehicle is halted state or going straightly under low speed (equivalent to walking speed). Press the
switch for inter-wheels diff-lock and the indicating lamp will be on after engaged.
Warning:
When driving, release the clutch before engaging!
2.1.2 Release: Stop accelerating and release the clutch, then press top of the switch. The indicating lamp will be off after the
lock is released.
- 81 -
Operation
Differential Lock Control
2.2 Inter-wheels diff-lock
Inter-wheels diff-lock is for locking the first and second driving axle.
Warning: Inter-wheel diff-lock can only be used when vehicle is going straightly.
The operation is same as operation for single driving axle vehicle (4x2 model).
Caution: 1. When the indicating lamp of inter-wheel diff-lock is on, the vehicle should not turn or drive in high
speed.
2. After getting through rough road, the diff-lock should be released immediately. Stop accelerating,
release the clutch and reposition the tilting switch of diff-lock. The diff-lock will be released after the
indicating lamp is off.
- 82 -
Operation
Operation
PTO Control
Operation of PTO (Take PTO after gearbox for instance)
Caution: PTO can only be used on low gears.
1. Engage:
Release the clutch and press the switch of PTO, the indicating lamp will be on, then shift the gear. The PTO only effects when the
gear is engaged.
2. Release:
Release the clutch and press the switch of PTO, after 3 seconds, engage the gear and the indicating lamp is off.
3. Operation of neutral switch for PTO
The PTO neutral switch is for shifting-locking, to prevent the vehicle from driving after engaging the PTO. The vehicle can not drive
when the PTO is working.
- 83 -
Operation
PTO Control
3.1 Use of neutral switch of PTO
When use the PTO during the vehicle is parking, use the neutral switch of PTO.
Warning: Shift to low gear before using PTO!
 Shift to low gear and press PTO switch.
 Press neutral switch, compressed air will force the gear to neutral (there is no output from sub box of gearbox at this
moment, but the main box is able to shift), the vehicle is in halted stated. In the meanwhile, the indicating lamp will be on.
Engage the PTO and power will be transferred.
3.2 Release the neutral switch of PTO
 Shift to neutral gear
 Press top of the switch and the indicating lamp will be off.
Warning: Shift to neutral before releasing!
- 84 -
Security
Service Brake
Braking system have four brake devices: Service brake (Foot brake), Auxiliary brake (Engine exhaust brake, exhaust valve brake
or both installed), emergency brake and parking brake (Hand brake) and trailer brake (for tractor truck).
1. Service Brake
1. Brake pedal 2. Exhaust brake button 3. Brake main valve 4. Cab front wall
Pedal controlling, dual circuit compressed air brake, the working pressure and the cutting pressure of pressure regulating valve
is 0.85 MPa (8.5Bar). The first loop effects on the wheels of rear driving axle or tandem rear driving axle; and the second loop
works on the wheels of front axle. Once the air pressure of one air cylinder in the two loops is lower than 0.55MPa, the pressure
indicator light will turn on, and please stop the vehicle immediately and find the reason of pressure leakage.
Do the full application of brake repeatedly and continuously in short time, it may cause pressure lower than 0.55 MPa (5.5 Bar).
Examination of pressure leakage: Stop the engine and pull up the control lever of hand brake, the pressure will reduce 0.05Mpa
at most in 2 hours, or reduce 0.01Mpa in thirty minutes.
- 85 -
Security
Auxiliary Brake
2. Auxiliary Brake
2.1 Exhaust brake:
When using auxiliary brake, step the exhaust brake button 2 and stop the engine,
then the vehicle can use the energy of engine to do the auxiliary brake.
The exhaust brake must be used when driving on the long downhill way; and it can
be used on the snowy and muddy road to reduce the possibilities of sideslip; when
meeting and on the rough road the exhaust brake also can be used to slow down in
advance.
Using the exhaust brake, it can reduce the times of using the main brake, and
decrease the abrasion and heat between the wheel and wheel brake, extend the
service life of wheels, reduce the fuel consumption and improve the drive security.
1-Brake Cylinder
Notice: When the gearbox is in neutral gear, the auxiliary brake doesn’t work.
When the gearbox is in the lower gear, the efficiency of exhaust brake is higher.
2.2 EVB Brake:
EVB is exhaust valve brake. Common rail diesel equips the exhaust valve brake device, which can help to reduce the speed and
control the vehicle. It can observably raise the braking performance when it works with exhaust brake at the same time, and
improve the drive security.
- 86 -
Security
Auxiliary Brake
Exhaust brake increase the intake and exhaust power consumption through keeping exhaust valve open, leaking the compressed
mixed gas in the air cylinder during compressing stroke and with the backpressure brought by exhaust brake, so as to promote
brake power. So that there is hardly energy returns to piston in the process of expansion stroke. Through engine repeatly
functioning, the forward momentum of vehicle is consumed. Meanwhile the speed is also cut down.
The engine adopts an exhaust brake valve (DC24V, 0.78A) for each cylinder, and installed under the valve cover.
2.3 Operation of EVB:
When the exhaust brake is open, release the clutch and accelerator pedal, step down the switch of exhaust brake, then the
exhaust brake and exhaust valve brake will function at the same time. The Jacobs exhaust brake will stop automatically when
you step down the clutch pedal or accelerator pedal. The exhaust brake will also stop by itself when the engine running speed is
under 1000 r/min. Moreover, under the premise of less than governed engine speed, make gear-box in the lowest gear to get
the maximum decelerator power.
Notice: 1. EVB is a kind of vehicle retarder device instead of parking device.
the vehicle completely, which is braking.
Service brake is only way to stop
2. Make sure the engine reaches its sufficient operating temperature before starting the exhaust brake.
3. As long as the exhaust brake is adopted, it is forbidden to shift without releasing the clutch.
When the vehicle driving in the wet and slipped way without trailer or the trailer empty, it is not allowed to use EVB device,
specially for the vehicle with single drive axle.
- 87 -
Security
Emergency and Parking Brake
3. Emergency and Parking Brake
Hand brake can be used as emergency and parking brake, it works
through energy-stored spring brake cylinder of rear driving axle. And
parking brake operates through controlling the handle of hand brake
valve.
When brake system has any errors, emergency brake starts
automatically pushing the energy-stored spring.
Release Position
①Handle of hand brake valve
Brake Position
②Handle of trailer hand brake valve
When the pressure of brake system is higher than 0.55 Mpa (5.5 Bar)
and the signal light of hand brake is off, the spring brake can be removed completely.
The usage of hand brake: Pull the handle. At the same time, the signal light on the instrument is on.
Releasing: Lift the handle, the handle will return to the discharge position automatically after releasing it. (Refer to the picture)
At the same time the signal light on the instrument is off.
Notice:
1. Hand brake must be pulled when the vehicle stops.
2. Before starting the engine, put handle of hand brake valve at the brake position; if not, the
pressure of brake system will be raised and all the parking brake will be removed.
- 88 -
Security
Trailer Brake
ABS Operation
When the indicating light of ABS testing is on, it expresses
ABS failure. Please go to service station immediately to
repair and maintain.
Trailer hand brake, works on the trailer or semi-trailer,
is separated from the brake system of tractor truck.
When loosing the hand brake valve handle of trailer, the
handle rebounds back to the initial position (The initial
position is as the above picture).
1. Dual circuit joint of air cylinder (red)
2. Dual circuit joint of brake (yellow)
3. Seven-holes trailer socket
- 89 -
Security
Brake Cautions
1. Urgently Loosing of Spring Brake Cylinder
When the connecting pipe of spring brake cylinder is braking self-powered because of leakage, loosen the bolt of cylinder to the
released position and the brake is released.
Notice:1. Before loosing the spring brake cylinder, shift into first gear and examine wheather the service brake
(foot braking) is normal.
2. When loosing the spring brake cylinder on the uphill/downhill road, please block the wheel to
prevent vehicle slippage.
2. Usage of Charging Connector
Because use the combined air dryer, combine the adjusting valve and the air dryer together, install charging connector on the
dryer. Screw on charging tube over the charging connector, and charge the wheel itself and also charge the wheel from the air
source outside.
3. Maintenance of Braking Line
When welding, cutting and drilling near the plastic pipe for braking, it should be subject to the following provisions:
a) Let out the gas in the pipe;
b) Cover the pipe in order to avoid to be damaged by the spark, fire and glowed chip;
c) The permitted temperature without any pressure pipe is 130C, the duration is one hour.
Warning: Battery and other electrical parts connected with the electronic device (main-control, driven,
instrument and ECU etc.) should be cut off or pull out!
- 90 -
Security
Driver’s Sitting Position
Correct driver sitting position is of much importance to the safety and comfort driving.
For driver‟s safety and reducing the damage of the accident, the following following adjusting program is strongly suggested:
1) Adjusting the steering wheel: The distance between the steering wheel and breast is less than 25 cm (Refering to the above
picture);
2) Adjusting the driver‟s seat forward and backward to make the driver to step on the accelerator, brake and clutch to the end
under the case of slight bowlegs.
3) Adjusting headrest: Upper edge of headrest is flush to the overhead (Referring to the picture).
4) Seat back is at the upright position, and the back should be fully fit in the seat back.
5) Wearing the safety belt correctly (Referring to safety belt instructions).
6) Putting the foot at the foot space, and make the vehicle to be the driver‟s control.
7) Adjusting the driver‟s seat manually.
- 91 -
Security
Driver’s Sitting Position
Front Passengers’ Sitting Position:
The distance between instrument plate and front passengers is not less than 25 cm.
For your safety and reducing the damage of the accident, the following following adjusting program is strongly suggested to the
front passengers:
1) The front passenger seat should be moved backward as much as possible.
2) Seat back is at the upright position, and the back should be fully fit in the seat back.
3) Adjusting headrest: Upper edge of headrest is flush to the overhead.
4) The front passengers‟ feet should be put in the foot space in front of the seat.
5) Wearing the safety belt correctly.
6) Adjusting the passenger‟s seat manually.
- 92 -
Security
Headrest
The Headrests Adjusting:
Warning!
The headrest adjusting is very important to protect the
passengers, and it can reduce the damage risk when
accident occurrs.
1. Removing or wrong position of the headrest may
increase the damage risk.
2. Wrong position of the headrest may cause serious
damage even death in the accident.
3. Wrong position of the headrest nay increase the
damage risk in the sudden driving conditions or
brakes.
4. Headrest should be properly adjusted according
to drvier or passenger’s height.
The headrest must be adjusted correctly to gain the best
protection.
Adjusting headrest: Upper edge of headrest is abreast to
the overhead as much as possible.
- 93 -
Security
Safety Belt
Every seat has one safety belt.
1. Wearing Safety Belt
Pull the seat belt lock, make belt around the shoulder and insert the latch into the socket until you hear the voice of meshing.
2. Releasing Safety Belt
Press the red button on the safety belt lock according to the direction of the arrow, pull out the latch, the safety belts will come
back to the original position.
- 94 -
Security
Safety belt
3. Safety Belt Alarm Instruction
3.1 Switch the key to the driving position, if the safety belts are engaged, the safety belt lock signal lamp on instrument does
not flash; if not, signal lamp will keep on without alarm buzzer.
3.2 After starting the engine, if the belt is not engaged, safety belt locking signal lamp lights up, and buzzer alarm in low
frequency and stop after 6 seconds; after inserting the safety belt well, the lamp is off and buzzer stop to alarm at the same
time.
3.3, if pull out the safety belt when the engine is working, the signal lamp is on and the buzzer alarm in low frequency for 6
seconds.
Notice:
Please wear the safety belt well before driving every time! Check the performance and functions of the
safety belt everyday.
- 95 -
Security
Pedal
、 Area
Pedal:
— All staff and pedal pad should not affect the operation and movement of
pedals.
— To ensure the pedals of accelerograph, brake and clutch are able to be
stepped down to the end without a hitch at any time.
— To ensure the pedal to be back to the position without a hitch.
— The pedal pad does not affect the pedal area, and fixed in the foot space.
— When the brake loop encounters error, the brake pedal needs the longer
pedal travel to stop the vehicle.
— Wearing proper shoes.
— The shoes should make foot to hold up well in order to have the good
pedal feeling.
Warning:
1. If the pedal could not make trouble-free operation, it may lead to dangerous driving conditions.
2. Do not put anything in the driver’s foot space. The staff may slide to the pedal area to prevent pedal
operations and result to no brake, operating the clutch or accelerograph in the sudden driving or
braking.
- 96 -
Security
Pedal
、 Area
Driver‟s side pedal pad:
—The pedal pad must be fixed in the foot space without affecting the
pedal‟s movement.
—Ensure the pedal pad immovable and no affecting the movement of the
pedal when driving. And pay attention to the warning.
—The pedal pad should not come in the pedal area or slide. Fixing
parts of the pedal pad must be fixed in the foot area.
Warning:
1. If the pedal could not make trouble-free operation, it may lead to dangerous driving conditions.
2. To ensure the pedal pad immovable.
3. Do not put any other pedal pads on the fixed pedal pad, because it can reduce the pedal area and
affect the pedal movement.-Danger!
- 97 -
Security
Sundries & Articles Storage
Warning:
1. Only soft articles or staff can be put in the glovebox.
2. Incompact articles loaded may lead to the serious damage.
3. All the articles must be put in the glovebox and fixed well.
4. When the sudden driving or accident occurred, hard and
heavy object splashing may lead to the serious damage if
the incompact articles loaded.
- 98 -
Maintenance
Vehicle Service Conditions
Table 1 Service Conditions of Vehicle
WGⅠ
WGⅡ
WG Ⅲ
Mileage per year less than 2x104 km of Mileage per year more than 2x104 km and Mileage per year more than 6x104 km
working duration not more than 600h
less than 6x104 km
Normal Condition
Bad Conditon
A
B
C
D
E
Good condition and long distance Short distance transport, Off-road, mountain Hot or cold region Sulfer content of fuel
transport, sulfer content of fuel is engineering truck, bus, and rugged road
(temperature always more than 0.05%
less than 0.05%
above 30℃ or below
etc
-10℃)
- 99 -
Maintenance
Cycle of Maintenance
Table 2 Cycle of Maintenance
Service Conditions
Items
WGⅠ
WGⅡ
WGⅢ
After running 1000~1500km
After running 30~50h
After running 1500~2000km
After running 1500~2000km
Routine Check (P)
Every 5000km Every 150h
Every 1× 104km
Every 1.5× 104km
1st-Grade Service
(WD1)
Every 1× 104km Every 300h
Every 2× 104km
Every 3× 104km
Every 2× 104km Every 600h
Every 4× 104km
Every 6× 104km
Every 4× 104km Every 1200h
Every 8× 104km
Every 12× 104km
Every 8× 104km Every 2400h
Every 16× 104km
Every 24× 104km
First-time Check
2nd-Grade Service
(WD2)
rd
3 -Grade Service
(WD3)
th
4 -Grade Service
(WD4)
- 100 -
Maintenance
Maintenance Items
1. Regular Maintenance Items
1.1
1.2
1.3
1.4
1.5
1.6
Check hand brake and service brake;
Check illuminating lamps, signal lamps and indication lamps (oil pressure, pressure in air reservoir, air filter maintenance
indicator and battery charge indicator, etc.);
Check the working mode of starter, alternator and battery;
Check tire pressure and condition;
Check the level of engine oil, coolant and steering hydraulic oil;
Drain water from air reservoir.
2. Graded Maintenance Tasks
Please refer to the second part for the checking and maintenance of the engine, transmission, front and rear axles, steering
gear.
Table 3-1
 Maintenance items include changing oil, checking and adjustment
Cab
Check the wiper
Re-tighten locking handle on driver‟s cab
Re-tighten engine radiator‟s cover
Check oil level of cab tipping hand pump
Check lifting cylinder
First-time
Check



Routine
Check


1st-grade
Service


- 101 -
2nd-grade
Service


3rd-grade
Service


4th-grade
Service








Maintenance
Maintenance Items
Table 3-2
 Maintenance items include changing oil, examing and adjusting.
1st-grade
Service
2nd-grade
Service
3rd-grade
Service
4th-grade
Service







Check spare tire fixing device



Check and adjust slide rail clearance of leaf spring






Check the fixation of battery



Check the fixation of fuel tank



Chassis
First-time
Check
Check fixation and action of towing hook

Re-tighten the bolts on cross member of the frame

Tighten front and rear leaf spring bolts and brackets

Check the fixation of wheel nuts
Routine
Check


First-time
Check
Routine
Check
1st-grade
Service
2nd-grade
Service
3rd-grade
Service
4th-grade
Service
Check the working condition of electrical system
(Instrument, lamps, wiper, and air conditioner).






Check electrolyte level and cell voltage





Check the fixation of battery terminal, coat
electrode with grease





Check electric tachometer and speed accuracy





Electrical System

- 102 -
Maintenance
Maintenance Items
Table 3-3
 Maintenance items include changing oil, examing and adjusting.
Brake System
Drain water from air reservoir
Check leakproofness of air pressure system
(With barometer)
Check brake lining thickness and adjust brake
clearance
First-time
Check
Routine
Check
1st-grade
Service
2nd-grade
Service
3rd-grade
Service
4th-grade
Service























Clean wheel brake
Check vulnerability of brake pipeline and hoses

Check brake chamber
Check footbrake, handbrake and exhaust brake
action (When do the trial running)





Check ABS





1st-grade
Service
2nd-grade
Service
3rd-grade
Service
4th-grade
Service




Vehicle
Short distance trial running (Including braking test)
First-time
Check
Routine
Check

Visual check for leakage






Check and tighten cargo body






- 103 -
Maintenance
Maintenance Items
Table 3-4
 Maintenance items include changing oil, examing and adjusting.
First-time
Check
Routine
Check
1st-grade
Service
2nd-grade
Service
3rd-grade
Service
4th-grade
Service
Water pump






Clutch release shaft






Clutch pedal shaft






Clutch release bearing






Universal joint and intermediate support of
transmission shaft






Steering knuckle and front axle





Leaf spring pin

Check leaf spring slide rail clearance of suspension






Shock absorber mounting











Lubrication
At least once every four weeks
Gearshift lever bracket
Brake camshaft and brake arm






Towing hook






Fifth wheel










Cab door hinge
Perform rust-proofing treatment of driver‟s cab
again according to schedule
Once every 12 months
Note: After cleaning the vehicle, re-lubricate all the parts which need lubricant at once, once a week for the vehicle operated on construction site.
- 104 -
Maintenance
Mandatory Maintenance
1. Purpose
Remove and clean the particles, burrs and other harmful impurities caused during the initial operation of vehicle, solve the
connections loosening problems resulting from the initial operation, carrying out a mandatory running-in maintenance, to
improve the reliability, so that make the vehicle in the best working condition to extend the service life of vehicle.
2. Implementation
Special service stations authorized by SINOTRUK can implement the mandatory service.
3. Mileage Requirement
The vehicle can enjoy a mandatory maintenance with the Warranty and Maintenance Manual of SINOTRUK, if the mileage is
between 2000 to 4000 kilometers and within six months.
4. Content
Please refer to the First-time Check of Table 2 for the details of checking.
- 105 -
Maintenance
Engine
1. Operation Attentions and Maintenance
For driving safety, the engine must be carried out routine inspections of each component. If somewhere is abnormal, the vehicle
should be sent to the repairing service station for maintenance.
Before running the diesel engine, the height of cooling level, fuel and oil level, and diesel level will be checked.
When the diesel engine is started, if it doesn‟t work within 15 seconds, restart it after 2 minutes.
After diesel engine is started, idle speed running will last for 2-3 minutes. Fuel pressure will exceed 100,000Pa. When cooling
water temperature is lower than 600C, do not run the engine at high-speed and heavy load at once, otherwise its wear
resistance and reliability will be affected.
In the case that the engine working with load, load and speed must be reduced before shutdown. Idle speed running must last
for no less than 5 minutes.
During running-in period (within 3000km), it is suitable for diesel engine to run only under medium load.
2. Routine Inspection and Maintenance
2.1 Oil Level Check
Check must be carried out after engine shuts down for 5 minutes with the vehicle parked on level ground. When the engine is
running or the vehicle is tilting, the oil level could not be measured accuratly.
- 106 -
Maintenance
Engine
Checking Methods:
1. Pull out the oil rule, clean the oil.
2. Re-insert the oil gauge completely, and then pull it out again, check the oil level. If the oil level in the grid within the region
(As shown in Figure 3-1), it indicates that it is normal.
Pic. 3-1 Oil level check
3. If it lacks of the oil, please fill oil. When refueling, do not exceed the "maximum" of oil gauge.
4. After using, re-insert the oil gauge correctly. Do not let the oil spill all around during refueling. Prevent the oil spills on other
components of the engine to avoid danger.
2.2 Coolant Level
Check whether the coolant water level is adequate or not.
Check the coolant level and add the coolant after the engine is cool.
The reason of sudden dropping in coolant level may be the leak of cooling system, please go to service station for maintenance.
- 107 -
Maintenance
Engine
2.3 Engine Status
Start the engine and check whether the exhaust gas, shaking and starting is normal, and check if there is abnormal noise when
the engine is at idle speed. If abnormal starting, black smoke, abnormal shaking or noise, please go to service station for
maintenance.
3. Maintenance Rules
3.1 Service conditions of vehicle refer to Table 1.
3.2 First check, routine check and maintenance cycle refer to Table 2.
3.3 Changing cycle of engine oil refer to Table 5.
3.4 Engine Maintenance Standard as Table 6.
- 108 -
Maintenance
Engine
Table 5 Changing Cycle of CF-4 Engine Oil in Different Conditions
Service Conditions
Changing Interval
WGⅠ
WGⅡ
WGⅢ
A
----
15000km
20000km
B
5000km/4 months/service time 200h
10000km/6 months/service
time 500h
----
C
5000km/4 months/service time 200h
10000km
15000km
D
5000km/4 months/service time 200h
10000km
15000km
E
5000km/4 months/service time 200h
10000km
15000km
1. For vehicles serves in various bad condition or always over-loads, interval of oil changing shall be shorten.
2. Ensure two times of oil changing in whatever conditions.
- 109 -
Maintenance
Engine
Table 6 Maintenance Range of Diesel Engine
Diesel Engine Maintenance Items
First-time Check
P
W1
W2
W3
W4
Replace diesel oil (At least once a year)
●
●
●
●
●
●
Replace oil filter or filter element
●
Check and adjust valve clearance
●
When changing diesel oil
●
●
●
●
Repalce fuel filter element
●
●
●
●
Clean fuel prefilter or replace filter element
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
Check coolant volume and add it to full
●
Replace coolant
●
According to table 4
Fasten cooling pipe clamp
●
Fasten inlet air pipe, soft tube, and flange connection
parts
●
Check air filter maintenance indicating light or indicator
Clean dust cup of air filter (Excluding automatic
exhausting type)
●
Clean main filter element of air filter
When indicator light or it indicates red
Replace safety filter core of air filter
After cleaning main filter core for five times
●
Check bearing clearance of turbocharger
Check, adjust clutch stroke and wire rope conditions
●
●
●
Electric components and electronically controlled system
Check it every 250 hours
wiring harness
Note: ● The mark means that the maintenance is needed.
- 110 -
●
●
●
Maintenance
Engine
Fuel Oil, Lubricating Oil, Coolant and Auxiliary Materials Used in Engine:
1. Fuel Oil
Summer: diesel which apply to the local market in summer.
Winter: diesel which apply to the local market in winter.
2. Lubricating Oil
2.1 Grade API CF-4 SAE 15W/40 engine oil is recommended.
2.2 High-grade oil is allowed to replace lower-grade oil.
Before starting the engine, check the height of the oil within the oil pan.
Warning:
1. Do not check the height of lubricating oil level when the engine is running.
2. It is not allowed to mix-use the different grade oils.
- 111 -
Maintenance
Engine
Table 6 Selection of Oil Brand
As the multi-grade oil with a flat viscosity curve, between the range of lubricating low temperature and high temperature, it has
good lubricating characteristic, so we recommend use multi-level lubricant.
Changing Engine Oil:
Check whether the oil color is normal and extraneous matter is mixed in oil or not when discharging the oil, so as to detect
hidden errors. After the oil is to be drained completely, clean the drain plug and then tighten it; replace with new oil filter
element, the new oil should be added into the engine to the upper limit of oil ruler. In order to prevent the case that starting the
engine without lubrication, turn the key switch to the starting position (Position 4) when the high-pressure oil pump is in the off
position, empty running for a while, and then start the engine and operate in low speed. Check oil filter if there is any leaks,
shut down five minutes later, check and add oil to the upper limit.
Notice:Do not replace the engine oil when it is hot.
- 112 -
Maintenance
Engine
3. Grease
Inject the general lithium grease into the oil cup of water pump in line with the requirements of the local market.
4. Coolant
Cooling system should be added with the long-acting cooling fluid, this fluid has capability of antifreeze rust. Please refer to the
ratio of long-acting coolant antifreeze instructions.
Warning:
1. When temperature is below 0℃, you should check the antifreeze concentration regularly.
2. Vehicles perennial running at areas above 0℃, water which has been treated with anti-rust and
anti-scaling could be used as the coolant; it is prohibited using untreated water as the engine coolant.
- 113 -
Maintenance
Transmission
1. Usage Requirements
Operate the transmission properly, and implement regular servicing and maintenance, which is crucial for vehicle‟s reliable
driving and the transmission‟s long life expectancy. Please comply with the following requirements for use:
1.1 Lubricant Brand
Please fill and inject 85W/90GL-5 vehicle gear oil in the transmission.
1.2 Proper Oil Level
Please make sure that the oil level is abreast with the observation slit of oil level. Check the oil level through the observation slit
on box flank until the oil level reached the slit and spillage happens. The oil injection volume is about 12L for HW18710
transmission (12.5L with power take-off added).
1.3 Inspection of Oil Level
Regular inspection should be made to the oil level. The car should be parked on flat road when checking the oil level.
Considering the inflation of hot oil, do not immediately check the vehicle that is just parked, and only when the oil level is
stabilized and the oil temperature comes close to the ambient temperature can we check the oil level, to prevent the inaccurate
measurement.
1.4 Re-supply of Lubricant
To prevent the chemical reaction of different kinds of lubricants, the re-supplied lubricant should be identical with the former
lubricant brand and specifications.
- 114 -
Maintenance
Transmission
1.5 Cycle for Lubricant Replacement
Discharge the used lubricant in the transmission and then rinse the strainer assembly when replacing the lubricant for
transmission.
The lubricant in the new transmission must be replaced between 2,000~5,000km.
For each 10,000km, the lubricant must be checked for its oil level and leakage. It should be supplemented and the strainer can
also be rinsed at any time if necessary.
For each 50,000km, the lubricant must be replaced.
1.6 Working Temperature
The maximum temperature for transmission during the continuous working period must not exceed 120℃ and its minimum
temperature must be below -40℃.
The lubricant will decompose and reduce the lifetime of transmission if the working temperature exceeds 120℃.
Any of the following conditions can cause the transmission‟s working temperature to exceed 120℃.
① Continuous driving at the speed no more than 32Km/h.
② Engine speed is too high.
③ Ambient temperature is too high.
④ Transmission is surrounded by eddy current.
⑤ Exhaust system is too close to the transmission.
⑥ Running at high-power and over-speed rotating.
- 115 -
Maintenance
Transmission
1.7 Working Inclination Angle
The working inclination angle for transmission must not exceed 150, otherwise, it may not be fully lubricated (the working
inclination angle is equal to transmission‟s installation angle on the chassis plus slope angle).
1.8 Draging and Sliding
When the transmission works, its countershaft rotates and drives the oil pump to run, plus splash lubrication, which can fully
lubricate the transmission. When the vehicle is dragged with rear wheels touching the ground and transmission system
connected, the main shaft rotates comparing to main shaft gear and the planetary mechanism also rotates, although the
countershaft gear and main shaft gear for main transmission do not rotate. This will cause great damage to the transmission‟s
planetary mechanism and localization elements of main shaft due to insufficient lubrication.
Pay attention to the following points to prevent this kind of phenomena:
Do not step on the clutch pedal to let the vehicle slid on neutral position.
When the vehicle needs to be dragged, draw the half axle out or disconnect the drive shaft, or have the driving wheel dragged
liftoff the ground.
2. Precautions
2.1 The clutch must be completely released and the gear shaft lever should be moved into relevant positions when shifting.
2.2 When parking, the gear shaft lever should be moved into neutral position in low gears area.
- 116 -
Maintenance
Transmission
2.3 When shift into low gear (Creeping gear) or reverse gear, it must be stopped first and then shift into relevant gear to
prevent the parts inside the transmission from being damaged.
2.4 When the transmission shifts from low gears to high gears (vice versa), do not skip gears, or it will influence the lifetime of
auxiliary gearbox‟s synchronizer.
2.5 When driving downhill, shifting between high and low gears is prohibited.
2.6 Shift to first gear or second gear to move in accordance with the road conditions.
2.7 Release the brake before the vehicle starts. For the vehicles that equipped with air cut-off brake, do not shift to relevant
gear and start until their brake valves are connected and the air pressure reaches the level required to release the brake.
2.8 On the event of any unusual phenomenon, such as abnormal sound or heavy operation during the use of transmission, the
vehicle must be parked immediately to check for any failure. Do not continue driving until the failure is eliminated.
2.9 The transmission is featured with interlocked mechanism for main and auxiliary transmission. The gear shifting for main
transmission is locked up before the auxiliary transmission shifts into relevant gear. In the event any failed shifting, it may be
affected by the interlock of main and auxiliary transmission. Check the sequential gear shifting cylinder and its gas pipeline
to ensure that auxiliary transmission has shifted into relevant gear.
2.10 Privately disassembly/knock down or assemble the transmission is strictly prohibited within warranty period.
- 117 -
Maintenance
Front Axle
1. Regular maintenance and care of front axle every 15,000km or every six months.
2. Check rotation of wheel bearings, replace grease, and check whether the wheel bearings can continue to use, adjust or
replace it if necessary; the grease used in wheel hub bearings, brake camshaft and the main pin, tie rod ball pins, brake gap
adjustment arm, etc. is for motor vehicles through the lithium-based grease.
3. Grease Volume:
3.1 Volume of grease for each wheel: at a total of about 0.6kg for wheel hub cavity and two bearings;
3.2 Each brake camshaft and the kingpin of the grease volume: approximately 0.2kg, adding to the bracket with the oil gun until
overflow from the holes;
3.3 Tie rod ball pins, brake lash adjuster arm should be filled with grease.
- 118 -
Maintenance
Rear Axle
Pay Attention to the Following Points in the Use and Maintenance of the Rear Axle:
1. Maintain Lubricant Volume, and Frequently Check Oil Volume of Wheel Reductor and Main Reductor.
Oil lacking may lead to early wear of running components and even cause burning damage. While, more lubricant does not
mean that it will provide better performance, because excessive lubricant may result in high temperature and even oil leakage.
For new vehicle‟s initial maintenance, when replacing lubricant of the wheel reductor, rotate the wheel till drain plug is in the
lowest position while filling plug is in the position near half height of the axle housing. Open the drain plug to drain out used oil,
screw it back and open the filling plug to fill lubricant to its height, and then screw back the filling plug. Rotate the wheel for
several times, locate it in the position where drain plug is in the highest position while filling plug is in the position near half
height of the axle housing. Open the filling plug to drain out excessive lubricant till oil level is kept in the height of filling plug,
and then screw it back.
There are two screw plugs on the rear axle housing: one is an oil drain plug in the bottom of axle housing, the other is an oil
filling plug in the position near half height of the axle housing. The normal oil level should be maintained in the height of filling
plug.
The main reducing gear and wheel reductor in rear axle use API GL-5, SAE 85W/90 gear oil. Generally, oil voume is 16.5L for
rear driving axle main reductor, 19.7L for middle axle main reductor and about 3L for each wheel reductor.
The oil change interval for rear axle gear oil is 50000km or one year. Gear oil should be replaced for the first 2000-3000 km
compulsory maintenance.
- 119 -
Maintenance
Rear Axle
2. Operation of Differential Lock
The interwheel differential in rear axle is used to automatically realize speed difference between left and right wheel when the
vehicle turns corner so as to avoid tire wear and mechanical damage. Engage the differential lock when the vehicle wheels on
one side skids on smooth or muddy road, at this time the left and right axle shaft become one rigidly coupled shaft, thus the
vehicle will drive away from the trouble road.
Notice:
After the vehicle driving out of rough road, disengage the differential lock immediately, or it will result in
tire worn and differential damaged.
3. Avoiding Serious Overloading
Serious overloading and loading concentration will result in axle housing deforming and break. Therefore, the loading capacity
shall be complied with the specified loading in accordance with certain driving conditions.
4. Other Precautions
If the connection fittings such as differential gear and driven gear, etc. need to be reassembled during repairing, smear the
coupling threads with LOCTITE 262 thread setting glue, and tighten the coupling bolt according to the specified torque.
If abnormal sound is heard during operation, do not drive the vehicle, check and repair immediately.
- 120 -
Maintenance
Steering System
1. Check hydraulic oil level inside the tank. First, clean oil reservoir and its surroundings to keep dirt out. Pay attention to the oil
stick mark when checking, the oil level should be the same as the oil stick when the engine operates; the oil level should be a
bit higher when the engine does not work.
2. The hydraulic oil of new vehicle needs to be replaced, and cleaned cartridge in the reservoir after the first 2,500Km, and then
each subsequent 20,000Km (or half a year) the vehicle needs to replace the hydraulic oil.
3. Check the oil surface height once a month, and check the cleanliness of hydraulic oil.
4. The procedure for changing oil as following:
4.1 Put up the front axle.
4.2 Open the cover of fuel tank; screw off the return pipe on the steering gear.
4.3 Start the engine, idle running about 10 seconds, and turn the steering wheel to its right and left limit position several
times, so as to drain oil from inside the oil reservoir, booster pumps, steering gear.
4.4 Re-tighten the return pipe (keep it clean and keep dirt out of the oil circuit), clean oil reservoir, oil filters and filter
elememts. It is best to renew filter element every time when changing oil.
4.5 After filling up hydraulic oil, run the engine at idle speed, turn left and right the steering wheel repeatedly, at the same
time, fill oil continuously till oil level no longer reduces and no bubble occurs. The oil level should be added on all the
components in the first-grade service.
- 121 -
Maintenance
Steering System
Notice: Please replace with the specified hydraulic oil (HVN32 Low Temperature Hydraulic Oil).
5. In the first-grade service, check the clearance of every rotary component such as steering tie rod and drag rod joint. If the
clearance is huge, the component should be replaced, and grease should be added on all the components in the first-grade
service.
- 122 -
Maintenance
Clutch
Running Parameter:
1. Working medium: air and brake fluid;
2. The largest working pressure: 4 MPa for brake fluid, 0.85 Mpa for air;
3. Working temperature: - 40℃~+ 80℃;
4. Brake fluid: complying with DOT3, DOT4 or JG3, JG4 standard;
5. Pedal travel: Max stroke 200mm; free stroke, 25mm for pull, 40mm for push;
6. Pedal force: not more than 190N with assistance.
Adjustment of Clutch Operation System
1. Check and Adjust the Clearance between Master Cylinder Pushrod and Piston:
When adjusting, push the pedal with hand smoothly till the main cylinder pushrod contacts against the piston, then adjust the
limit bracket until the clearance between limit bracket and pedal is about 1mm. Tighten the limit bracket nut. Ensure there is
0.5mm~1mm clearance between the pushrod and piston, this clearance should not exceed 1mm, or it will reduce the effective
travel and influent the effect of clutch.
- 123 -
Maintenance
Clutch
2. Adjust Clutch Brake Control Valve:
Step on the clutch pedal fully, at this time the working travel of main cylinder pushrod should not be less than 32mm, and the
clutch pedal should have control valve to move 3~5mm. Fix the brake control valve, tighten the bolt, and then adjust the limit
screw of the pedal bracket, making the screw cap contact against the clutch against the clutch pedal (when the clutch pedal is
stepped down fully). This can prevent the brake control valve from coming off the pedal bracket.
3. Release the Air in Hydraulic System Thoroughly:
Air in hydraulic system can reduce the effective travel of booster cylinder pushrod, and the clutch can‟t be released thoroughly,
thus shifting becomes difficult.
When assembling and disassembling oil tube, be sure to release the exhaust valve of booster cylinder first. Fill the specified oil
to the reservoir. At the same time step on the clutch pedal and release air from the exhaust valve, then tighten it. After stepping
on the clutch pedal rapidly for several times, hold the pedal tightly, release the exhaust valve till no air comes out, then tighten
the exhaust valve.
Repeat the afore-mentioned steps for 2~3 times, air in hydraulic system will be released completely.
- 124 -
Maintenance
Clutch
Attentions:
1. During the exhaust process, relax the pedal after the exhaust valve or an associated tube nut is tightened, so as to avoid
inhalation of air, lifting the pedal to the maximum height in order to add the brake fluid inside the tank to the master cylinder
fluid anvil cell.
2. Re-adjust the clearance when you maintain the new vehicle for the first time. Check the vehicle for second grade
maintenance every 12,000km and for first grade maintenance every 4,000km. Push the clutch rocker arm with hand, there
should be gap in the head of limit bolt.
3. You must adopt DOT3 or DOT4 brake fluid as actuating medium in hydraulic system. When mounting and dismounting the
pipeline, you can use the Loctite572 to seal the union nut and connector.
4. When changing brake fluid, drain the remaining fluid out of the system thoroughly, and change to the specified brand fluid
manufactured in the same batch.
5. Brake fluid is corrosive. Avoid brake fluid splashed on the human body and the paint surface of the vehicle during the exhaust
process.
- 125 -
Maintenance
Air Conditioner
Maintenance
Air-conditioning
Unit
Compressor
Item
Content
Coolant Volume
Coolant Leakage
Check coolant level
Check leakage with halogen checker
Check cracks and damage
Check leakage of connectors and tightening of
clamps
Replace desiccant and filter
Hose and Pipe
Coolant
Oil Seal
Belt
Bolt
Evaporator Cartridge
Wind Motor
Evaporator
Condenser
Electrical
Apparatus
Element
Expansion Valve
Condenser Cartridge
Wind Motor
Connector and Plug
Heat Sensitive Resistance Switch
Magnetic Clutch
Magnetic clutch bearing
Refill with specified coolant
Check leakage trace with white paper
Check tightness of belt pulley and check wear
Check tightness, check and check change all of
them, if necessary
Check dirt, clean if necessary
Check running condition
Check running condition, remove filter gauze
and clean
Check dirt, clean if necessary
Check running condition
Check looseness of wire clamp plug
Check action
Check if specified requirements has been met
If it can‟t turn steadily, please replace it
Check Period
Every
week
+
Every
month
Every two
month
Every
year
+
+
-
-
+
+
-
+
+
+
+
+
+
+
+
+
Specification: "+” indicated adjustment or repair if necessary; “_” indicates replacement.
- 126 -
Every
quater
+
+
+
Maintenance
Battery
Check the surface and proportion of liquid electrolyte
every three months. The surface is 10~15mm higher
than the electrode plate; the proportion is more than
1.24 g per cm3.
Take off the battery into the warmer room when the
vehicle does not run for a long period and the
temperature is low.
Check whether the battery electrode pile and wire
connection clip is loose and the battery conditions are
normal or not when the vehicle runs for each 500 km.
- 127 -
Maintenance
Changing and Replacing Parts
Your vehicle is designed based on the latest technical knowledge of security, so it provides excellent active and passive safety. In
order to maintain this state, it is forbidden to change parts arbitrarily. So if the vehicle must be added other accessories, carry
out technical improvement or replace parts, pay attention to the following instructions:
1. Before purchasing the accessories and parts for replacement or technical improvement, ask for the SINOTRUK sales
agencies‟s advice first.
2. SINOTRUK sales agency provides original accessories, parts and components, and professional installation services.
3. We suggest using original accessories and parts only, and installing them at SINOTRUK service agency. Due to the damage
caused by violation of operation, SINOTRUK service agency does not provide quality assurance.
4. If the additional installation of the accessories which will directly affect the driver's control of the vehicle, such as speed
control devices, these devices must get CE (European Community recognized mark) or "CCC" mark which approve equipment
can be installed in your models.
5. If the connected electrical equipment does not directly control the vehicle, such as refrigerators, horns, or fan, CE (European
Community recognized mark), or "CCC" mark should be attached to them.
6. If your vehicle needs technical midification, please note our principles, that is, do not modify the vehicle without our
permission; do not perform to damage the vehicle; the transportation safety and operating reliability should be ensured.
SINOTRUK service agency will provide professional service or introduce professional state under particular cases.
- 128 -
Maintenance
Changing and Replacing Parts
Notice:
1. Reliability, security and acceptability of the original accessories and parts have the approval and is
suitable for the vehicle.
2. For other brand parts and components, we could not provide quality warranty, even if they have offical
approval from the technical inspection supervision authorities’ acceptance.
3. For unauthorized vehicles modification and the adverse consequences caused by the modification, no
warranty will be provided.
- 129 -
Do It By Yourself
Driver's Tools and Spare Tire
Notice:
1. Ensure that the driver’s tools and spare wheel firmly fixed, in order to avoid loosen in accidents and
sudden braking situations.
2. The vehicle must not be started when it is lifted.
3. Ensure the vehicle is lifted by appropriate support block if you work under the truck.
4. The jack must be screwed completely before putting back to workbox, and make the crank handle firmly
resisted the side of the jack.
- 130 -
Do It By Yourself
Changing Wheels
1. When changing a wheel, take care not to damage the stud threads.
2. The matching surface between the brake drum and rim must be absolutely free from paint, grease or dirt.
3. It is essential that the contact face of the wheel nut is clean and free from dirt or grease.
4. Before installation of wheel, clean the rim matching with wheel locating hole and wheel reductor housing, and coat it with a
little grease.
5. Coat threads of the wheel studs and nuts with a little grease, oil or antifreeze.
6. All the threads of the wheel nuts are right-hand threads. Put on the wheel and tighten the wheel nuts in cross sequence
while the wheel is still raised, then low the wheel and tighten the nuts with a torque of 550~600Nm.
7. Every time when the wheel is changed, the nuts must be retightened after driving 50Km. And later on, retighten the wheel
nuts every 1000Km.
- 131 -
Do It By Yourself
Trailer
1.2 Lift the hand lever 1 on the fifth wheel, put the lever to the
upper long eye pull it out until the position slot locks housing.
At that time, the fifth wheel is ready to couple.
1.3 Coupling during backing the tractor truck, after putting
drawbar pin to the connecting jaw in the fifth wheel, coupling
hook 3 and wedge block 2 lock the coupling jaw automatically
and complete the coupling. At the same time the lever returns
to its original position. It means the operation is correct.
1. Coupling the Trailer
Semi-trailer:
The coupling of tractor truck and trailer is conducted by fifth
fifith wheel. Coupling procedure:
1.1 Secure the semi-trailer stands still.
- 132 -
Do It By Yourself
Trailer
2. Uncoupling the Trailer
2.1 Secure semi-trailer or trailer stand still.
2.2 Uncoupling the semi-trailer with dual circuit brake system, first uncoupling the reservoir
line (red) and then the brake line (yellow). It is essential to adhere to this order,
otherwise the trailer brake will be released.
2.3 Uncoupling the trailer: Put forward the hand lever 1 of the automatic locking
mechanism (in the travel direction of the truck) until the coupling jaw is unlocked. Drive
forward the tractor to complete the uncoupling operation. Return the hand lever to its
original position if the trailer will not be coupled with for a long period.
2.4 Uncoupling the semi-trailer: Put out the hand lever of the fifth wheel until the position slot locks housing, the edge block 2
will uncouple hook 3. Drive forward the vehicle, trun the drawbar, release the drawbar pin, and finish the uncoupling
operation. Return the hand lever 1 of the fifth wheel to its original position if the semi-trailer will not be coupled with for a
long period.
3. Cautions
3.1 Connecting compressed air lines and electric cables, please ensure there is no stress, kinking or abrasion will occur when the
vehicle turns or rebounds.
3.2 After connecting the compressed air lines, adjust the load-sensing pressure regulator (if fitted) on the trailer in accordance
with requirements of the trailer manufacturer.
3.3 With the dual circuit brake system, the connectors are red to red(on the right)and yellow to yellow (on the left).
- 133 -
Do It By Yourself
Cab Tilting System
Cab tilting and lifting system
1. Cab tilting operation
1.1 Before tilting, remove all the loose articles from the cab.
1.2 Before tilting, open the radiator cover first (Pic. 3).
1.3 When tilting, nobody should stand near the front of the cab
(Pic. 4).
1.4 Turn the titling hand lever of the titling oil pump to
“↑”position, tip up the cab with hand pump (Pic. 5).
1.5 Turn the tilting hand to”↓” position, tip down the cab to its
original position with hand pump.
Warning:
① Manual hydraulic oil pump
② Transfer handle
Because the oil cylinder can fall back automatically
at the top die point, when the distance between the
lock pin and the lock catch is 40~100 mm, the cab
will fall back automatically.
③ Lever
④ Fuel plug
- 134 -
Do It By Yourself
Cab Tilting System
1.6 After the cab has been tilted down, the rubber bellows connecting with the top intake duct must cling to the bottom intake
duct so as to keep the dust outside.
1.7 During the period when the cab is being tilted down, check if the guide pad of the front air bag is aligned. After the cab has
completely fallen back, check if the front air bag is upright, if not aligned, tip up and down the cab again.
1.8 Finally check cab lock indicator on the instrument. If the cab is unlocked, the cab lock indicator will light up.
Notice:
When titling, the cab must be tipped forward beyond the top die point,
otherwise the next operation procedure could not be continued.
Air filter clogged
2. Filling Oil and Releasing Air of the Titling System
Filling oil and releasing air of only after the cab returning to its original position.
About 0.41 HVN32 low temperatures hydraulic oil should be used, to ensure that the hydraulic oil is
clean and in accordance with the specification before filling.
Filling procedures:
① Open the oil plug and fill up the specified hydraulic oil.
② While titling up the cab slowly with hand pump, fill the oil continuously.
③ Tilt down the cab and drain the superfluous oil at the same time.
④ Tilt up and down the cab again with hand pump, after titling down the cab to its original position, check and fill up the oil again.
⑤ Finally, screw the oil plug.
- 135 -
Do It By Yourself
Cab Tilting System
3. Check Function of the Titling System
3.1 Tilt the cab forward to top die point, check the working condition during tilting down. If the system is working in good
condition, the cab will tip down slowly with resistance rather than strike down.
3.2 When titling the cab to 30°, the cab can be kept in this position for 20 minutes without sinking.
(1). Front suspension: (Pic. 6)
Warning:
When adjusting, pressure of air bag should not be over 2kg.
Pic. 6
- 136 -
Coil spring of front suspension (or air spring)
Do It By Yourself
Cab Tilting System
(2). Rear suspension: (Pic. 8)
With air springs:
Notice:
If front and rear suspension is both air suspensions,
clean the air bag in time to prevent it from aging,
when the air bag is stained with grease during its
application and repair.
1. Hydraulic lock
2. Shock absorber (air bag) of rear suspension
3. Limiting block
4. Stabilizer bar
5. Height control valve
6. Shock absorber (coil spring may be adopted according to working conditions)
of rear suspension
Fig 8
The hydraulic lock and the lock shaft should be coated with lithium-based grease.
The height of left and right shock absorber of rear suspension should be the same. Adjust track bar nut to change their height
to 270± 2mm.
- 137 -
Do It By Yourself
Cab Tilting System
4. Check the Suspension System
After the cab has been mounted on the frame, tilt up and down the cab.
5. Other Cautions
5.1 Check if the air bags of front and rear suspension inflates and deflates normally and if the front rocker arm turns flexibly.
5.2 Check if the hydraulic lock engages and disengages normally, and at the same time, check the working condition of hydraulic
lock indicator (in normal condition, the indicator will go out when the hydraulic lock locks up, and it will light up when the
lock releases).
- 138 -
Do It By Yourself
Common Errors and Solutions
Front Axle
Errors
Error Source
Solutions
Lubricate the kingpin of steering knuckle, check the clearance
between steering knuckle and front axle.
Heavy Steering
Inadequate lubrication
Lubricate the kingpin of steering knuckle and track-rod ball pin.
Improper toe-in adjustment
Re-adjust toe-in
Improper pre-tightening of hub bearings Re-adjust the pre-tightening force of hub bearings.
Flexible Steering
Ball pin of tie-bar flexible and worn-down Tight or replace the ball pin
Steering knuckle bush worn-out
Replace steering knuckle bush
Improper pre-tightening of hub bearings Re-adjust the pre-tightening force of hub bearings
Ball pin of tie-bar flexible and worn-down Tight or replace the ball pin
Wheel Flutter
Steering knuckle bush worn-down
Replace steering knuckle bush
Clearance between steering knuckle and
Re-adjust the clearance
front axle is too large
Whether one side of friction block is
Replace the friction block
polished or not
Clearance between friction block and
Initial adjustment and function check
retarding disc
Whether friction block can move freely
Remove the brake pads, clean the brake pads, fixed base plate
Brake Side-slipping within the fixed base plate or not.
and brake calipers
Whether the air pressure on both sides
of brake chamber of axles are the same
Refer to the vehicle manual.
or not (with barometer measuring the
pressure)
Remove the air relief plug or not
Remove the air relief plug of brake chamber
Steering knuckle is not flexible
- 139 -
Do It By Yourself
Common Errors and Solutions
Front Axle
Errors
Braking Drag
No or inferior
Braking Effect
Error Source
Solutions
When the brakes are released, whether there are
compressed air in brake chamber or not.
When parking braking is released, whether all the
spring braking are released in the brake chamber or
not.
Check the clearance between the brake pads and
retarding disc is right or not
Whether brake pads can move freely within the fixed
base plate or not.
Sliding function of brake caliper is normal or not
Remove the air relief plug of brake chamber or not
Whether the brake pads are polished or not
Check the clearance between the brake pads and
retarding disc is right or not
Retarding disc is in good working condition or not
Whether the air pressure on both sides of brake
chamber of axles are normal or not (with barometer
measuring the pressure)
- 140 -
Refer to the vehicle manual
Refer to the vehicle manual
Initial adjustment and function check
Remove the brake pads, clean the brake pads,
fixed base plate and brake calipers
Change sliding pin and bush
Remove the air relief plug of brake chamber
Replace the brake pads
Initial adjustment and function check
Replace the retarding disc
According to the vehicle use requirements,
implement the remedial measures
Do It By Yourself
Common Errors and Solutions
Rear Driving Axle FAQ Troubleshooting
1. Oil Leak
There are several leaking places of rear driving axle. Oil leaking place of final gear is always at the input shaft. It is usually
because of damage of worn-out oil seal of the input shaft (driving gear shaft) , or loosen of oil seal spring. When maintaining it
should be noticed that if oil leaks from outside of oil seal, it shows the outside of oil seal and housing are matched loosely.
When reassemble the outside of oil seal and oil seal seat hole on the housing should be cleaned, and apply LOCTITE603 solid
glue to the outside of oil seal and punch the seal into the oil seal seat hole. If the oil seal is intact, but oil still leaks heavily,
check the axle housing ventilation devices(which should be checked frequently). If the ventilate port is jammed, the heat
brought from movement of axle may push the lubricant outside by accumulated pressure. This may usually be ignored.
There are three parts should be checked when the hub leaks, the O type ring between the hub and wheel reducer‟s shell, the O
type ring between the hub oil seal seat and axis tube of axle housing, the seal of hub. Normally the seal of hub leaks more
often. When reassemble the hub seal should notice that the hub has two seals of the same dimension but materials, normally
put the one with yellow mark or engraved mark to the inside, while the other one to outside. If the outer ring of oil seal and the
shell connection loosing, use LOCTITE603 solid glue to the outer ring of oil seal.
If the axle head leaks that shows the end cover and planet carrier contact surface is not airproof, which is connected without
mat, we can disassembly them and clean the end cover and wheel reductor housing flange, then use LOCTITE587 to
reassemble them. Glue trail should be continuous.
If find out the blowhole of axle shell leaks and the wheel reductor leak oil very often that commonly means the oil seal of half
shaft has installed in a wrong way or has broken down.
If the axle head leaks, there would be oil stain on brake lining and brake drum, which can cause failure of brake.
- 141 -
Do It By Yourself
Common Errors and Solutions
2. Overheat of Hub
Overheat of hub commonly arises from excessive pre-tightening force of hub bearing, which commonly occurs after maintenance.
If haven‟t tighten the axle head nuts according to regulation during maintenance, the pre-tightening force is excessive, which will
cause over heat of hub. The hub should be reassembled according to regulation. Certainly, distortion and broke down of hub
bearing also can arise over heat of hub.
3. Overheat of Brake Drum
There are many factors for overheat of brake drum, some are resulted from mechanical brake parts and some are resulted from
brake control air path system.
Firstly, check out whether the brake chamber back to place quickly after braking. If the brake chamber can not back to place
quickly or back to place slowly, driver may remove the handspike of brake chamber and the brake adjusting arm to check whether
the brake chamber back to place quickly, if not, it means failure of brake chamber and brake control air path. And if the brake
chamber back to place quickly after removing the handspike of brake chamber and the brake adjusting arm, then should check
whether the brake camshaft running neatly.
Deformation of the brake camshaft, lacking oil of axis bush or deformation/dislocation of camshaft bearing, can all make the
failure of brake chamber back to place to cause the over heat of brake drum.
Broken or loosing of brake shoe return spring may cause overheat of brake drum or make frictional noise.
During the normal driving, there should have a certain gap between the braking friction plate and the brake drum (normally 0.2
mm), if the gap is too large, it may affect the braking effect; and if too small, it will arise overheating.
- 142 -
Do It By Yourself
Common Errors and Solutions
The heat dissipation of brake drum is not good condition, frequently braking action will make the brake drum overheating very
soon, which will seriously even burn tire valve and cause air leakage of tire. So if vehicles traveling downhill in a long-distance,
using engine exhaust braking is highly recommended instead of using service brake frenquently, in order to prevent overheating
of brake drum.
4. Abnormal Noise from Central Powertrain
If there is sudden abnormal noise coming from the rear axle housing while driving, stop the vehicle immediately for inspection.
Generally, this abnormal noise indicates parts have been damaged.
The falling apart of the supporting bearing for the differential, the serious pit corrosion or abrasion of the bearing, the loosening
or falling off of the set bolt of the driven gear, the loosening of the engaging sleeve for the differential lock as well as the tooth
breaking of the differential gear may cause serious abnormal noise.
If the noise due to gear abrasion is continuous and the level of such noise increases with the increase of vehicle speed, it is
generally caused by the pit corrosion of the bearing, abrasion of driving gear or the scratch pit corrosion of the tooth surface. If
the noise is not abvious when driving, but high noise when slowing the vehicle down by withdrawing fuel, it is generally caused by
the drag mark or pit corrosion of the tooth back of the driving gear.
If there is no obvious noise when the vehicle is normally traveling in a straight line, but abnormal noise when the vehicle is
turning at the corner, it is apparently caused by the damage or burning of the differential gear, or by the moving of differential
lock‟s loosened engaging sleeve.
If there is continuous noise after replacing the driving and driven gears and the level of such noise increases with increase of the
vehicle speed, check whether the backlash of the driving and driven gears and the contact trace of tooth surfaces are qualified,
and pay special attention to whether the driving and driven gears are assembled as a matched set.
- 143 -
Do It By Yourself
Common Errors and Solutions
Rear Driving Axle FAQ Troubleshooting
The deformation of axle housing can also cause the abnormal noise from the rear axle, which should be attended to during
inspection. In case of abnormal noise from the rear axle, do not drive the vehicle forcibly. Remove and check the rear axle
immediately. The falling apart of the bearing, the loosening of the set bolt and damage of the gear may, if not repaired in time,
result in more serious consequences.
5. The Failure of Differential Lock
When the differential lock is needed to put up, push the switch but the signal light does not on. The first thing you should do is to
check out whether the push rod of differential cylinder moves. When finding the push rod could shoot out, however, not in right
postion, that means the head of mating gear tooth mated with the head of gear peak but not in the right position. When move
the truck front and back the differential lock will work naturally. If the differential cylinder doesn‟t work, it indicates some
problems is the electricity, air control system of electromagnetic valve. Then, just loosen the outlet connection of magnetic valve
to observe whether some compressed air output, if not that shows the problem from circuit control system of magnetic valve or
magnetic valve itself; if yes, that indicates the problem comes from the working cylinder.
If pushing rod puts the differential lock in right position after pressing the differential lock switch, however, the signal light is not
on, obviously the problem is from the switch of signal light or signal light itself, which is easy to check out by using the test lamp.
6. Rear Wheel Abrading Tire
There may be several possibilities for rear wheel abrading tire: the distortion of tyre steel ring, loosing of hub bearing and
malposition of rear axle. The reason for malposition of rear axle is commonly the cracking of screw of center armor plate.
- 144 -
Do It By Yourself
Common Errors and Solutions
Clutch
Errors
Clutch Slipping
Clutch Incomplete Releasing
Reasons
Solutions
There is no release bearing clearance, and
clutch is half-releasing.
Clutch plate lining has been worn down to a
dangerous level.
Release bearing clearance is too wide, and
effective separate distance are not enough.
The air went into the clutch hydraulic
system, and effective separate distance
become smaller.
Adjust the release bearing clearance as
specified.
- 145 -
Replace friction plates
Adjust the release bearing clearance as
specified.
Remove all the air in the clutch
hydraulic system.
Do It By Yourself
Common Errors and Solutions
Air-Conditioner Error Diagnosis and Resolution Table
Errors
1. High pressure is low
2. High pressure is high
3. Back pressure is low
4. Back pressure is high
Possible Reasons
Solutions
Leak
Expansion valve error
Return-air valve closed
Lack of freezing medium
Drier blocked
Compressor return-air valve leak
Compressor reed valve damaged
Air in the system
Condenser blocked
Exhaust valve was closed
Freezing medium overcapacity
Lack of freezing medium
Compressor piston worn-out
Compressor head gasket leak
Tube jammed or squeezed
Compressor return-air valve leak
Moisture in the system
Expansion valve trap valve blocked
Expansion valve sensing bulb flexible
Leak checking and repair
Replacement
Turn on
Liquid charging
Replacement
Replacing the valve
Replacement
Re-inject freezing medium
Clear the condenser
Open the exhaust valve
Discharge redundant freezing medium
Add the freezing medium
Repair
Replace head gasket
Replace tubes
Replace the valve plate
Replace drier
Clean and replace the drier
Tightening the sensing bulb retaining clip
Freezing medium overcapacity
Expansion valve can not be closed
Compressor reed valve damaged
Compressor head gasket leak
Exhaust redundant freezing medium
Replace expansion valve
Replace reed valve
Replace air cylinder gasket
- 146 -
Do It By Yourself
Common Errors and Solutions
Air-Conditioner Error Diagnosis and Resolution Table
5. Compressor doesn’t work
6. Poor cooling effect
7. Evaporator coil freeze
Driving belt damaged
Replace belt
Clutch wire damaged
Replace wire
Compressor piston damaged
Replace compressor
Thermostat switch failure
Replace thermostat switch
Clutch coil damaged
Replace coil
Coil freezing, the temperature adjusted
Tighten down the thermostat switch, and
overvaluation
defrosting
Hot air infiltrates into cab
Turn off heat source valve
Drier clogged
Replace the drier
Lack of freezing medium
Add the freezing medium
High pressure is a little high
Refer to 2
Return pressure is a little low
Refer to 3
Return pressure is a little high
Refer to 4
Drier blocked
Clear and replace the drier
Expansion valve error
Replace expansion valve
Thermostat switch failure
Replace thermostat switch
Thermostat switch improper adjustment
Adjust to the working condition
Insufficient air capacity going through
Examine evaporator fan
evaporator
- 147 -
Do It By Yourself
Common Errors and Solutions
Air-Conditioner Error Diagnosis and Resolution Table
Misalignment belt pulley
Adjust the belt pulley axial location
Too tight or too loose
Right adjustment
Improper specification
Replacement
Damaged idler bearings
Replace the bearing
Fuse is burned down
Replacement
Pilot switch failure
Replacement
Injured motor of fans
Replacement
Motor voltage is low
Check the wires
Contact unreliable
Examination
Wires become flexible or short circuit
Troubleshooting
Crooked rotor spindle
Replacement
Controller resistance is burned down
Replace the resistance
Low voltage
Examine the engine
Screws used to fix the blades
Tightening the screws
11. Leak of hose or
Connectors leaking
Repair or Replacement
connectors
Hose leaking
Replace the hose
8. Trouble in Belts
9. The fan doesn’t work
10. The fan runs too slow
- 148 -
Technical Data
Frequently-Used Vehicle Data
Volume Data
Assembly
Fuel tank capacity (L)
Engine Cooling system (L)
Petroleum Product
Diesel
Long-lasting
Brand
Volume
Diesel which apply to the local temperature
antifreeze
anti-corrosion Heavy
duty
long-lasting
antifreeze
400/300/
260
40
coolant
anti-corrosion coolant used in four seasons
Engine Lubrication system (L)
Engine oil
API CF-4 SAE 15W/40
24
Transmission (L)
Gear oil of heavy duty vehicles
85W/90 GL-5
13
Clutch (L)
Brake fluid
SAE 116/ DOT3
Steering (L)
Hydraulic liquid (Low temperature)
HVN32 hydraulic liquid (ATF III)
3.5
Rear-axle (L/each axle)
Gear oil of heavy duty vehicles
85W/90 GL-5
23
Tilt-cab assembly(L)
Hydraulic liquid (Low temperature)
HVN32 hydraulic liquid (ATF III)
0.4
Notice: Actual volume is subject to the actual configuration.
- 149 -
About 1L
Technical Data
Frequently-Used Vehicle Data
Data for Adjusting
Pedal
Travel of clutch pedal (Free travel)(mm)
Brake Shoe Clearance (mm)
Travel of brake chamber push-rod (Travel of piston rod)(mm)
Type
9.00-20
Single tyre
700
Air pressure of tyres (kpa)
Dual tyre
770
- 150 -
10.00-20
740
810
40
0.61
57 (min)
11.00-20
12.00-20
740
740
810
810
Technical Data
Logo
VIN
- 151 -