CA5083 XXYPK2L1A80 Operation Manua GF-6000l

Oper at i on Manual
Model: CA5083XXYPK2L1A80

Cab-over-engine Diesel Truck

Brief manual
Forward

1

Welcome to choose FAW Truck

FAW model CA5083XXYPK2L1A80, cab-over-engine cabin truck is a new product
developed by FAW, metal and cab-over engine type cabin, CA6-75 mechanical gearbox,
CA4DF2-13 diesel engine, turbo charging, intercooler, Euro-2 emission. The truck has the
advantage of high performance and low fuel consumption.
For better drive and maintenance of this truck, this manual introduces the detail of
operation, maintenance, adjustment and trouble shooting. Please carefully read this book to
master the driving method to operate the truck properly, to prolong the service life to make
maximum profit.
All of the contents of this manual are latest. The reprint version will contain the changed
content.
The copyright of this manual belongs to FAW. Without permit, any person or unit cant
duplicate it.

Wish you a pleasant journey!

China FAW Group Imp. & Exp. Corporation

January, 2006

Brief manual
Content

Vehicle identification1
Brief technical properties2

Fuel, lubricating oil9
Symbol mark12
Operation mechanism13
Indicator lights and instruments15
Switch, button and handle 21
Correct operation28
Correct drive47

New vehicle running-in55
Regular maintenance57
Maintenance and adjustment of main assemblies67
Replacing lubricating oil105
Lubrication table111
Emergency treatment113
Fault causes and solution114

Main bolt and nut tightening torque125
Bearing table128
Oil seal table129

Brief manual
Outline diagram

Brief manual
Forward

1

Vehicle identification

China FAW Group Corporation
Vehicle type CA
Engine type Load kg
Engine power kW TW kg
Chassis number
Engine number
Date of manufacture Y. m. d.

Vehicle model Engine model Loads Gross weight
CA5083XXYPK2L1A80 CA4DF2-13 3570 8200

Vehicle nameplate lie in outside and middle of right longitudinal beam.

Engine parameters
Engine model
Max.power/rotation
speed kW/(r/min)
Max. torque/rotation
speed Nm(r/min)
Min.fuel
consumption rate
g/kWh)
CA4DF2-13 96(2500r/min) 390/( 1400-1600r/min) 208

Brief manual
Brief technical properties

2

CA5083XXYPK2LIA80
General parameters
Chassis curb weight kg 3735
Chassis gross weight kg 8200
Front kg 2150
Gross axle weight (chassis)
Rear kg 1585
Front kg 2700 Gross axle weight
(Full-load) Rear kg 5500
Length mm 7557
Width mm 2385
Overall Dimensions
(chassis)
Height mm 2725(no load)
wheel base (full-load) mm 4250
front mm 1800
Wheel track
rear mm 1740
Front suspension (full-load) mm 1232
Rear suspension (full-load) mm 2075
Distance between cab back and rear axle
center (full-load)
mm 3600
Distance between body geometrical center
and rear axle center (full-load)
mm 3200
Length mm 5400
Width mm 2284 Inner body dimensions
Height mm 600
Min. Ground clearance (full-load) mm 220
Vehicle (full-load) Approach angle
22

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3
Vehicle (full-load)Departure angle
15
Camber 1
Inclination 6 Front wheel alignment
Caster 130
Toe-in mm 26
Min. turning diameter (by front outside
wheel trace center)
m 17.8
Max turning angle of front inside wheel 40
dynamic mm 412.5
Wheel radius(full load)
static mm 407
Top speed km/h 90.5
Max. Grade ability % 28
60km/h m 36.7
Brake distance(load)
40km/h m 33.8
Parking brake on slope(5min) % 18
Fuel consumption L/100km 20
Max. continuous running mileage km 700
Max Noise from outside of vehicle when
accelerating running
dB(A) 83
Minimum speed (high shifting gear) km/h 28
Capacity parameters
fuel tank L 150

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Cooling system L
25 (no heater)
26 (Include heater)
Lubricating system (including engine oil
filter and engine oil cooler)
L 14
Gear box oil volume L
8.3without PTO
9 With PTO
Rear axle oil volume L Around 3.5
Power steering gear and reservoir L Around 3
Shock absorber (each) L 0.74
Clutch hydraulic control mechanism L Around 0.4

Adjustment parameters
intake mm 0.30
Valve clearance (cooling state)
exhaust mm 0.35
Fan belt tension (plus 78N) mm 10-15
Normal temperature of engine coolant 75-95
Free traveling of clutch pedal mm 35-45
Total traveling of clutch pedal mm 180
Air pressure of brake kPa 784-833
front mm 2510
Brake chamber push-rod space
rear mm
3010
Clearance between brake drum and brake
hoof-plate of running brake (measure the middle
shoe plate at brake drum inspect hole)
mm 0.6-0.1
Front wheel kPa 560
Tire pressure
Rear wheel and spare wheel kPa 670

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5
Brief description of structure
Engine
Model CA4DF2-13
Type In-line six-cylinder, four-stroke, water-cooled,
turbocharger, central-cooled, direct-injection
Compression ratio 16.8
Cylinder replacement 4.751 L
Max. torque 390 Nmat 1400 r/min
Max. power 96 kW(at 2300 r/min)
Piston space 125mm
Cylinder diameter 110mm
Min. fuel consumption 208 g/(kWh)
Cylinder ignition
sequence
1-3-4-2
Fuel supply advance angle before upper dead-point 91
Cooling system Pipe radiator, centrifugal water pump, wax temperature
regulator, plastic fan and silicon oil fan clutch, with dilator
Fuel injection bump P7100
Fuel injector P model, 6 spouts
Governor Full speed controller
Fuel delivery pump KS plunger model, fuel delivery pressure is156.8kPa
Fuel filter Double-level rotation type, paper filters core (model is
X0710A)
Air cleaner The filter is dry paper filters core with safe filters core
Clutch 350
Transmission CA6-75 mechanical transmission, 6 forward gear, 1 reverse
gear,

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Gears speed rate
Gear 1
Gear 2
Gear 3
Gear 4
Gear 5
Gear 6
Reverse gear
Over speed gear
6.515
3.796
2.284
1.428
1
0.815
6.060
propeller shaft Open, 2 piece, with 3 universal joints
Rear axle deceleration ratio is 5.43
Frame Boundary beam pressing riveted structure. Longitudinal
beam front is variable section, middle and rear are straight
sections, max. section size is (section heightwing width
plate thickness) 237mm 75mm 7mm, and longitudinal
beam is infrastructure board connection structure; there are
hooks at front and rear frame.
Suspension Front and rear leaf springs are both longitudinal symmetrical
semi-ellipse leaf spring structure. Rear end is flying rings
structure, front suspension is installed with 50mm
bidirectional sleeve shock absorber, and rear suspension with
auxiliary plate spring .
Structure parameters Action length(mm)width(mm)height(mm)
leaf spring number
Front spring 13507611-2 13507610-5
Rear spring 14757611-10
Rear auxiliary spring 11707614-3
Plate spring center space
Front spring
830 mm
Rear spring 1004 mm

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7
Front axle Integral forging forming.
Spare tire riser
Catenary one gear differential structure, transmission ratio
is 17, it mounted at lower part of frame behind rear axle.
Wheel Rim is 8.25-16 model,
Steering gear Cycle integral power steering gear, gear ratio is 20.48
Braking system Adopt front and rear independent two-way pneumatic brake
system, braking valve is straight-step double-cavity piston
series valve. Equipped with four-loop protection valve,
fast-release valve, relay valve, and exhaust braking valve.
Air compressor Single-cylinder water-cooled type
Running brake Front and rear brakes are all pneumatic drum ones
Parking brake Adopting spring energy-storage braking cylinder,
controlled by manual braking valve, acting on rear driving
wheels; Parking braking system is equipped with fast-release
valve.
Auxiliary braking Engine exhaust braking, engine exhaust braking valve and
control cylinder is equipped in silencer inlet pipe,
electromagnetic valve pneumatic control
Air reservoir The main gasholder is integral double-cavity type (the front
cavity volume is 17L, it is used for front braking; its rear
cavity 23L is used for rear wheel braking. There is a
single-cavity gasholder with 20 L, used for separator water.
Electric system 24V, cathode wire tapping
Battery 6-QAW-120D, two in series
Generator Magnetic field outside wire tapping, silicon rectifier AC
generator, with neutral-point tap, voltage is 28V, electricity is
55A.
Starter Electromagnetism control, max. output power is 6kW

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8
Other electric equipment Heater motor is 24V permanent magnetism, output power is
85W. Wiper motor is permanent magnetism double-speed
DC motor, equipped with combination instrument,
combination switch and warning system linking steering
wheel. Circuit protection system consists of two pieces of
fusible wire and 18-plates fuse box. Circuit control system
consists of 8 relays. Combination switch consists of 8
switches, and set the automatic return unit of turning switch,
and starting switch has the anti-theft mechanism and stop
unit of self-lock steering wheel.
Vehicle body
and accessories
Cab is forward metal closed type, adopts panorama and
curving surface windshield; and equipped with torsion bar
spring booster switching mechanism and safeguard by safety
hook. The interior is equipped with high backrest driver seat
with multiple functions, passenger seat with adjustable
backrest angle, with safety belt. With three-gear electric
wiper; single-arm glass regulator, card type door lock;
windshield syringe, plastic carpet, large sphere rear-view
mirror, air mixed heating system and multi-point injection
defroster, and second-level pedal mechanism, as well as new
headlights, front small light and side turning light. Select
electric door and window.

Operation manual
Fuel and lubricating oil

9


Fuel
Must use good quality diesel fuel .
The user should select proper diesel fuel according to local temperature condition,
in compliance with following.

Air temperature above 0 0 -10 -10 -20 -20-35
Diesel fuel type No.0 No.-10 No. 20 No.-35

The fuel filled when new vehicle leaves the factory is:
Summer: GB252 grade one No. 0 light diesel
Winter: GB252 grade one No. 35 light diesel
If the diesel is mixed with fuel such as gasoline and alcohol, fire may occur, so
this case should be avoided absolutely.

Operation manual

10

Caution
Before filling fuel, stop running first, and pay attention to whether there is open
flame, to prevent unexpected thing occurrence.
Diesel fuel must be deposited at least 48 hours before it is filled into fuel tank,
not including any impurity and water.
The filling container must be clean, preventing dust and impurity from entering
it.
Do not fill diesel when engine is running, not spattered diesel outside.

Operation manual

11

Lubricating oil
Lubricating oil can be filled into diesel engine after filtering( see on picture) .
The diesel engine series vehicle type is exhaust-driven supercharger and central
refrigeration turbine diesel, must select engine oil above grade CD.
Lubricating oil viscosity is influenced greatly by temperature, lubricating oil
should be select according to the stipulation of national standard(GB11122),
based on local temperature.
If local temperature overstep the utmost, it only start capability but damaged
diesel engine.
Engine oil must keep clean, not be polluted by dust and impurity.

The lubricating oil filled when new vehicle leaves the factory is:
General areas whole year: 15W/40 CD(-20 40) grade diesel engine oil.
Summer (south areas): 40CD(040) grade diesel engine oil.
Winter (cold areas):5W/30CD(-3040) grade diesel engine oil.

Operation manual
Symbol indication

12
Symbol indication

Turningsymbol

Battery chargecondition

Engineoil pressure
warning

Brakingsystemtrouble

Parkingbrake

Master switchfor
lights

Legspaceventilation

Master power switch
e

Electric andpneumatic
hornconversionswitch

Fuel

Coolant temperature

Cigar lighter

Exhaust braking

Heating

Cabtoplight

Differential lock

Windshieldwiper

Workinglight

Enginepreheating

Vehicledoor

Cabtilting

Reversinglight

Lightsandlanterns

Filter block

ABS

ADM

Foglamp

Danger signal

Parkinglight

Windshielddefrost and
defog

Power takeoff indicator
light

Contour light

Highbeamlight

Operation manual
Control mechanism

13
Control mechanism

1-steering wheel 2-turning switch, light switch 3-instrument cluster 4-fog
light switch 5-starting switch 6-wiper switch, washer switch, exhaust brake
switch, danger warning switch 7-air conditioner switch 8- cigar lighter 9-
ashtray 10-heating control lever 11-manual valve 12-gear control lever
13-accelerograph pedal 14-braking pedal 15-clutch pedal 16-glass regulator
handle 17-door lock inside handle 18-steering wheel lock handle 19-horn
button 20-clutch oil tank

Operation manual
Control mechanism

14

1-voltage meter 2-air pressure meter 3-fuel gauge 4-water temperature meter
5-oil pressure meter 6-warning indication lamp 7-speedometer 8-engine
revolution meter 9-rear fog switch 10-pre-heat button 11-windshiel washer
switch 12-wipper switch , exhaust brake switch and danger warning switch
13-lock knob of ignition switch 14-ignition switch 15-lock handle for steering
wheel 16-horn button 17-light switch, turning light switch 18-front fog light
switch

Operation manual
Indicator lights and instruments

15
Parking braking indicator light
The light comes on when parking braking valve (i.e. manual valve) is at braking
position, which remind the driver turn the parking braking valve back the
front( ravel parking braking) in time when the vehicle starts to run; and the light
goes off when fast-release valve pressure reaches 392kPa.
Power indicator light
Indicate the charging state of generator. The light comes on when the engine
begin starting, showing it has been charged; if the light comes on when the
vehicle is running, it is necessary to check whether the power supply system
trouble occurs.
Check whether V-belt has breakdown and V-belt tension is normal.
Check whether high current fuse of charged circuit is blown out; if it has been
blown out, replace it.
If there is no abnormal in the above two items of check, which shows the
charging system has trouble, remove it in time.
Braking system trouble warning light
After brake warning light comes on, braking effect decline obviously, extremely
danger, the vehicle cannot continue running absolutely. If the braking system has
air leakage, the brake shall lose its action.
When pneumatic braking system has trouble or pipe has air leakage, gasholder
pressure drops to 441kPa, the warning light comes on. When running if the light
is bright, must stop vehicle to check, after the trouble is removed, it can run.

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Run the engine in middle rotary speed, until the warning light goes out.
Check whether the match pipes and pipe joint of all sections has air leakage.
If the warning light does not go out, or it comes on soon after it goes out, the
braking system should be repaired.
Start preheating indicator light.
When starting engine, after starting switch switching in ON gear, press starting
preheating button, the preheating indicator light comes on; release the button,
relieve preheating, the indicator light goes out, preheating system finishes work.
Engine oil pressure and engine oil filter warning light
When the key switches in power, oil pressure indicator light comes on. After the
engine starts, the indicator light goes out.
When the engine oil pressure drops to 605kPa, the light is comes on. If the light
comes on when running, which shows that the engine oil is deficient or engine
filter is crammed, at that time, must stop vehicle to check, and drive it after the
trouble is removed.
When it is cold, the warning light still comes on temporarily after the engine
starts sometimes due to the engine oil viscosity rising, this phenomenon is not
abnormal.
If the light comes on when the engine is running, the vehicle should be parked on
safe place to check.
Check engine oil level, if it is deficient, complement.
Check all section of the engine to see whether there is oil leakage.
The oil level is normal and there is no oil leakages, showing that lubricating
system has trouble, remove it.

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Cooling water level/engine over-hot warning light
When engine coolant is deficient or the engine is over-hot, the warning light
comes on.
Dont ignore the warning light; Otherwise the engine temperature rises
excessively, to lead to sinter.
If the warning light comes on, and water thermometer hand get outside of the red
area, showing that the engine is over-hot, the following operation should be done.
Operate the engine at the rotational speed slightly higher than idle speed, to make
the engine temperature drop.
If the warning light comes on, but the water thermometer is in normal position,
showing that the coolant is deficient, the following check should be carried out.
Stop the engine until the coolant temperature drops.
Check whether radiator and its match pipe have water leakage.
Open radiator water tank cap, and fill coolant fully.
If finding water leakage, go to garage to repair.

Caution
Dilator cap can be reopened until the water temperature drops. When open the
cap, cover it with cloth, slowly unscrew to the first stop, after pressure relief, and
open the pressure cap, to avoid hot water erupting to cause scald.

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18

Air pressure meter
Air pressure meter is double-hand type.
The upper hand indicates the front cavity air pressure of air holder, the front
cavity air is used for front wheel braking.
The lower hand indicates the rear cavity air pressure of air holder, the rear cavity
air is used for rear wheel braking.
When vehicle is running, braking air
pressure must keep in the range of
784-833kPa.

Speed odometer
aindicate vehicle running speed
bindicate vehicle cumulate total
running mileage
During the wear away period (2500km),
Max. Speed does not exceed 60km/h.

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19

Fuel gauge
Indicate the fuel level in fuel tank.
0: show no fuel in the fuel tank.
1: show full fuel in the fuel tank.
After close starting switch, the hand still indicates the fuel level in the fuel tank.
Fuel tanks volume is 300L, this is equipped with conceived fuel tank.
Continuous running mileage of vehicle is 1000km.

Water thermometer
Water thermometer indicates engine coolant temperature, scale 110 expresses
high temperature, 50 low temperature, 110-50 expresses normal temperature..
After the engine is cold started each time, it is necessary to run at low speed to
preheat rising temperature, until the coolant temperature reaches above 50, it
can start to run.
In running, observe carefully water temperature, to make coolant temperature
keep 75-95(about at the middle of both scales).
If the hand is outside of scale 110, it shows that the engine is getting over heat, it
is necessary to stop to check, remove the trouble.
In normal operation circumstance, radiator curtain is fully open, temperature
controller and fan clutch shall automatically adjust coolant temperature, to make
it at optimal working temperature. When it is particularly cold, lower the radiator
curtain to adjust coolant temperature.

Operation manual

20

Voltmeter
Voltmeter reading range is 0-32V. 16-24V and 30-32V are red area, normal
voltage is at middle position.

Engine oil pressure meter
Indicate the working pressure of lubricating oil in main oil-way of engine.
After the engine starts, it is necessary to check engine oil pressure.
Scale 6 expresses high pressure, 0 expresses low pressure.
In running, often observe engine oil pressure. When the engine runs normally, if
the hand of engine oil pressure meter is 06, the pressure is normal. If the
engine oil pressure is over low, the hand does not move or the hand moves
suddenly, must be stop vehicle to check, to prevent parts from burning out. When
the engine is working, the engine oil pressure does not lower than 100kPa.

Operation manual
Switch, button and handle

21
Combination switch
Combination switch includes: light switch, change lights switch, turning signal
switch, wiper switch, washer switch and danger warning switch.

Left handle (light switch, turning signal switch)
This switches control lever, at left side of turning column

High beam and low beam conversion
Overtaking dimming

Operation manual

22

Light switch
To turn the knob at the end of left handle, to make the handle be at OFF
position, turn off all light.
When the left handle turns to position, front and rear small lamps,
instrument light and rear license plate light come on.
Raise the handle, high beam and low beam of headlight comes on
simultaneously, giving overtaking signal; after releasing it, headlight goes off.
When the left handle is turned to position, headlight, front and rear dim
lamps, instrument light and rear license light come on.
Raise the handle to the top, high beam and low beam of the front light come on
simultaneously. Raise the hand to the top again then release, returning low
beam.
Repeat rising and releasing, may send the vehicle meeting signal that high
beam and low beam alternate conversion.

Turning switch
When the left handle is on middle gear position, turning light goes off.
Push the left handle forward, right turning light comes on, at the same time,
corresponding turning indicator light on the instrument cluster flash.
Pull the left handle backward, left turning light comes on, at the same time,
corresponding turning indicator light on the instrument cluster flash.

Operation manual

23

Right handle (wiper switch, windshield washer switch, danger warning
switch, exhaust braking switch)
This switch is control lever, at the right side of turning column.
Wiper switch

Danger warning

Windshield wash

Operation manual

24

When right handle is in the middle position (OFF), the wiper not to work.
When right handle is turned to LO position, the wiper works at a low speed.
When right handle is turned to HI position, the wiper works at a high speed.
When right handle is turned to INT position, the wiper works intermittently.

Windshield washer switch
Windshield washer switch is at the end of wiper switch.
Press the switch at right handle end inward, detergent will spray on windshield
glass; When loosening, spray stop.
When wiper switch turns to OFF position, press washer switch, the wiper
should automatically wipe twice.

Caution
Washer spray cannot exceed 5 seconds for each time; the interval to next spray
cannot be less than 25 seconds.

Danger warning switch
This switch can simultaneously turn on and turn off left and right turning light
power.
Use it when vehicle in trouble, or parking at danger place.
When right handle is raised to the middle position, front, rear, left and right
turning lights flash simultaneously.
Raise the right handle to the top, after loosening, the right handle falls
automatically, 4 turning lights go off simultaneously.

Exhaust brake switch
Push right handle forward, at OFF position, exhaust brake does not work.
Pull right handle backward, at ON position, exhaust brake will work.

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25

Starting switch
starting switch key and vehicle door key are
the same one.
LOCK: Shut off electric circuit
ACC: Turn the key rightward (clockwise) to
gear 1, switch in accessory gear. When vehicle
stop, if want to use some electric equipment
(radio cassette, etc), turn the key to this gear,
then can operate the corresponding electric
equipment.
ON: Continue to turn the key to gear II, switch
in electric circuit.
S: Continue to turn the key to the bottom, start engine, after loosening, the key
returns automatically.

Key locking
When the key is inserted into the starting switch, turned LOCK position to
ACC position, the lock locking button(white button) will spring automatically,
to make the key not be pulled out, preventing the key from pulling out from
lock hole due to vehicle vibration in running.

Fog light switch
Fog light switch is roller type, at steering wheel jacket.
Please use fog light when it is foggy or sight is not good in cloudy day.
Press the switch at ON position, the fog light comes on; The switch is returned,
the fog light goes off.

Operation manual

26

Electric and pneumatic horn conversion switch
The vehicle is equipped with electric horn and pneumatic horn, and set the
conversion switch on the instrument cluster, the user can convert them
randomly.

Cigar lighter
Press down the cigar lighter switch, until
resistance wire is red and hot, it automatically
pops out, at that time, pull out the button to use it.
Dont hold the lighter in to block it pop-up;
otherwise, it will overheat to cause danger.
If the lighter doesnt pop out within 30 seconds,
which shows the lighter in trouble, remove it to
prevent fire.
When the lighter doesnt work well, stop using it.
Dont leave the vehicle when the lighter is
pulled.
Deformed lighter cannot pop-up, replace it with
right lighter.
Dont use the lighter socket for plug-in
accessories. They may damage it or cause
electrical accident.
When the ignition switch must be in the ON or
ACC position, it can be used.
Ashtray
Beside the lighter is equipped an ashtray.
Put Cigar end and match into the ashtray after they are completely.
Was put out; then press the ashtray cover well.
Dont put things other than cigar end or be full of cigar end; You may bring a
fire.

Operation manual

27

Steering wheel locking handle
Steering wheel locking handle is installed
on the steering post, release the locking
handle can adjust steering wheel and
steering post positions. When adjusting,
raise the locking handle, make the steering
wheel relieve locking, at that time the
steering wheel can slide upward and
downward or swing forward and backward.
The steering wheel can slide upward 40mm,
downward 20mm; swing 5 forward and
backward respectively.

Parking braking control valve (manual
valve for short)
Manual valve is at the right side of driver
seat.
When braking, pull the manual valve to the end.
When relieve braking, lift the pull button 2 of the manual valve, at the same
time push handle 1 forward to the end.
Caution
Use the manual valve only for parking.
In running, when running braking fails or other dangers occur, the manual
valve is allowed to use, but dont replace running braking.
Steering wheel

Steering wheel locking handle
Braking position
Relieve braking

Operation manual
Correct operation

28
Correct operation
Outside unlock of left door:
Insert the key into lock hole, turn 90
clockwise then return, pull out the key, then
hold the outside handle, and press strongly
press-button with thumb, pull outward, to
open the door.

Outside locking of left door
Close the door properly, insert the key
into lock hole, and turn 90 anticlockwise, the
door is locked. The key can be pulled out
after it returns.

Right door operation is the same as left
door, but the direction is reverse:
Inside unlocking of door
Raise lock button, then pull inside handle, to
open the door.

Inside locking of door
Close the door, press the lock button, to lock the door.
Note: When the door is not closed completely, the light inside of cab
comes on; after the door is closed properly, the light goes off.
Outside handle Press-button Lock body

Lock button

Inside handle Inside arm
Glass regulator handle

Operation manual
Correct operation

29

Cab ventilation
Natural ventilation is implemented
through air ways on interior and upper
walls of cab, airflow enter the cab
through airways and vent grid,
manually trigger grating to adjust
airflow.
Forcing ventilation, heating and
defrosting are to send fresh air into the
cab through floor vents, central vent
grating and left and right side defrost
nozzle.

Glass regulator operation
Left door: Turn handle clockwise, door
glass fall.
Turn handle anticlockwise,
door glass rise.

Right door: Turn handle anticlockwise, door glass fall.
Turn handle clockwise, door glass rise.
Vent grating

Lock button

Inside handle Inside arm
Glass regulator handle

Operation manual
Correct operation

30

Central control door lock (optional)
Press remote device locking button outside of the door, left and right doors
can be locked simultaneously.
Press remote device unlocking button, left and right doors can be unlocked
simultaneously.

Inside locking of door:
Close the door, press the locking button inside of left door, left and right
doors can be locked simultaneously; Press the locking button inside of right
door, only right door can be locked. Press the front end of door control switch,
left and right doors can be locked simultaneously.

Inside unlocking of door
Pull the locking button inside of door, or press the rear end of door controls
switch, the door is in unlocking state, pull inside handle backward, to open
the door.

Operation of electric glass regulator (optional):
Driver side can control left and right door glass regulators.
Press the front end of control switch of left door glass regulator, left door
glass rise, release it, glass stop lifting, right door operation is the same as left
door.
Press the rear end of control switch of left door glass regulator, left glass fall,
but release it, the glass continues falling up to the low stop point.
Press the rear end of control switch of right door glass regulator, right glass
fall, release it, the glass stops falling.

Operation manual
Correct operation

31

1

2

3

Left door Right door

1-inside lock button 2-inside handle 3-right door regulator switch 4-left door
regulator switch 5-door lock control switch

Operation manual
Correct operation

32

Adjustment of drivers seat
Front and back adjustment:
When adjusting front and back positions, step
on the floor, pull rightward slide-way
regulation handle, to make the regulation
board take out toothed plate, use the friction
force of the body and seat-bottom to make the
seat slide to necessary position, then release
the handle, to make the regulation plate and
toothed plate fit, restore locking.
The front and back adjustment of the seat can
be divided into 8 gears, Max. Adjustment
quantity is 140mm.

Backrest angle adjustment:
When adjustment, pull backward the angle
regulation handle to relieve locking, the
backrest will incline forward automatically
due to spring elasticity, use the body backrests pressure to adjust the back to
proper angle, then release the handle to restore locking.
The original angle of the back is 1230; it can be adjust forward to 22;
backward to 46, divided into 23 gears.

Slide-way handle
Slide-way regulation handle

Operation manual
Correct operation

33

Headrest position adjustment
Must adjust the headrest to correct position, and fix well.
When adjusting the drivers seat headrest position, pull the headrest
regulation lock plate, after open the lock plate, press down or raise the
headrest, to the position you want, then release your hand to lock.
Passenger seat: except for the front and back adjustment function, other
functions are as the same as the drivers.
In running, dont make the backrest incline
backward, otherwise, when emergency
braking, passengers body will slide off the
seat to suffer from serious injury.
Middle seat: The back can tilt forward,
behind the back is equipped with a glove
box.
Height adjustment of selecting drivers seat:
Pull upward height adjustment handle,
adjust front handle 3, relieve locking, adjust
seat front angle with human body weight,
after adjusting to proper position, release
handle, then lock it again.
Adjust rear handle 4, relieve locking, adjust
seat rear angle with human body weight,
after adjusting to proper position, release
handle, relock, and finally reach the goal of
adjusting seat height.

1-front and rear adjusting handle 2-angle adjusting handle
3-front handle of height adjustment 4-rear handle of height
adjustment
5-rigidity adjusting handle 6-electric heating pad plug
Unlock

Operation manual
Correct operation

34

Front and back adjustment:
Pull upward the front and back adjusting handle 1, relieve locking, adjust seat
assembly forward or backward with human body strength, after adjusting to
proper position, release the handle, relock.

Angle adjustment
Pull upward the angle regulation handle 2, relieve locking, adjust seatback
angle forward or backward with human body strength, after adjusting to
proper position, release the handle, relock.

Rigidity adjustment:
Turn rigidity adjusting handle 5 forward or backward, adjust to driver weight
value according to the scale on the handle, so as to adjust the seat mat rigidity
suitable for driver.

Passenger seat adjustment:
The height adjustment, front and back adjustment, angle adjustment of
passenger seat is the same as driver seat adjustment, only without rigidity
adjustment.

Seat electric heating unit:
Turn on the electric heating seat switch on instrument cover, and then the seat
can be heated.

Operation manual
Correct operation

35

Seat belts (selection)
In order to reduce the damage occurring in vehicle bumping or emergency
braking, it is very important to use seat belt correctly.
Before vehicle start to run, make sure all passengers fastening the seat belts.
It is extremely dangerous to remove or fasten the seat belts in running, must
do it when vehicle stops.
One seat belt is not allowed to used by tow passengers.
Note abraded seat belts, this kind of seat belt is not only non-effective, but
also very dangerous.
After fastening seat belts, should sit up on the seat, make the back lean
against the seatback. If sitting posture is not upright that will reduce the
protection effect of seat belts.
When vehicle is running, dont over-tilt the seatback, otherwise, when vehicle
bumps, passengers body will pull out from the seat belts, to cause
passengers neck hanging, suffering from unexpected injury such as cervical
vertebra wreckage.
In order to avoid abdomen crush in vehicle bumping, must fasten the seat belt
on bones, also note the shoulder belt position.
When fastening seat belts, make sure the seat belts are not twisted up. The
area of the twisted section, which will bring over large pressure on human
body, causing danger.
If the seat belts have broken, and burst at the seam, or the belt buckle effect
is abnormal, replace them immediately.
When vehicle bumping accident occurs and the seat belts receive impact
force, although the seat belts are not found damage, the seat belts should be
also replaced.
Dont insert impurity into the belt buckle of the seat belts, dont transform or
take off the seat belts either.
Seat belt cleaning: When the seat belts are dirty, they should be cleaned with
neutral detergent, dont use bleacher, dye or dry cleaning agent, which can
seriously damage their strength.
Fastening seat belts: sit upright on seat, make the back against the seatback
comfortably, slowly pull out tongue and insert it into buckle until you hear a
click, make sure the seat belts have not twisted section; loin belt is fastened
on bone, the lower the better.
Releasing seat belts: press red button, the belt will automatically wrap, when
the belt is wrapping, hold the tongue until it wraps.

Operation manual
Correct operation

36

Sundries box
Dont put the things that may fall down or roll, or they may roll out to block
safe running when vehicle starts or stops.
Before vehicle starts, must close the cover.

Outside rear view mirror
Outside rear view mirror can be adjusted manually to the desired angle, to
reach satisfactory effect.
Rear view mirror should be wiped to keep mirror cleanness.

Adumbral board
When driving, if the sun irradiate directly, lower the adumbral board.
Adjust the adumbral board to proper angle, to guarantee both the drivers
sight and effective visual field.
Pull out the adumbral board from the fixed clip, swing to door side, to keep
out sidelight.

Operation manual
Correct operation

37

Radio/cassette player
Dual-track, AM/FM stereo radio cassette tape player, it has LED frequency
and clock display function, high tone and low tone compensation function,
remote and local reception control function, automatic reverse function, etc.
Power supply (SW), volume (VOL) button: Turning clockwise until you hear
click, showing switch in power, may adjust volume.
TUNE button: Turn this button, display frequency on LED screen
correspondingly change, may select corresponding broadcasting station.
Volume output balance (BAL) button: Adjust left and right track volume
balance.
Tone control button: Adjust high tone and low tone to make tone quality
optimal.
Frequency/clock selection button: Change the selection of reception
frequency and clock display on LED screen.
Band (BAND)button: AM and FM switch
Stereo control button(ST): Normal / Stereo selection.
Remote/near control button(DX): Remote broadcasting station and near
broadcasting station switch.
Clock set button(SET): Hour set button (H), minute set button (M): press (H)
button or (M) button, LED will display clock. If the adjustment is need, adjust
hour or minute.
When vehicle stops, if using the radio, first turn the starting switch key to
switch in accessories gear.

Operation manual
Correct operation

38

Emblem mark

1-TUNE knob (for radio channel selection) 2-power, volume knob 3-tone control
knob 4-clock set button 5-LED display screen 6-cassette holder

Operation manual
Correct operation

39

Cab tilting forward and return
Cab tilting forward:
Cab locking control mechanism is at the left side of cab back.
Pull out safety pin 6 from the pinhole, pull control handle 7 down to the end,
make main hook detach from lock latch assembly 2 (see the right figure in
next page).
Pull outward pull-rod 5, make safety hook detach from lock latch fixed rack 3,
at that time, the cab can spring upward to one balance position.
Push upward handrail 12, make cab 11 lift, so as to make support rod
assembly 10 strengthen out, at that time, the cab is balanced, push upward
lock hook, insert linchpin 8 into lock hole, lock the support rod, see the left
figure in next page.

Caution
Support rod linchpin must be inserted into the hole actually, to avoid the cab
fall to cause personal injury.

Cab return
Stand outside of left front wheel, pull out linchpin 8(see the left figure in next
page), turn downward lock hook, at the same time hold handrail 12, pull
downward, to make the can fall.
When the cab fall, safety hook 4 (the right figure in next page) will lock the
lock latch fixed rack 3, the cab will be advance locked.
Push upward control handle 7(as the position in the right figure in next
page), to make main hook 1 lock the lock latch assembly 3.
Insert safety pin 6 into pin hole, at that time the cab is locked.

Operation manual
Correct operation

40

1-main hook 2-lock latch assembly 3-lock latch fixed rack 4-safety hook
5-pull-rod 6-safety pin 7-control handle 8-slip-pin 9-lock hook
10-support rod assembly 11- cab 12-armrest

Operation manual
Correct operation

41

Operation of air conditioner (heating, cooling)
1: A/C switch: A/C switch is cooling switch. Cooling equipment is a selection.
When wanting to operate cooling equipment, press this switch,
compressor begins operation; Want to stop, please press this switch
again.
2: Cooling outlet shift control rod
Air blows toward selected direction from the central or left and right
outlets.
Air blows out from the center, left, right or floor.
All air blows from floor.
All air blow toward front glass window (frost prevention device).
Air blows toward the center, left, right and front glass window.
Air blows toward the center, left, right and front glass window.
3: Interior and exterior air shift control rod

Interior circulation: make the air within the cab circulate.
Exterior circulation: input exterior fresh air.

Operation manual
Correct operation

42

4: Fan switch
OFF stop

Gentle breeze
Mild wind
Normal wind
Strong wind

5: Temperature regulation control lever
Left side (COOL)blow cool wind
Right side (WARM)blow warm wind

Operation tips
Heating: When wanting the cab interior become warm, place control lever 3
in interior circulation position

Operation manual
Correct operation

43

Ventilation: Place control lever 3 in exterior circulation position, other control
lever positions are as shown in the figure.

Defrost: All control lever positions are as shown in the figure.

Caution
When using heating, the engine coolant temperature should be above 75.
When using heating in winter, the heating outlet switch on engine cylinder
head should be opened first.
Antifreeze is required to use in cold areas. If antifreeze is not used, when
vehicle stops for a long time, it is necessary to open discharge valve, to
prevent generating ice block in pipeline or freeze heating radiator.

Operation manual
Correct operation

44

Using tire chain in winter
Tire chain installation
Tire chain should be installed firmly, to avoid to take off or collide and
interfere other parts in running.
The tire chain suitable for tire size should be mounted.
Dont mount tire chain on front wheel.
When installing, check whether tire chain and it spring drawstring have
abrasion.
After running 5-15 minutes, check whether tire chain has looseness or
dropout.
After install tire chain, driving speed should not exceed 30km/h.
On the road without ice and snow, dont use tire chain; Otherwise chain is
easily damaged.
The bending section of cross chain should be at outboard.

Cross chain

Operation manual
Correct operation

45

Inside chain is all used to make it become non-residual state and link hook,
pull the cross chain of inside tire outward, to eliminate inside chain looseness.

Outside chain Middle chain Inside chain

Hook

Cross catena
The hook that temporary fix outside chain is as shown as the figure.
Strain the middle chain as far as possible and connect hook.

Hook

Strain both ends of outside chain and connect hook.

Hook

Operation manual
Correct operation

46

Make sure all hooks and tire side-wall become parallel state, at the same time,
make sure all chain has no twisted section.
Fix residual chain with wire, to prevent contact other parts.

Fasten spring clamp, all sections of spring clamp should face the outside and
evenly installation.

Spring clamp

Operation manual
Correct drive

47
Correct drive
General starting of engine
Place gearlever in the neutral position, strain manual valve, then switch in
power with key(turn the key clockwise to ACC position).
Step on clutch pedal, continue to turn the key to start engine, as soon as the
engine starts, release the key immediately.
After the engine works smoothly, uniformly release clutch pedal.
After starting, check engine oil pressure and coolant temperature.

Caution for starting:
Make sure whether there are people or barriers in the under part, front, left and
right of the vehicle with eyes or rear view mirror.
Make sure whether there are bright warning lights.
Make sure manual valve is in relieving braking state.
When starting, dont step on accelerograph suddenly, to prevent the engine oil
pressure from rising suddenly, while the engine oil is over viscous, which
cannot reach the friction surface of all parts in time, to accelerate part abrasion.
Starter is not used for more than 5-7 seconds each time, after each failure,
restarting must be after 2 seconds. If three successive starting fails, check
whether oil pipeline and circuit have trouble, restart after finding the cause and
removing it, and dont start forcedly.
After engine starts, dont step on gas pedal suddenly, to avoid engine running at
high speed.
After engine starts, first work for several minutes at low speed, until water
temperature reaches 50, begin to run, but dont idle work over long.
For the vehicles that dont drive for a long time, or the engine oil and engine oil
filter cylinder are replaced, must start motor first, to make lubricating oil get on
all lubricating surface, then start the engine.

Operation manual
Correct drive

48

Caution for winter
When the temperature is lower than 5, must particularly maintain the diesel.
Must use the engine oil and diesel for winter, dont mix diesel with water, to
avoid block oil-way.
When replacing low-temperature engine oil, discharge the engine oil in the
original disc and oil injection pump of the diesel completely, and clean engine
oil filter, engine oil disc and engine oil receiver, then fill low-temperature
engine oil into the engine disc and oil injection pump. When diesel working
environment temperature is below -10, the replacing oil cycle should be
shortened.
Before starting, pull down radiator curtain.
When starting the engine, first the starting preheating button, then start the
engine with key.
After the vehicle stops in winter, discharge water until the waters temperature
drops to 40-50.
In cold areas, it would be better if the vehicle would not stop in the open,
otherwise, when starting, must warm engine oil disc to make engine oil not
over dense. If the vehicle does not use antifreeze, the water tank must be filled
boiled water, and use heater so as to start easily.
When starting engine below -35 temperature in winter, if using hot-water
heater, the water temperature should not be over high, to avoid cylinder body
crazing.

Operation manual
Correct drive

49

Engine preheating
After engine starts, first preheat to make temperature rise, during this period, to
observe the working conditions of all instruments, indicator lights and warning
lights.
In the period of preheating, indicator lights come on,
but along with oil and air pressure rise, warning light go off.
When the hand of pressure meter indicates 450kPa, engine oil pressure will
reach 100kPa, and coolant temperature will get above 50, at that time, the
vehicle possesses driving condition.
At that time parking braking light still comes on, which remind you
release manual valve before driving.
Notice
Please avoid preheating operation in bad ventilation places is harm to your
health.
Caution
Dont operate engine in garage or closed place for a long time, since air cannot
ventilate well, danger occurs easily
Dont park vehicle for a long time under the condition of engine working.
Vehicle should be parked in good ventilation places, and adjust A/C system to
make outside airflow into the vehicle.
Avoid inbreathe engine exhaust, since CO in exhaust is toxic gas,
over-inbreathing will make person be suffocated to death.
Often to check the exhaust system.

Method of engine starting after long parking
After the vehicle is not driven for a long time, or engine oil and engine oil filter
cylinder, which will cause lack engine oil in the engine, so before starting the
engine, turn the engine crankshaft with starter according to the following
method, to make engine oil roll into all sections of engine.
Make the engine crankshaft turn with starting motor, the purpose is not to make
engine start, therefore, dont step on accelerator pedal.

Operation manual
Correct drive

50

After turning the starting key to S position, release it.
Make sure pull manual valve.
Push gearlever into neutral position.
In the state of not stepping on accelerator pedal, turn the starting key to S
position, rotate engine for 15 seconds.
Caution: The vehicle with supercharged engine must rotate engine according to
the above-mentioned method before starting.

Starting engine in cab gradient state
Start engine in cab gradient state in order to check and repair, first take the
following safe measures, then start engine with starting key.
Be sure to apply parking braking, and fix wheel with stow-wood.
Make sure gearlever is in neutral position.
Make sure there is not any person around vehicle.

Flame preheating type low temperature cold-starting
When surroundings temperature is below 0, the system will automatically
work.
Switch in ignition switch ON position, when engine water temperature is above
0, the preheating indicator light will automatically go off after it comes on
2 seconds, the preheating equipment dont work.
If the engine water temperature is below0, the preheating indicator light
comes on, preheating plug is powered and temperature rises.
After preheating 262 seconds, preheating indicator light will goes off, to give
a hint that driver may start engine.
At that time switch in START gear, fuel electromagnetic valve operates current,
diesel oil passes through oil pipe to preheating plug, to forming flame, heating
admission.

Caution
If dont start operation within 30 seconds after the indicator light goes out,
preheating unit will automatically stop working.

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Correct drive

51

Vehicle running
Vehicle can start running only under the conditions that the engine works
normally, all instruments, indicator lights and warning lights are normal.
Place the manual valve in relieving braking position when starting.
In running, notice that the engine coolant temperature keep 75-95.
Notice observing engine oil pressure, it is not lower 170kPa in low-speed
running; Doesnt exceed 490kPa in high-speed running, or stop the vehicle to
check, to avoid burning parts.
In running, if some section has trouble, for example, if air holder pressure drop,
warning light will come on; At that time, must stop vehicle, strain manual valve,
and after the trouble removal, and the warning light goes out, continue to drive.
Under general conditions, dont start rapidly, accelerate suddenly and brake
urgently as far as possible.
When shifting gears, must boost evenly, and put into gear to the end. If it is
difficult to shift gears, transmission control mechanism should be regulated.
In running, dont put foot on clutch pedal all along, the foot should leave the
pedal after shifting gears.
Strictly prohibit shifting gears without stepping on clutch.
Vehicle may shift reverse gear only after it stops completely stably.

Operation manual
Correct drive

52

Driving on hill road
When driving along long and steep ramp, use exhaust brake, and also can use
engine to brake, that is, put gear control rod in the gear position for same slope.
When braking force is deficient, use foot to increase braking.
In order to reduce abrasion and heating phenomena in braking, before drive
down on long and steep ramp, first reduce speed and shift to low gear.

Caution
When driving downhill, strictly prohibit cutting out engine.
When driving downhill, transmission is not allowed to put into neutral position.
When driving upslope, if vehicle speed gradually decreases, must shift to low
gear in time.

Driving on ice and snow road
Please use tire chain when driving on ice and snow road.
Be sure to reduce speed, avoid urgent acceleration and urgent braking.
Strictly prohibit urgent braking and urgent turning when driving at high speed,
if not, the vehicle will bring about sideslip and uncouple to cause accident.

Driving on rainy road
When driving on rainy road, the speed should be controlled, the best is not
more than 35km/h.
When driving in rain, the rain may enter into brake drum to influence braking
effect; Therefore, it is necessary to step on brake pedal, to check braking effect.
Avoid urgent braking and urgent turning, if not, the vehicle will bring about
sideslip and uncouple to cause accident.

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Correct drive

53

Vehicle stop
When vehicle stops, first release accelerator pedal, to reduce the speed.
Step on brake pedal evenly, after the vehicle stops stably, step on clutch pedal
to put transmission into neutral position, then pull the manual valve to the end,
to make it keep braking state.
Cut off power (turn starting switch key to LOCK position).

Driving in foggy day
Turn on fog light, drive at low speed, note road centerline and front running
vehicles taillight.
If fog is heavy, stop running, and park the vehicle in safe places, at the same
time, turn on distress warning switch, to make front, rear, left and right turning
lights flash simultaneously.

Economical driving
Unnecessary high-speed driving, and high-speed driving while placing
gearlever in low gear may both increase fuel consumption.
After acceleration, shift the gearlever to high gear in time, smoothly release
clutch pedal.
After shifting gearlever to direct gear or overspeed gear, be sure to keep certain
speed.
In driving, coolant temperature should keep within normal range.
The tire without sufficient charge may impair fuel economization.
Avoid long engine preheating idle.
Dont often step on clutch pedal or brake pedal.
Guarantee accurate orientation of front wheel.

54

Maintenance Manual

Maintenance manual
New vehicle running-in

55
New vehicle running-in: running period is 2500km
New vehicle running-in condition has great influence on vehicle life, working
reliability and economical property.
After receiving new vehicle or vehicle has a big repair, especially, the engine
must carry out running-in compliance with the requirement strictly, then it can
put into operation.

Running requirement
Within 200km in running-in period, never load; Within 1500km, the load does
not exceed 70% of rating load; after 1500-2500km the load can increase to 90%
of rating load.
Select smooth and good road surface.
Correct drive and operate.
Smoothly switch in clutch, shift gear in time.
Avoid sudden accelerate and rapid braking.
Often observe the temperature of transmission, rear axle, wheel hub and brake
drum, if it is seriously hot, find out the cause, and remove immediately.
During running-in period( especially 1500km), all gear speeds are not allowed
to exceed 65% of max. Speed of that gear, all gear speed limits are as follows:

Maintenance manual

56

Vehicle type CA5083XXYPK2L1A80
Gear 1 Dont exceed 7km/h
Reverse gear Dont exceed 7km/h

In running-in period, particularly notice engine coolant temperature and engine
oil pressure, they must within specified range.
In load state, check and tighten plate spring U-bolt nut. The tightening torque:
front spring is 350-450Nm, and rear spring is 600-700Nm.
Check, clean or replace filter element.
Check coolant level height.
Check all sections tightening condition, lubricate all sections.
In thermal vehicle state, replace engine lubricating oil, wash engine oil disc.
Replace engine oil filter.

Maintenance manual

57

Clean the filter core, and joint and filter netting of oil intake pipe of fuel
delivery pump
Check engine idling rotational speed, V-belt tightness degree.
Replace the lubricating oil of engine, transmission and rear axle, clean
vent-plug.
Clean, lubricate and adjust wheel hub.
Clean battery exterior.
Clean the filter core in steering oil tank.
Remove the oil and water in gas holder.
Check engine suspension component connection.
Check all sections connection of the body interior and exterior.
Check and tighten all connection bolts of chassis, especially propeller the
tightness of transmission shaft universal joint flange bolt, steering mechanism
connection bolts
Check the free space of clutch pedal.
Check and adjust the clutch release bearing clearance of 2-3mm.
Adjust front wiring harness.
Check and tighten all connection parts of front shaft.
Check parking braking equipment.
Lubricate all section according to the items in 4000km column in lubrication
table.

Maintenance manual

58

Normal operation
In order to prolong vehicle life, and get high economic benefit, guarantee safety,
operation must be as follows:
Turn on power switch.
Make sure the position of the transmission .
For engine starting operation, please refer to the engine staring specification
section.
When the engine temperature is comparatively low, dont raise engine
rotational speed very fast, which will intensify the abrasion of engine motion
parts.
The vehicle may start to run until the braking system pressure reaches or
exceeds 650kPa.
The vehicle must start to run with gear 1 when it loads.
Avoid throttle full-gear starting and emergency braking. The throttle full-gear
starting shall lead to clutch damage or uneven tire abrasion. Emergency
braking shall accelerate the abrasion of tires and braking friction plate.
Avoid sudden turning while vehicle is adjusting.
Dont allow vehicle over-load operation, over-load shall shorten vehicle
duration.
When loading goods with mechanical equipment, the goods are tipped into
wagon from low position as far as possible, to avoid forming force-impact,
causing part damages.
Dont stream water into fuel reserve tank while cleaning vehicle.
Strictly prohibit turning off power switch in engine operation process; be sure
to turn off power switch after vehicle parking.
Before tilting cab, be sure to check whether there are dumped things, if there is,
must clean up.

Maintenance manual
Regular maintenance

59
Regular maintenance
Daily maintenance
Check before driving
Check engine lubricating oil level height: Park at flat road surface, after the
whole vehicle is warm, stop 10 minutes, check oil level, take out oil gauge, wipe
it clean with clean cloth, insert to limit position, then pull out again, observe oil
level position, the oil level must be between two marks of oil gauge.
If the oil level is near or lower than the lower scale mark , must to fill engine oil
immediately, to make the oil level reach the upper scale mark as far as possible.
If the oil level exceeds the upper scale mark, discharge excessive engine oil from
the outlet bolt of engine oil disk.
During new vehicle running-in period, engine consumption is comparatively
more, so check the oil level twice each day, after the running-in period, check it
once each day.
Check fuel tank storage content.
Check the connection of fuel feeding control mechanism and oil cutting-off
mechanism.
Check cab locking.
Check whether all lights are
normal.
Check coolant storage, and
fill in time.

Maintenance manual
Regular maintenance

60

Check tire pressure
Measuring tire pressure should
be carried out when tire is in
room temperature state.
Pressure specifications:
Equip 10.00-20 tire Front wheel 560kPa
Rear wheel and spare tire 670kPa

Tire pressure should keep in the range of specified value. If the tire pressure is
over high, which will accelerate abrasion, shorten tire life; if the pressure is over
low, crack will generate, and influence driving speed, increase fuel consumption.

Maintenance manual
Regular maintenance

61

Check in driving:
In safe place, while driving at about 20km/h, check braking effect and steering
mechanism work.
Check shock absorber.
In driving, if you find the vehicle has abnormal continuous dithering, stop
running to check whether shock absorber has leakage.
After driving on bad road for a while (not less than 10 km), stop running to touch
shock absorber to feel whether it is hot; If not hot, it shows that the shock
absorber doesnt play a role of vibration damping, must replace it with a new one
in time.
In driving, observe all instrument working condition, especially is engine oil
pressure meter, water thermometer, barometer.
Often listen to whether there is abnormal sound from engine, once there is
abnormal sound, stop running to check immediately, to find out the cause and
remove it.

Filling and discharging of coolant:
Preparation for coolant
The preparation and inspect for water-cooling engine coolant is a very important
step, because corrosion, cave erosion and icing leads to engine destruction.
Coolant consists of water, high-effective anti-freeze of anti-corrosion, anti-cave
erosion and anti-freeze. Anti-freeze concentration of coolant should not be lower
than the following limit:
Anti-freeze in cooling system Distilled water
Max. volume 50% 50%
Max. volume 35% 65%
Note: recommend using FAW F35 long-acting anti-freeze.

Maintenance manual
Regular maintenance

62

Coolant filling
Open expansion tank pressure cap, fill coolant on inlet, until it be filled to upper
reticle( heating valve must be opened).
After covering the pressure cap, start engine, operate about 5minutes, be sure
water thermometer hand is beyond the center, touch the water chamber on
radiator, and stop until you feel warm. After a while, open the pressure cap, if the
coolant level in the expansion tank drops, need to fill coolant more, until the
coolant level of expansion tank has not obvious change before and after
operation.
When it is used normally, if the engine is over hot or coolant warning light comes
on, must check coolant level height, if necessary, refill it in time.

Caution
Dont open the pressure cap in hot state immediately, to avoid the hot-pressured
gas in cooling system spilling to cause scald. Open the pressure cap of hot engine
until the engine stops 10 minutes. Put wiping rag on the cap, first turn the cap to
first stop, and turn on the pressure cap after pressure releases!

Coolant discharging:
When using anti-freeze in winter, but the temperature is below -35, after
returning the vehicle to the garage, must discharge coolant.
There are two discharging water switches, one is at cylinder body left side, and
the other is under radiator outlet pipe.
While discharging water, must open the pressure cover on the expansion cap.
If there is still partial remain coolant in pipe, unscrew the relative low pipe clamp,
discharge remain coolant from the connection.
After coolant is discharged completely, start engine at idle about 1 minute, to
discharge coolant thoroughly.

Discharging water
Switch handle

Discharging water valve

Maintenance manual
Regular maintenance

63

Daily check after stopping driving:
Discharge the storage water in wet gas
holder (wet gas holder is at left of the
vehicle)
Check whether there is scratch, crack or
abnormal abrasion.
If such things as metal plate and stones
embed tire surface, must remove in time.
If there are such things as, stones between
double tires of rear wheel, must remove in time.
4000km maintenance takes tightening and lubricating as the main.
(Implement routine maintenance items and add the following times)
Whenever vehicle runs 4000km, check and tighten the connection bolts and nuts
of engine suspension, intake and exhaust manifold, noise silencer, and check
whether all bushes are good.
Check main bearing cap, connection rod, and cylinder cap bolt tightening torque.
Check regulation valve clearance, and check oil feed advance angle.
Check and tighten the connection bolts of transmission shaft universal joint pin
and middle support, steering mechanism (especially steering crossbar pull-rod,
upper/lower steering knuckle arms, steering propeller shaft, etc.), steel plate
spring, half shaft and wheel.
Clean and maintain engine oil filter and diesel filter, remove the dust on air filter
element.
Wash engine oil disc, replace lubricating oil, wash engine oil receiver filter
screen.
Discharge the oil dirt and water in gas holder.
Check fan belt tension degree.
Check tire pressure, and inflate according to specification.
Check and tighten the connection bolt nuts of cab and carriage.
Check whether the expansion tank liquid level is between high and low scales.
Observe the connecting of supercharger and inlet and outlet pipes, dont leak gas.
Check whether supercharger bearing has oil leakage, if there is remove in time.
Carry out lubrication according to lubrication table.

Check valve
Discharge
Valve

Relief valve
Water drain valve

Maintenance manual
Regular maintenance

64

8000km maintenance takes check and adjusting as the main (to implement
4000km maintenance items and add the following items)
Replace engine lubricating oil, wash engine oil disk.
Check and fill the lubricating oil of transmission, rear axle and dredge vent-plug.
Adjust and lubricate front and rear wheel hub and wheel brake.
Adjust the clearance between brake shoe friction sheet and brake drum
Check parking brake working condition,
Check steering wheel free turning.
Replace power steering oil.
Check tire, and change position according specified sequence.
Check and adjust front wheel toe-in.
Clean fuel tank, fuel delivery pump filter screen and pipeline.
Clean engine oil fine filter retro, clean sediment in rotor case interior wall,
dredge jet nozzle.
Clean the main filter element of secondary air filter.
For the maintenance of bath air filter, please refer to the above operation
description.
Adjust valve clearance.
Clean diesel coarse filter element; Replace diesel fine filter and engine oil filter
element.
Lay emphasis on check safety parts (e.g. all pull-rods and pipelines in braking
system, crossbar pull-rod, knuckle arm, drop arm and all connection sections in
steering system).
Check shock absorber; If finding it is out of work, replace it in time.
Check the bushes in steel plate spring support and sling, if necessary, replace.
Lubricate according to lubrication table.

Maintenance manual
Regular maintenance

65

24000km maintenance (to implement 8000km maintenance items and add the
following items)
Whenever vehicle runs 24000km, check and replace brake friction sheet.
Dismount rear axle transmission shaft, tighten drive bevel gear flange nuts and
middle transmission shaft flange nuts according to specified torque.
Dismount the rear caps of jackshaft and rear axle housing, clean decelerator
interior cavity, tighten differential bearing cap nuts and differential housing nuts
according to specified torque, replace the lubricating oil of jackshaft and rear
axle.
Replace lubricating oil of transmission.
Check steel plate spring support and sling bush abrasion, if necessary, replace.
Replace the main filter element and safe filter element of secondary air filter.
For the maintenance of oil bath air filter, please refer to the above operation
description.

48000km maintenance takes assembly disassembly and eliminating hidden
danger as the main (to implement 24000km maintenance items and add the
following items)
Whenever the vehicle runs 48000km, clean up crankshaft box ventilation unit.
Clean cooling system and fuel tank.
Clean engine oil cooler.
Check injection pressure of oil injector and injection condition on test table by
professional, carry out necessary adjustment.
Check fuel feed advance angle, and carry out necessary adjustment.
Adjust engine oil pump if necessary.
Replace the braking liquid of clutch hydraulic operation.
If necessary, dismount cylinder head, clean and check all parts and grinding
valve.
Besides the first 48000km treatment according to the condition, since then, every
48000km, carry out necessary the check, regulation and maintain of engine, to
eliminate hidden danger.

Maintenance manual
Regular maintenance

66

Engine disassembly should be determined according to its working condition,
any engine that has good working performance, should not be disassembled, or
prolong disassembly cycle, to keep its original technical performance.
Oil injection pump generally does not require adjustment, if the engine does not
work normally, must check and adjust on oil injection pump test table by
professional.
Remove the carbon deposit on supercharger compressor, turbine cap and rotor
vanes.
Dismount and check parking and running brake controls and pipeline. Clean
gasholder single-way valve, check brake valve, and adjust if necessary.
Dismount and check air compressor according to its condition.
Dismount and check clutch, transmission, propeller shaft, rear axle, front shaft
and steering system if necessary.
Replace power steering system oil and the cylinder element in steering oil tank.
Dismount and check spare tire regulator, replace seriously abraded parts, clean
and lubricate.
Wheel rim is scaled, and painted.
Check chassis frame conditions (the presence and absence of deformation, crack,
rivet looseness and drop-out), if necessary repair.
Check, repair and maintain vehicle body and accessories, replace damaged parts.
Maintain starter and generator, and check bearing.
Check and adjust battery electrolyte density.

Maintenance manual
Maintenance and adjustment of main assemblies

67
Air filter
Maintain air filter carefully and in time, which is very important to prolong
diesel durability.
Air filter core must keep clean, if not, the filter core block will make engine
power reduce, oil consumption increase, and accelerate engine abrasion.
The vehicle runs in general areas, every 8000 km, clean the main filter core
once; If often runs in windy and dust areas, shorten maintenance mileage
appropriately.
Whenever the main filter core is used 24000km or one year, replace with new
filter core, at the same time replace safe filter core.
The safe filter core is not allowed to clean, only replaced.

1-main filter core 2-safe filter core 3-tightening nut 4-end housing

Notice
The user should buy the filter core that is produced by the original manufacturer,
and also buy the filter core that is qualified and provided test report by FAW
Technical Center.
Dont buy non-qualified filter core, since non-qualified filter core will cause
the engine non-normal abrasion.

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68

Maintenance of air filter:
when maintaining, first unscrew
tightening nut, open filter cap, take
out main core, clean the dust
inside of housing.
Knock slightly two end of filter
core with hand or wood stick, and
as knocking, turn the filter core, to
make dust drop. Also blow clean compressed air not larger than 600kPa
outward from filter core interior outward, to remove dust.

Notice for air filter maintenance:
Filter core cannot be cleaned in gasoline, kerosene, can only be blown with
compressed air or knocked with hand.
If finding main filter core is blocked or damaged, must replace in time.
In the process of maintaining air filter, note not to destroy filter paper, to
influence filter effect.
When mounting, must first check the rubber seal ring between filter core end
surface and housing to see whether it is intact, then, mount it into the housing,
if it is damaged, must replace it in time, to guarantee good seal. Check nut seal
ring, then tighten nut.
Check the seal of filter core seal ring and housing, to see whether it is intact,
and whether the connection pipeline is tight, if the sealing is not good, dust will
enter directly into cylinder, to accelerate engine abrasion.
For the maintenance and adjustment of the modified vehicle type that can select
Oil bath air filter (that is primary filter), please refer to the operation and
maintenance description of filter body.
The air filter mentioned above is secondary air filter.

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69

Notice for secondary air filter maintenance:
Main filter core cannot be cleaned in gasoline, kerosene, can only be blown
with compressed air or knocked with hand. Safe filter core can only be replaced,
not allow to clean.
If finding main filter core is blocked or damaged, must replace in time, and at
the same time replace safe filter core.
In the process of maintaining air filter, note not to destroy filter paper, to
influence filter effect.
When mounting, must first check the rubber seal ring between filter core end
surface and housing to see whether it is intact, then, mount it into the housing
body, if it is damaged, must replace it in time, to guarantee good seal. Check
nut seal ring, then tighten nut.
Check the seal of filter core seal ring and housing, to see whether it is intact.,
and whether the connection pipeline from filter outlet to engine supercharger
inlet is loose or broken, if necessary, replace, otherwise, dust will enter directly
into cylinder, to accelerate engine abrasion.

Crankshaft housing ventilation
Whenever a vehicle runs 2000km, check whether connection pipeline is loose
or broken, if necessary, replace.
Whenever a vehicle runs 8000km, check and clean crankshaft housing oil-gas
separator. When cleaning it,
first soak oil-gas separator in
gasoline for several minutes,
then scrub and blow off it
with compressed air.
When oil-gas separator is
blocked, must replace in
time.
Oil-gas separator

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70

Rotation engine oil filter
Generally, every 6 months or every 8000km, must replace engine oil filter.
In dust areas, every 3 months or every 4000km, must replace engine oil filter.
Replace engine oil filter assembly.
Use special tool kit to turn anticlockwise, to dismount engine oil filter.
When installing, coat engine oil on new filter rubber seal gasket
Filter installation surface must be even and smooth, doesnt have dirty things or
rubber remainder.
Tighten engine oil filter clockwise, and after rubber gasket touches seating
plane, re-tighten it one circle.
1

5

1-gasket 2-combined bolt 3-seat 4-rotation engine oil filter
5-engine cylinder block
Notice
The user must purchase the rotation engine oil filter assembly that is produced
by the original manufacturer, also can purchase the engine oil filter assembly
that is qualified and provided report by FAW Technical Center.
Dont purchase non-qualified product, otherwise, it will bring about engine
non-normal abrasion and parts damage.

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71

Engine oil fine filter
When a new vehicle runs 2000km, clean rotor.
Generally, every 8000km, clean rotor and sediment in rotor cover interior wall,
dredge nozzle 6.
Rotor dismounting method:
First take down cap nut 1, take down housing 4, take down tightening rotor nut
2, take down thrust shim, to take out rotor assembly 5. Then as unscrew
pressing nut, rotor cap rises, to take out rotor.
Note in dismounting and check:
Because rotor assembly is through dynamic balance, must put and take slightly,
dont collide to avoid destroying it dynamic balance.
Remove foreign matter with bamboo sheet, wood batten, not with metal things,
to avoid scratch parts.
Note to mount according original mark, dont miss seal parts. Check seal ring
intactness. After mounting rotor should rotate easily. Pull up the rotor, check
whether its spill quantity is 0.4-0.8mm. If there is no axial spill quantity, find
out the cause.
Generally, dont dismount intake
pressure limit valve 7.

1-cap nut 2-nut 3-block 4-housing
5-rotor assembly 6-nozzle
7-intke pressure limit valve

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72

Diesel coarse filter
Every 8000-12000km, clean filter core.
When cleaning or replace filter core, unscrew sedimentation cup fixing ring
with special spanner, take down sedimentation cup and filter core, and clean
them with kerosene.
When mounting, dont miss gasket, then screw sedimentation cup fixing ring
slightly with hand.
If it is necessary to dismount inlet and out joints, check whether spacer is intact,
if it is damaged, replace in time. J oint tightening torque is 20-25Nm.

Diesel fine filter
Diesel fine filter plays an important part in guaranteeing normal work of oil
injection pump and oil injector. If finding oil cannot pass through fine filter,
must dismount and check, replace
with new filter.
Generally running 8000-12000km,
replace with new filter.
When replacing with new filter, first
coat lubricating oil on gasket, then
turn it on seat, and screw it with
hand.

Caution
When mounting, check sealing ring
intactness, if it is damaged, replace
in time. Dont miss sealing ring.

Inlet connection outlet connection

Tightening bolt

Sedimentation cup

Filter element

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73

Oil injection pump
Oil injection ump has been debugged strictly before leaving the factory, lead
sealing section cannot be changed. If adjustment is needed in operation, must
carry out on test table by professional.
Coupler cannot be replaced randomly, to avoid influencing diesel performance.
If diesel cannot work normally, or injection time and injection amount are
abnormal, the maintenance and adjustment must be done on test table by
professional.

Notice for oil injection pump
dismounting and mounting:
In operation process, if it is necessary to
dismount injection pump, dont dismount
injection pump stand, if not, which will
cause injection pump and air compressor
with different core, resulting in
connection disk plate damage.
When dismounting, in order to oil feeding
advance angle not change after
remounting, must make a mark on
advance unit.
If only dismounting injection pump,
unscrew two bolts 3 for fixing connection
disk, in this way, when mounting, the
advance angle does not change.
Dont dismount bolt 1 connecting
coupling on steel plate as far as possible,
because the coupling is damaged easily in
remounting.
When remounting injection pump on
engine, pay a particular attention to
timing adjustment: That is, guarantee the
alignment of mark on advance unit
exterior circle (it is the first cylinder
feeding start point of injection pump).
If there is any error, must unscrew two bolts 2 connecting flange to adjust
advance angle, that is, let the reticule on steel plate align 0 line on flange,
finally screw down bolts.
Oil delivery pump Advance unit
1-bolt connecting coupling 2-bolt
3-bolt fixing connection disk

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74

If only dismounting injection pump, when mounting, first make 1-6 mark on
flywheel advance 101align the hand
on the flywheel, or make the scale on
shock absorber align the hand on the
body, and be sure that engine first
cylinder piston is in compression
process(that is, inlet and outlet valves
close simultaneously), then let the scale
on advance unit align the mark on the
pump body, then can mount coupling.
When mounting coupling, dont change
the mark position.
If while dismounting injection pump, dismount air compressor, besides aligning
the timing mark on the flywheel, and be sure that engine first cylinder piston is
on the stop point in compression process, at the same time, unscrew screw-plug,
to make the timing hand in flywheel housing align the mark on injection pump
propeller gear, then mount air compressor, at last, mount injection pump
according to former request..
To assure the same core both injection pump and air compressor, the error is
not larger than 0.3mm.
Check method of oil feeding advance angle:
Dismount the high-pressure oil pipe of the first cylinder injection pump.
Turn crankshaft anticlockwise, at the same time observe carefully the presence
or absence of oil level fluctuation of injection pump outlet valve connection
(that is, the oil level just begin to rise), stop turning crankshaft immediately.
Examine whether the angle pointed out by the hand on pulley end or flywheel
shell observation hole is the advance angle data specified in above two items. If
necessary, re-examine once more, if it is correct, adjust.

Flywheel
housing

Flywheel
Screw-plug

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75

Adjusting method of oil feed advance angle:
Turn anticlockwise crankshaft up to the advance angle value specified for this
engine type in front of the first cylinder upper dead-point, and conform it is the
first cylinder compression upper dead-point.
Unscrew the plate coupling bolt of advance unit end, rotate advance angle, at
the same time, observe carefully the first outlet valve connection oil level, if
there is fluctuation, stop rotating, and screw down coupling bolt.
Rotate crankshaft, recheck oil feed advance angle, the method is the same as
the above-mentioned.

Oil injector
When maintaining every 48000km, it is necessary to check the unlock pressure
and injection condition of oil injector, if necessary, clean and adjust.
Professional must do repairing and replacing nozzle. When pumping oil at 30
times per minute, the pressure is 22-23Mpa, spray must be uniform,
interruption must be thorough, and can hear particular ringing sound. (see
following figure)
When oil injector cannot inject oil well, dismount needle valve coupler to wash
(wash in clean diesel oil), and adjust pressure up to specified value.

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76

Needle valve and needle valve
body are pairing coupler, cannot
be exchanged in repairing.
When oil injector is reinstalled on
cylinder head, dont miss the head
copper grommet and rear dust ring,
the copper grommet must be good,
if not, injector will bring about air
leakage or is blocked, new oil
injector require to use copper
grommet to adjust protective
height.
When checking oil injector, dont
exchange cylinder nozzles, to
guarantee oil injector tip to protect
cylinder head bottom plane within
allowed range.

Oil delivery pump
Whenever a vehicle runs 8000km,
oil delivery pump inlet connection,
filter screen and pipeline should
be cleaned.
In operation, if finding the oil
delivery pump feeds impeded, or
doesnt feed, check whether oil pipe connection has leakage, and inlet
connection filter screen is blocked.
If there is air in oil delivery pump, which may handicap the normal operation of
oil delivery pump, therefore, the oil injection pump works again after it stops
operating for a long time, or replace oil pipe and connection, air will enter into
it, must discharge air. Discharge method is: unscrew discharge bolt, press the
hand pump pull button of oil delivery pump continuously, after discharging air,
tighten screw.
The piston spring, check valve, dust cover, sealing ring and gasket of oil
delivery pump are all consumable, cannot be used repeatedly, whenever they
are dismounted, must be replaced.
Bad spray Good spray
Discharge bolt

oil delivery pump oil injection pump advance unit

Maintenance manual

77

Adjustment of valve clearance
The clearance between valve rod and rocker is called valve clearance. Valve
clearance should keep within specified range, to guarantee engine work
normally. If finding valve sound, adjust in time.
Generally every 8000km adjust once.
Valve clearance (cool state)
Inlet valve: 0.30mm;
Outlet valve: 0.35mm;

Adjustment sequence:
Toggle flywheel ring gear from the sight hole at left side of flywheel, to make
1-6 mark on the flywheel align the hand fixed on flywheel housing, and to
make the first cylinder valve unlock simultaneously, then adjust valves
4,5,8,9,11,12 clearances in turn.
Then crank crankshaft one circle, to make the mark on flywheel align the hand
(at that time to make the sixth valve unlock simultaneously), adjust valves
1,2,3,6,7 and 10 clearances in turn.

Adjustment method:
Unscrew locking nut with special spanner and screw drive, insert feeler gauge
between valve stem end and rocker arm,
tighten adjusting bolt, to make the feeler gauge
be pressed slightly, when drawing out it, you
feel slight pressure, see the figure in next page.
Screw down locking nut again, then recheck
once with feeler gauge.

Maintenance manual

78

Supercharging system
The connection of supercharger and inlet and exhaust pipes must be tight, if
there is air leakage between exhaust pie and waste gas turbine, supercharger
efficiency will drop greatly, diesel exhaust temperature will rise sharply, to
damage valve and supercharger.
Before a new diesel starts, must fill clean engine oil into supercharger and the
engine oil filter of the supercharger, to guarantee the supercharger bearing to
get lubricating as soon as the diesel starts. After a vehicle runs 8000-10000km,
must replace supercharger engine oil filter element.
Before the diesel stops, let it idle about 3-5 minutes to make supercharger
rotation speed decrease and temperature drop, and listen to supercharger
rotation sound. If finding any abnormal, must stop to check immediately. If
supercharger rotor doesnt rotate easily, with detent or abrasion sound, they
should be sent to qualified service station to repair.
Every 500h or 30000km, must check supercharger rotor spindle clearance, and
remove the dirt and soot on compressor turbine shell and rotor vane. At that
time, dismount turbine supercharger from diesel, replace the metal spacer
between supercharger exhaust pipes. Dont allow removing the scaling on rotor
component with mechanical method, the scaling must be cleaned with gasoline
or other detergent to wash aluminium parts.

Caution
Dont make any rotation parts dismounted from turbine supercharger be
damaged or deformed, otherwise, turbine balance will be influenced. And any
rubber sealing elements cannot be damaged either.

Maintenance manual

79

1-tunbine casing 2-thermal baffle
3-turbine component 4-turnbine end
sealing ring 5-bearing shield ring
6-floating bearing 7-middle shell
8-distance thrust sleeve 9-thrust bearing
10-oil scraper board 11-compressor end
dog component 12-compressor casing
13-shaft seal 14-compressor end sealing
ring 15-compressor impeller 16-diffuser
17-O-rubber sealing ring

Axial clearance check:
Nestle the contact of dial centesimal meter against the end of turbine drive shaft,
press down the shaft to centesimal meter to record indicated numerical value,
then push the shaft reverse to record numerical value. The difference between
both values is axial clearance, which cannot exceed 0.20mm.

Radial clearance check:
Nestle the contact of dial centesimal meter against impeller body top, press
down impeller to record indicated numerical value, then raise impeller to record
numerical value. The difference between both values is radial clearance, which
cannot exceed 0.65mm.

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80

Check and adjustment of fan belt and water pump belt
Check whether the belt has tortuous shell crack, chip, stripping, and strong
layer broken and damage, if it has, replace.
Tension of fan and water belts should be often checked, over-tightness will
make water pump bearing and generator bearing damaged early;
over-looseness will cause belt creep to make engine over-hot.
New belt should be rechecked and adjusted once after running 15 minutes after
a new belt is adjusted; check once after running 1000km, later, the belt
deformation gets stable, and is checked every about 2000km.
Press 78N load on single belt, belt deflection should be 10-15mm, if it is not,
adjust the belt with moving generator and adjusting arm relative position.
When installing belts, the centerlines of several pulleys must be on the same
plane, if not, the belt durability will be shortened.
When check, tense and replace belts, must stop.
The pulleys must be tightened reliably on water pump flange, dont allow any
looseness.
When replacing belts, two belts must be replaced simultaneously, a new one is
not collocated with an old one

Fan and fan clutch
1. Fan: If fan has the following
conditions, must replace immediately.
Whether fan vane butt gets white, or
has crack.
Serious deformation and torsion of
fan vanes.
Fan vane is broken.

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81

2. Fan clutch: Fan clutch must be check and adjusted 100% before it leaves the
factory, dont dismount randomly in operation. If finding that the fan vanes has
silicone oil, which shows silicon leakage. If there are the following conditions
when checking, replace fan clutch.
Fan clutch bearing has silicone oil bleeding.
Double metal temperature sensor is damaged, such as broken, loose, seized,
lost.
When turning it with hand, there is abnormal sound or it is not turned.
When turning it with hand, fan clutch is abnormally easy.
Fan vane tip swings over large
In fan hub interior and fan clutch edge there is silicon exudation.
At fan clutch pin shaft, and housing and front cap junction surface there is
silicon oil exudation or when engaging, fan rotation speed drops over 10%.

Emergency measures:
When the vehicle is running, under the conditions that fan belt is not loose,
temperature regulator, water pump, and fan work normally, radiator is not
blocked, if coolant is over hot, check and replace fan clutch.
Under the condition that fan clutch has leakage, pry double-metal temperature
sensor, turn clockwise (about 25) pin shaft valve plate to make fan clutch in
engage state.
Replace in time until
return the vehicle to the
garage.

1-fan clutch assembly
2-fan assembly
3-locking block

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82
Water pump
If there are the following conditions, replace water pump
Water pump impeller and shaft is loose. When grasping connection flange, turn
impeller with hand, the impeller and shaft turn.
Water pump flange and shaft is loose. When grasping impeller, rotate
connection flange with hand, the connection flange and shaft turn.
Water sealing leak.
Bearing makes abnormal sound or is seized. (Since the water pump adopts
shaft-connected bearing, it is unnecessary to maintain and fill lubricating oil
routinely.
Water pump impeller and water pump casing eroded seriously. The impeller
doesnt work, make water in hull or the link surface between hull and cover
board make water.

Caution
Since water pump assembly adopts integral pressing process, if there appear the
above-mentioned conditions, must replace water pump assembly, not parts.

Temperature regulator
Check the unlocking temperature of temperature regulator.
Put temperature regulator into water trough and heat water up to specified
temperature.
Check the unlocking temperature of temperature regulator.
The unlocking temperature of temperature regulator should be 762, if the
unlocking temperature of temperature regulator is not within the
above-mentioned temperature, temperature regulator should be replaced.
Check temperature regulator lift:
When temperature continues to rise, and keeps 86, check temperature
regulator lift. The temperature regulator lift should be 8mm, if the lift does
not reach the specified value, replace temperature regulator.
Check spring force when the temperature regulator is closed completely, if
necessary, replace temperature regulator.
Check hose and diaphragm to see whether they have wax leakage, if necessary,
replace temperature regulator.

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83

Dilator
Besides the main cycle of the whole vehicle cooling system, a dilator cycle is
provided. The dilator is installed on the gantry beam at cab back, used for
complement coolant and exhaust for the main cycle.
The dilator should be checked whether it has phenomenon short of coolant. If
the baffle within the dilator can be seen, or water level warning indication
appears, must complement coolant in time.
The dilator should be checked often to see whether it has coolant leakage, if
there appears coolant leakage, repair or replace in time.

Filling water level

1-through spillway 2-pressure cap 3-exhaust hole 4-air chamber 5-exausting pipe
6-wet return 7-water level warning switch 8-baffle

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84

Cooling system cleaning
Regularly check engine coolant quality.
Check whether there is excessive rust, sediment and sealing gasket remainder
on radiator cap and radiator inlet seat.
Check whether there is oil layer on coolant surface, suspended matter in
coolant, coolant emits funk.
If the above-mentioned conditions appear, replace coolant immediately.
Regularly clean incrustation in cooling system. When maintaining at 48000km,
must clean cooling system.
In order to prevent cooling system block, determine cleaning interval according
to the operational conditions.
For the vehicle on good road, recommend to check and clean cooling system
every 100000km.
For the vehicle in construction site, recommend to check and clean cooling
system every 25000km.

Cleaning method:
Put a cleaning basin under radiator, discharge the original coolant completely,
and dismount the wind cover on the radiator.
Blow the radiator with compressed air, dont bump radiation belt.
Wash the radiator with high-pressure water, clean dust and the dirt on radiation
surface. Dont wash generator, wire and electric components directly.
Fill sodium carbonate water solution (0.6 sodium carbonate every 23L water)
into the cooling system, start the engine and operate at middle speed until the
cleaning solution temperature reaches 82, 5 minutes, after stopping,
discharge the cleaning solution.
Fill clean water into cooling system, the engine operate at middle speed 10-15
minutes, open the discharging water bolt of radiator, discharged water solution.
Mount wind cover.
Operate the engine until normal temperature makes remaining water
evaporation. When 48000km maintenance or operation half and one year, it is
necessary to wash reverse the radiator and engine.

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85

Reverse washing radiator: Dismount the radiator hose, connect a proper
washing gun at radiator outlet, fill the radiator with clean water, and charge
compressed air, the pressure in the radiator doesnt exceed 110kPa, to avoid
damaging the radiator, repeat this process until the water gets clean.
Reverse washing engine: Dismount the radiator hose, connect a proper washing
gun at engine outlet, fill the engine with clean water, and charge compressed air,
the pressure in the radiator doesnt exceed 110kPa, to avoid damaging the
radiator, repeat this process, until the water gets clean.

1-discharge switch 2-wind casing 3- fan clutch 4-water pump 5-fan
6-radiator curtain 7-radiator 8- temperature regulator 9-engine oil cooler
10-outlet pipe 11-dilator 12-dilator pressure cap 13-water level warning switch

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86

Clutch
Clutch body doesnt need any adjustment in its installation and operation
process.
Release bearing is oily bearing. When maintaining, never soak the bearing into
kerosene or gasoline, it can be installed only after oil stain is wiped out with
cloth. If finding the bearing is out of work, replace in time.
Clean the oil stain under clutch casing vent hole cover, to guarantee the clutch
have good ventilation and heat dispersion effect.

Check of clutch control system functions
Step on pedal repeatedly, the clutch should separate thoroughly, and engage
smoothly. The maximal Pedal force (new vehicle ) should not more than
160-210N.
If the clutch doesnt separate thoroughly, check whether the pipeline has
leakage, if it has, find its cause. After fault is removed, re-exhaust, charge brake
fluid
If the pedal doesnt return, check whether the pedal free travel conforms to the
requirement. The clutch pedal free travel is 35-45mm.

Maintenance of clutch control system
Every 2000km, check the oil level of clutch oil reservoir, its oil level height
should keep at H line, if it is not enough, complement in time (brake fluid is
LD3000 type).
Every 20000-25000km, replace brake fluid once.
Every 48000km, replace master pump, booster pump assembly and release
bearing assembly.
Every 100000km, replace the steel-backing compound bush of release yoke
shaft.
the brake fluid is mixed with air when filling, which will influence thorough
separation of clutch, therefore, when filling brake fluid, must exhaust.

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87

Exhaust method:
Oil reservoir is filled with brake fluid, take down the dust cap on outlet
bolt-plug of clutch booster pump, unscrew the outlet bolt-plug, insert one piece
of transparent plastic tube, and insert the other end into the container with brake
fluid.
Step on clutch pedal repeatedly, to make the brake fluid in oil reservoir pump
from the master pump into pipe and booster pump, at the same time, observe
the exhaust condition in the container, pull out the plastic tube until no bubbles
spill, make sure the air is discharged out completely, then when the pedal is
stepped to the end(keep this state), tighten the outlet bolt-plug(tightening torque
is 25-30Nm), put on the dust cap, release the clutch pedal.
In the process of filling oil and exhaust, if the brake fluid in oil reservoir
reduces, complement in time.

Adjustment of mileage travel of
clutch pedal
Release the tightening nut of limit bolt
5(this bolt with exhaust brake is clutch
switch), turn the limit bolt, to make the
total travel of pedal(from the pedal
center to the starting point ) in
150-170mm, then screw down
tightening nut.
Adjustment of clearance between
master pump piston and push-rod
end
After the total travel of pedal is adjusted
well, unscrew push-rod tightening nut, turn eccentric bolt, to make master
pump tappet tip just touch piston concave bottom, or between them has
0.2-0.65mm gap. If this gap is not check easily, the tappet oscillating quantity
method of master pump cylinder upper outlet can be used, the oscillating
quantity is 0.8-1.4mm, after adjustment is finished, tighten the eccentric
bolt.

Caution
Over small pedal free travel shall make release bearing early abrasion.
Over big pedal free travel shall make clutch separate not thorough.
Inside Outside

Eccentric mark
must be at inside

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88

Transmission
Transmission structure
This transmission is three-axle synchronous mechanical transmission.
There are seven forward gears and one reverse gear. All gears are engaged
gears.
All gears on two shafts are installed on two-tier needle bearing, gear two to
gear 7 is installed with lock-pin inertia synchronizer, gear 1 and reverse gear
are engaged sleeve.
Top cap is installed with reverse gear switch, output end is installed with
speedometer mechanism.

Maintenance of vent-plug
When a vehicle is running, the oil temperature in transmission rise, the
difference between inside and outside pressure of transmission is eliminates
through vent-plug, to keep the inside and outside pressure balance, to avoid the
high pressure in transmission damaging sealing element, resulting in
transmission leakage. Often check whether there is dirt foul on vent-plug, if
there is, remove in time, to keep vent-plug clean and unimpeded.

Notice for transmission operation
Correctly and reasonably operate and maintain transmission, which is very
important for raising the dynamic property, economical property, safety and
reliability.
Drive at high gear as far as possible, to guarantee the engine at economical
speed area, to raise whole vehicle dynamic property and economical property.
When the vehicle accelerates, can do trip stop operation, make full use of
engine braking.
Carefully observe road condition, the vehicle runs by neutral position and
inertia.
If not necessary, dont operate frequently rapid acceleration or emergency
brake.
Shift gears: When shifting gears, the driver should know the running range of
all gears speed, to avoid shifting the gear unsuitable to the speed, so as to
prevent engine and transmission system parts overspeed and overload.

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89

Adjustment of clutch: When shifting gear, clutch pedal should be stepped to the
end, at that time the thorough separation of clutch will influence greatly
transmission shift performance and synchronizer, so must check clutch pedal
travel, check whether clutch separates thoroughly and engage completely.
Check method of thorough separating position of clutch: When the vehicle
stops, let the engine idle, at that time, step on the clutch pedal to the end,
several seconds later, move the transmission control lever engage gear 1, if
engagement sleeve makes harsh gearshift sound, the clutch does not separates
thoroughly, need to adjust the clutch; otherwise showing the clutch separates
thoroughly.

Transmission shaft and middle support
Whenever the vehicle runs 8000km, check the axial clearance of propeller shaft
middle support.
Check method: Pull bearing with hand, you feel obvious clearance(that is, axial
clearance is over 0.40mm), replace bearing.
When the clearance is over 0.30mm, which will result in propeller shaft
vibration and middle support sounding, must adjust immediately.
Whenever the vehicle runs 24000km, dismount rear axle propeller shaft,
tighten the drive bevel gear flange nut and middle propeller shaft flange nut.

Caution
When mounting propeller shaft, mount it according to the original mark (slide
fork and nosing fork on shaft axle tube are at the same plane).
Propeller shaft cannot be mounted reverse.
When propeller shaft leaves the factory, it has been carried out dynamic
balance. In operation and maintenance, avoid impact to guarantee its balance
precision.

Maintenance manual

90

Maintenance of rear axle
Whenever a vehicle runs 48000km, if necessary, dismount and check rear axle,
adjust decelerator and differential bearing advance tightening load, as well as
drive and driven bevel gear engage imprint and tooth clearance.
In order to raise gear support rigidity, retain correct engagement of gear,
decelerator and differential bearing must have advance tightening load. Bearing
advance tightening load is inspected with the torque to rotate gear.
When inspecting advance tightening load, bearing must be lubricated. Gear
rotates repeatedly along two directions not less than 5 circles, to make rotor be
in the correct working position of inner and outer ball track.
Gear advance tightening load must be proper, over tightness shall lead to
bearing damage.

Adjusting the advance tightening load of drive bevel gear bearing
Press the internal ring and roller assembly of 9728/9220 bearing, and the
internal ring of 42708 column roller bearing on the journal of drive bevel gear,
before pressing, the journal should be painted with some lubricating oil. Mount
the drive bevel gear into bearing seat assembly, select properly thick regulation
gasket, and mount it on the drive gear shaft. Then mount 30613B (27713E)
bearing internal ring and roller assembly on the drive bevel gear.
Press the drive bevel front bearing internal ring with 90kN force, at that time,
the torque of turning bearing seat should be 2.5-4.5Nm. Select properly thick
regulation gasket to the bearing advance tightening load to be needed, the
bearing advance tightening load should be checked after the bearing is
lubricated and turns several circles.

Tighten the drive bevel gear nosing nut with 650-700Nm torque, then punch
and rivet nosing nut lock edge.
When mounting the drive bevel gear assembly into decelerator shell, the total
thickness of regulation gasket under bearing seat end T1 is calculated in the
following formula(see the figure below)

Maintenance manual

91
H=c+73
cmeasure the distance from T1 to T2 end
face on the drive bevel gear assembly
express the difference between the
actual assembly distance of the drive bevel
gear on T3 enface and the theoretic
assembly distance (the actual assembly
distance is larger than the theoretical
assembly distance, the difference is +,
otherwise, it is -).
73 constant (308-235)

Note: H value only round, not omit, and take as 0.10 integral multiple. The
gaskets with thickness 0.1 and 0.2 are both not less than 2 pieces.

Maintenance manual

92

Check bevel gear engagement:
Inspect gear engagement imprint with applying-color method under no-load
condition.
Drive an driven bevel gears under correct engagement condition:
The engagement imprint of convex and concave surface of driven bevel gear
teeth should comply with the requirement of the left figure: The engagement
imprint should be at slightly small end of tooth long direction middle section,
and the tooth height direction middle section.
The engagement imprint of drive bevel gear may reach the upper edge of the
gear.
If the bevel gear engagement and tooth-face clearance cannot conform to the
above requirements, readjust with the method shown in left figure, until they
conform to the requirements.

Mounting differential assembly and adjusting the advance tightening load
of differential bearing
Mount differential assembly and bearing outside ring into decelerator shell,
mount regulation ring and bearing cap (dont confuse the original position of
left and right side bearing cap mounting ).
Tighten the connection bolt of differential bearing cap, up to no gap between
bearing cap and differential shell. When mounting, must paint check glue on
the bolts.
Tighten left and right side regulation rings, make the axial position of both side
regulation rings about the same, adjust the advance tightening load of
differential bearing with regulation ring, the torque for rotating differential
assembly is 2.0-4.0Nm, must inspect the advance tightening load after the
bearing is lubricated and rotates numbers of circles.

Mounting drive bevel gear and bearing seat assembly
Mount the drive bevel gear regulation gasket calculated correctly into bearing
seat, Mount 42708K bearing outer ring and roller assembly into decelerator
shell bearing hole, mount drive bevel gear and bearing seat assembly into
differential shell, tighten drive bevel bearing seat bolt with 26020Nm torque.
When mounting, must paint check glue on the bolts, check the tightening
torque with tightening force spanner completely.

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93

Adjusting the side clearance of drive and driven bevel gears
After mounting drive bevel gear assembly, turn left and right side regulation
rings, change the axial position of drive bevel gear, so as to adjust the backlash
of drive and driven bevel gears.
In order not to change the differential bearing advance tightening load regulated
well, the advance and retreat quantity of left and right side regulation rings
must be equal.
Measure backlash on about trisection position of driven bevel gear, the
backlash should be 0.25-0.4mm, variable is not larger than 0.10mm.

Checking and adjusting the engage imprint of drive and driven bevel gears
After adjustment of drive and driven bevel gear backlash and bearing advance
tightening is completed, inspect gear engage imprint with applying-color
method, tooth-face engage imprint should comply with the requirement of the
figure below, if not, adjust it with the method shown in the table in next page,
up to complying with the requirement. Dont change bearing advance
tightening load when adjusting.
After the adjustment of backlash and engage imprint is completed, tighten
differential bearing cap tightening bolt with 65020Nm torque, must check
tightening torque with tightening force spanner completely.

Driven bevel gear convex Drive bevel gear concave

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94

Maintenance of suspension
When a new vehicle running-in
200km, in load state, tighten U-bolt
nut according to the specified torque.
When a new vehicle running-in
500km, in load state, tighten U-bolt
nut.
When running-in ends(2500km), in
load state, tighten U-bolt nut.
After the vehicle puts into normal
operation, must tighten U-bolt nut
every 200km in full-load state,
successively three times, it gets stable, carry out routine maintenance.
. Plate spring U-bolt nut tightening torque is:
Front suspension: 350-450Nm
Rear suspension: 500-600Nm

Shock absorber
Shock absorber is hydraulic bi-directional cylindrical. when a vehicle is
running, in the shock absorber stretching and compressing process, the
hydraulic produces damping force through return valve and its corresponding
throttle system, so as to make the spring vibration rapidly attenuate to improve
the vehicle running smoothness.
Stop the vehicle after driving it on bad road surface for a while, touch the shock
absorber to see whether it is hot. If it is not hot, which shows there is no
resistance, the shock absorber has not been plaid a part in shock absorption. If
one temperature is high, the other is low, the difference is large, showing that
the resistance with low temperature is much less.
The shock absorber has no resistance, generally it is short of oil, or the
important parts have been damaged, they must be dismounted to check.
In vehicle running, if finding abnormal continuous vibration, must check
whether the shock absorber has leakage, which generally occur at two positions,
one is at shock absorber rod, the other is at oil reservoir nut. The oil leakage
must be eliminated, to ensure shock absorption effect.

Maintenance manual

95

Notice in shock absorber operation:
Service in time after faults appear, for example, replace such parts as oil sealing
or replace with new oil. Sometimes replacement delaying leads to serious
Shock absorber damage to scrapped.
If it is necessary to replace shock absorber rod, replace oil sealing
simultaneously.
Avoid only complementing new oil, but neglect careful dismount and wash.
If it not necessary, youd better not to change valve parts.

Dismounting of shock absorber:
Clean the dust and dirt on shock absorber appearance.
Clamp the connection ring under shock absorber on vice.
Pull the shock absorber rod to the end, to make clearance appear between the
dust cover and hydro-cylinder, then unscrew oil reservoir nut with special
spanner.
Pry out the sealing ring from guide seat slot with narrowing picker, and then
pull out piston and guide seat from working cylinder and oil reservoir cylinder.
Spill all shock absorber liquid within cylinder, take out the working cylinder
from the oil reservoir cylinder, if not necessary, dont dismount bearer
assembly from the working cylinder.
If it is necessary to replace oil sealing, must dismount the shock absorber rod
and piston assembly, still clamp the connection ring on vice. Then unscrew the
return valve nut to dismount the piston.

Maintenance manual

96

Adjustment of front toe-in

Toe-in value is:
AB=26mm

Every 8000km, must check the toe-in once.

Toe-in adjustment method:
When adjusting, the vehicle stop at flat ground, J ack the front shaft, to make
the wheel at straight line run position.
Unscrew the tightening nut of left and right cross rod connection, turn cross rod,
to make the toe-in value be 2-6mm after the front wheel drops on the ground.
Finally tighten cross rod connection bolt nut.

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97

Max. Front wheel turning angle
Max. Front wheel turn is: 43.
Max. Front wheel turning angle is controlled by the limit bolt installed on
turning knuckle. Adjusting the length of limit bolt can adjust max turn angle of
front wheel.

Regular exchange of wheel positions
Whenever the vehicle runs 8000km, must be
exchange wheel positions according to the Limit bolt
sequence as shown in the figure.

Maintenance manual

98

Free turn quantity of steering wheel
Whenever the vehicle runs 8000km, check the free turn quantity of steering
wheel.
When adjusting, put the front wheel at straight running position, turn the
steering wheel leftward and rightward, stop until you feel resistance(at that time
the front wheel should not deflect, the turn quantity should not exceed 15.
If the turn quantity is over big, do the following check:
Whether the front wheel hub bearing clearance is proper.
Whether steering longitudinal and lateral pull-rods connection is loose.
Whether the conception of steering arm and arm shaft is loose.
Whether the axial clearance of steering arm shaft is over big.

Caution
When mounting steering propeller shaft, must make slide fork and
propeller shaft universal joint fork at the same plane

Maintenance manual

99

Wheel hub
Whenever the vehicle runs 8000km, clean, lubricate and adjust wheel hub
bearing.
When lubricating the wheel hub bearing, must clear up old lubricating grease;
To fill new lubricating grease between bearing inner ring and retainer roller.

Adjustment of front wheel hub bearing
When adjusting, sustain the front wheel, take off wheel hub cover1, level up
locking washer 3, take off locking nut 2 and lock ring 4.
Tighten adjusting nut 5 with 100-150Nm torque. When tightening, turn wheel
hub in forward and reverse directions, to make bearing roller at correct
position.
Tighten the adjusting nut 5 reverse 1/41/3 circle, to make the arresting pin on
nut and the adjacent hole on lock ring overlap, at that time, the wheel hub can
turn freely, without obvious
swing.
Tighten the locking nut 2
with 200-250Nm, and bend
the locking washer 3 to lock
up the nut.
Pulling wheel hub bolt with
spring steelyard to check the
starting force of turning
wheel hub, the tensile force
should be 19.6-58.8N.

1-wheel hub cover 2-locking nut
3-locking washer 4-lock ring 5-adjusting nut

Maintenance manual

100

Adjustment of rear wheel hub bearing
When adjusting, sustain the rear wheel, draw out half shaft, dismount nut lock
plate.
Tighten the nut with 250Nm. When tightening, turn the wheel hub in forward
and reverse directions, to make bearing roller at correct position.
Return the nut about 1/7 circle, to make the screw hole on the nut align the hole
on locking plate, install bolt. At that time, the wheel hub should be able to turn
freely, without obvious swing.
For the vehicle adjusted, pay attention to the wheel hub temperature in first
running 10km. Touch it with your hand, if the wheel hub is hot, showing,
bearing is over tight, must readjust.
When replacing the internal oil sealing of a new wheel hub, apply a thin layer
of lubricating oil on each working surface.

Nut
Locking plate

Maintenance manual

101

Partial adjustment of wheel brake
The partial adjustment of wheel brake is carried out after brake shoe friction
sheet is abraded, in order to reduce the clearance between it and brake drum.
The partial adjustment generally is carried out whenever a vehicle runs
8000km.

Caution
When adjusting, dont unscrew the tightening nut of brake shoe plate and
change the shaft installation.
In order to make left and right wheels have the same braking effect, the
push-rod travel of left and right brake chambers should be Min. Difference
value as far as possible, not exceed 5m.
Prohibit adjusting the brake through
turning connection fork, and change
push-rod length.

Adjustment method:
Take down the dust cover of regulation
arm (as shown as arrow ).
Push the regulation arm locking sleeve
to the hexagon head to expose scroll
shaft, turn the scroll shaft with spanner, to
make the clearance between brake drum and
brake shoe keep 0.4-0.7mm(measure at dust
cover check hole).
Brake chamber push-rod travel:
Front brake chamber 2510mm
Rear brake chamber 4810mm

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102

Battery
Battery liquid level must be 10-15mm higher than protection board, when it is
not enough, complement distilled water or clean cold boiled water, never fill
sulfuric acid or electrolyte.
In general areas, whenever the vehicle runs one year or 48000km, check
electrolyte density.
In particular air temperature areas, adjust electrolyte density according to local
condition.
When air temperature is 30-35,
electrolyte density is 1.260g/cm
3

When air temperature is 25-30,
3

When air temperature is below 25,
3

Protection board

Maintenance manual

103

Adjustment of headlights
Stop vehicle on dark light and flat road surface, to make headstock 1.83m away
from screen (or wall).
Dismount the headlights decoration cover, switch in low beam, tighten off the
regulation bolts of outside two headlights, to make low beam shape section
and two sections graphic of screen outside overlap(as shown in the figure
below).
Switch in inside headlights high beam, tighten off the regulation bolts of inside
two lights, to make the brightest point of the high beam shape and two boxes of
screen inside overlap.(it be shown in the figure below)

Maintenance manual

104
Replacing headlight bulb
Dismount headlight group from the front.
Take out the rubber seal ring behind the light shell, then take the bulb.
After replacing, mount them to the original position.
Often clean the reflector of all lights and lanterns with clear water, then blow
them with compressed air, or wipe them with deer leather, dont wipe
reflector with cotton cloth or cotton yard.

Maintenance manual
Replacing lubricating oil

105
Whenever the assembly is disassembly, and reassembly, all bearing, bush, etc.
should be lubricated; paint lubricating grease on relative motion parts friction
surface.
Often check the lubricating oil level height of all assembly, and add in time.
When the vehicle running reaches the specified mileage, must replace the
lubricating oil or bearing oil of corresponding assembly.
Replacing lubricating oil cycle of all assembly
Engine every 8000km
Transmission every 24000km
Rear axles every 24000km
Steering system every 48000km
Shock absorber every 48000km

Notice
Strictly select the lubricating oil conforming to standard according to the
specification.
Strictly prohibit using the lubricating oil from different trademark and
manufacturer together.
Lubricating oil can be filled into diesel until it is filtered.

Maintenance manual

106

Replacing lubricating oil for engine
Park vehicle on flat road surface, put
limited slip block at wheel.
In thermal vehicle state(oil temperature
is about 80), unscrew discharging oil
bolt under engine oil disk(oil is hot,
dont scald your hand), remove the
foreign matter absorbed on bolt-plug.
After the oil is discharged completely, tighten discharging oil bolt-plug.
Open the oiling cap on cylinder head cover.
Oil new lubricating oil, to make the oil level to the upper limit of oil gauge.
Start the engine, let it idle for several minutes, 30 minutes after stopping, check
with oil gauge, the oil should be between two marks, if not, continue charging.
Replacing oil cycle for engine:
When a new vehicle running-in is 500km;
When a new vehicle running-in is 1000km;
When a new vehicle running-in ends (running2500km);
Every running 8000km;
Lubricating oil (GB11122)
General areas whole year: 15W/40CD diesel engine oil
Summer (south areas): 40CD diesel engine oil
Winter (cold areas): 5W/30CD diesel engine oil

Maintenance manual

107

Replacing lubricating oil for transmission
Whenever the vehicle runs 8000lm, check
transmission oil level height, and charge
enough according to specification.
When replacing the oil, must discharge
all lubricating oil of the transmission,
then fill new clean lubricating oil.
When charging, let the oil level reach the
charging inlet.

Replacing oil cycle of transmission:
When a new vehicle running-in ends
(running 2500km).
Every running 24000km.
Oil:
75W/90 common vehicle gear oil(GL-4) in winter
80W/90 common vehicle gear oil(GL-4) in whole year except winter

Caution
Must replace lubricating oil in warm state.
Note dont be scalded by hot oil.
Remove the foreign matter absorbed on discharging oil bolt-plug.
Dredge vent-plug.

Maintenance manual

108

Replacing oil for rear axles
Oil:75W/90 GL-5 in winter
Oil:80W/90 GL-5
Oil charge: about 45L (charge oil until oil level hole spills oil)

Whenever a vehicle runs 8000km, check rear axle oil level, charge enough
according to specification.
When charging, let the oil level reach the charging inlet.
Rear axle charging inlet bolt-plug is on the main decelerator shell.

Replacing oil cycle of rear axle:
When a vehicle running-in ends (running 2500km).
Every 24000km.

Caution:
Must replace lubricating oil in
thermal vehicle state.
Note dont be scalded by hot oil.
Remove the foreign matter absorbed
on discharging oil bolt-plug.
Dredge vent-plug.

Maintenance manual

109
Power steering system
When a vehicle runs 8000km, replace hydraulic oil; and later every 48000km or
one year, replace hydraulic oil and the filter element in steering oil tank.
Must keep clean when replacing oil, dont let any foreign matter enter steering
system. After replacing oil, check whether there is oil leakage everywhere.
Oil: 8M hydraulic transmission oil (condensation point-35) according to
G08-010-99
Oil charge: about 3L.
Replacing oil method for power steering system:
Dismount the low pressure oil pipe
connection, then let engine idle, turn
the steering wheel left, right up to the
limit position (pay attention to the
steering wheel cant stop at limit
position exceed 5 seconds) 23 times,
to make the oil discharge completely.
Then switch off engine, remount the
connection.
Open steering oil tank top cap, charge
hydraulic oil into oil tank, let the oil
level over cylinder element cover. Let
engine idle, turn the steering wheel left,
right up to the limit position (pay
attention to the steering wheel cant
stop at limit position exceed 5 seconds),
continue to charge oil into the oil tank,
until the oil level doesnt drop, and
there is no air bubble. The oil level
should be between upper and lower
marks of oil gauge (see the figure).
Oil gauge

Maintenance manual
Lubrication Table

110

Maintenance manual
Lubrication Table

111
Lubrication Table
Interval mileage(km) No. Lubrication section
4000 8000 2400
0
4800
0
Lubricant agent Lubrication
point number
Remark
1 Engine General areas wholeyear: 15W/40CD(-20
40)
Diesel engineoil
Summer (south areas): 40CD (040
)diesel engineoil
Winter (cold areas): 5W/40CD(-3030
)diesel engineoil
1 Every 8000km,
replace
lubricating oil,
check oil level
with oil gauge
daily
2
3 Clutch hydraulic controls LD3000 braking fluid 1
4 Transmission 80W/90 general vehiclegear oil (GL-4) 1
5 Propeller shaft universal joint
pin and middlesupport
Vehiclegeneral lithiumlubricating grease 7
6 Propeller shaft slidefork

Vehiclegeneral lithiumlubricating grease 1 Takeout spine
sleeve, clear
grease
7 Rear axle 80W/90 GL-5 hypoid gear oil 1 Clean vent-plug
8 Front and rear leaf spring Vehiclegeneral lithiumlubricating grease 12
9 Shock absorber 50% grade1 No. 32 steamturbineoil
50% No.25 transformer oil
2 Calculateby
weight
10 Wheel hub bearing Vehiclegeneral lithiumlubricating grease 4 Dismount hub,
lubricating
greasein
bearing interior
cavity
11 Steering gear 8M hydraulic transmission oil
(condensation point is -35) by
G08-010-99
1
12 Steering knucklemain pin Vehicleall-weather lithiumlubricating
grease
4
13 Steering drag link and
tie-rod
Vehicleall-weather lithiumlubricating
grease
4

Maintenance manual
Lubrication Table

112
Continued
Interval mileage(km
No. Lubrication section
4000 8000 24000 48000
Lubricant agent
Lubrication
point
number
Remark
14 Steering transmission shaft
slidefork and universal joint
pin bearing
Vehicleall-weather lithium
lubricating grease
3
15 Steering column sphere
bearing

lubricating grease
1
16 Front and rear braking cam
bracket and support frame
lubricating grease
4
17 Sparetireregulator Vehicleall-weather lithium
lubricating grease
1
18 Gearlever coupling Vehicleall-weather lithium
lubricating grease
1
19 Braking adjusting arm Vehicleall-weather lithium
lubricating grease
4
20 Engine exhaust braking
control cylinder piston
lubricating grease
1
21 Speedometer soft shaft Vehicleall-weather lithium
lubricating grease
1
22 Clutch oil holder LD3000 braking liquid 1
Note: fill lubricating oil replacelubricating oil fill lubricating grease coat lubricating grease

Maintenance manual
Emergency treatment

113
Emergency treatment
Tire inflation
During the vehicle running, if tires have air leakage, inflate the compressed air in
gasholder of the vehicle into the tires.
Inflation method: Unscrew the deflating valve on the gas holder, screw one end
of the inflating hose of the tire into it, the other end is connected with tire valve,
then open the deflating switch, start the engine to let air compressor work, that is
to charge a tire.
After inflation, check it with air pressure meter, and adjust the sir pressure to the
sissified value.

Replacing tires
Left and right side wheel nuts are dextrorotary thread.
When dismounting a tire, first unscrew the wheel nuts, then jack up it until the
tire separate from ground, then, unscrew nuts, take down the tire.
When mounting, be sure to coat lubricating grease on bolt and nut thread.
When the nuts are screwed on, lower the tire on ground, then screw down nuts
according to the specified torque and the sequence shown in the figure.
Tightening torque is 450-500Nm.
When replacing two tires, jack up the two
wheels, and mount inside and outside tires
respectively.
The valve of inside and outside two tires
should be stagger. When mounting the rear
wheel, the valve nozzle should align brake
drum splay.

Maintenance manual
Fault analysis

114
Fault analysis
Fault Reasons Solution

1. Thereis air in fuel system. Dischargetheair in thesystemwith manual oil
pump, check whether thesystemhas air leakage.
2.Fuel filter and fuel finefilter aredirty Check, clean or replacefilter.
3.Thereis block in fuel system(delivery oil pump fuel intake
joint filter gauzeor filter)
Dismount, clean
4. Delivery oil pump does not feed fuel, or discontinuously
feed fuel.
Check and repair
5. Fuel injector does not spray well. Check fuel injector unlock pressureand spray
condition
6. Fuel injector unlock pressureis over low. Readjust
7. Fuel feeding advanceangleis wrong. Check and adjust
8. Engineoil gradeis wrong or viscosity is not right. Replaceengineoil
Engine starts
difficultly
1. Fault in fuel
feeding system
9. Fuel does not conformto standard. Check and replaceengineoil
1. Cylinder pad ablation, air spill. Notecoolant consumption, observewhether cylinder
pad has air leakage, thereis excessivesir in cooling
system, handleor replace
2. Air spills seriously after piston ring abrasion. Replacepiston ring
3. Piston ring colloid. Eliminate colloid and replacepiston ring
4. Valveseal is not tight. Check valvespring, valvecleanse, valveseal bevel
seal condition and do corresponding handle
2. Cylinder
compression
pressureis
insufficient.
5. Compression ends, temperatureis low.

Usestarting preheating unit, warmup theair in air
intakepipe

1. Battery voltageis insufficient. Charge, to makevoltagereach thespecified
requirement
2. Starter wiring is looseor oxidized. Replace and tighten connection
3. Electric
systemfault
3. Starter gear cannot embed flywheel tooth ring. Check and repair starter attracted-iron mechanism

1.Valveclearanceis wrong Check valveclearance
2. (Should beunhitched) Clutch is not unhitched. Check clutch
3. Temperatureis lower than thelimit. Check
4. Parking brakevalveis in braking position. Check
5. Gearlever is not in neutral position. Check gearlever neutral position
4. Thefaults
caused by other
reasons
6. Cooling fan does not work/belt is broken or seized up. Check and replacefan belt

Maintenance manual
Fault analysis

115

Continued
1. Thereis air in fuel feeding system. Press oil delivery pump handleto discharge air
2. Water in fuel is excessively much. Check fuel water content, replace with qualified
diesel oil
3. Fuel pipelineleak. Check and remove
4. Speed regulator does not work normally. Check and calibratespeed regulator(repair by
professional)
5. Valveclearanceis wrong. Adjust valveclearance
6 .Fuel filter or diesel finefilter is dirty. Check, clean or replace
7. Fuel does not conformto standard. Replaceengineoil
8. Cooling fan doesnt work/belt is broken or seized up. Check or replacefan belt
9. Cylinder spill gas. Check cylinder head bolts, if necessary, replace
cylinder pad, check cylinder jacket bulgeheight and
height difference, adjust it through adding sheet
copper.
10. Every cylinder feeds oil unevenly.
a. Every cylinder of fuel injection pump feeds oil
unevenly.
Check and adjust on thetest table by professional.
b. Fuel injector sprays improperly or coupler is seized up. Check fuel injector injection condition, wash it on
test tableby professional or replacecoupler.
Enginecan
start, but the
operation is not
smoothly or
cannot be
controlled.
c. Fuel injection pump plunger spring is broken. Replacespring ( by professional)
1. Air filter is crammed. Removefilter element dust or replacefilter
element
2. Valvespring is broken or valvepush rod is damaged. Replace
3. Valveclearanceis wrong. Adjust
4. Cylinder compression pressureis insufficient. Find out reason and solve
5. Fuel feeding advanceangleis not right. Check and adjust
6. Fuel feeding systemhas air or is blocked. Releaseair, dredgeoil-way
7. Fuel feed is insufficient. Check fuel injection pump plunger and oil-out
valve, etc
8. Injected fuel atomization is not good. Check, clean furl injector, adjust pressure
9.Engineis over hot
10. Exhaust pipelineis blocked.
Check cooling system, removecrammer
Removecrammer
Enginepower is
insufficient, and
thepower
declines
suddenly.
11. Speed regulator does not work normally.

Check speed regulator, and adjust
correspondingly.

Maintenance manual
Fault analysis

116

Continued
12. Fuel injection pump does not supply sufficient fuel. Check fuel injection pump plunger and oil-out
valveabrasion condition, if necessary, replace
13. Fuel quality is low. Replacewith fuel conforming to specification
requirement.
14. Surrounding temperatureis too high or operation in
high elevation area.
Under the condition of high elevation area or very
high surrounding temperature, theactual power of
theenginewill decline, so theuser should decrease
load.
Enginepower is
insufficient, and
thepower
declines
suddenly.
15. Central cooler is blocked, and pipelinehas leakageto
damage.
Clean central cooler and sealing pipeline
1. Fuel injection timeis over early, to makecylinder
interior send rhythmic and silvery metal knocking sound.
Adjust fuel feeding advanceangle
2. Fuel injection timeis over late, to makecylinder interior
send toneless and unclear sound.
Adjust fuel feeding advanceangle
3. Clearancebetween piston and cylinder is over big, after
enginestarts thecylinder sends clash, which gets weak
along with theenginewarming up.
Replacepiston or cylinder jacket.
4. Clearancebetween piston pin and pinhole, sending light
shrill, which is moreclear at idle.
Replacethepart, guaranteeclearance.
5. Clearancebetween main bearing and connecting rod
bearing is over big, crash can beheard when engine
rotation speed reducesuddenly, the sound is heavy and
strong at low speed.
Replacethepart, guaranteeclearance.
6. Crankshaft axial clearanceis over big, crash of forward
and backward moving of crankshaft can be heard at idle
speed.
Replace thrust sheet, guarantee the specified
clearance
7. Valvespring is broken, push rod is bent, valveclearance
is over big, etc., noise or light rhythmic knocking sound
can beheard at cylinder head.
Replaceparts, check and adjust valveclearance
8. Gear clearance is over big duo to abrasion. When
rotational speed reduces suddenly, crash can be heard at
gear chamber.
Replacegear according to actual condition
Abnormal sound
is sent when
engineis
working.
9. Piston bumps cylinder heard, metal crash can be heard
around cylinder head at low speed.
Check whether distributing gear mark is right; To
check compression clearance, if theclearance is less
than 0.8mm, replacecylinder pad.

Maintenance manual
Fault analysis

117

Continued
10. Valveand swing armclearanceis over big, thereis metal
crash in valvemechanism.
Check and adjust valveclearance
11. Water pump bearing or enginebearing is damaged to
send continuous sound.
Replacebearing or water pump generator
assembly
Abnormal
sound is sent
when engine is
working.
12. Supercharger shaft bend or impeller deformation causes
impeller and volutefriction.
Check and replace
1. Engineoil level is over high, to makeengineoil spill. Check and decline oil level
2. Valverod oil seal is damaged. Replaceoil seal
3. Piston ring counteracts or is seized, resulting in over big
abrasion.
Check and remove
4. Supercharger lubricating oil seal is out of work. Repair supercharger, guaranteegood seal.
Engineexhaust
smokeis
abnormal.
1.Bluesmoke
rises

5. Piston ring apertures arein thesameside. Remount by 120 distribution
1. Fuel injector atomization is not good, with seep. Check injection pressure, check coupler
2. Thereis water in cylinder. Check and remove
3. Thereis excessive water in fuel. Replacethespecified fuel
2.Whitesmoke
rises

1. Engineis over-load. Reduceload
2. Fuel injection is too much. Adjust fuel feed
3. Fuel feeding is over late, and afterburning is too much. Adjust fuel feed advanceangle
4. Air filter is blocked, and air is insufficient. Removefilter element dust, check supercharger
rotor rotation or replacefilter element
5. Valveclearanceis wrong. Adjust valveclearance
6. Individual cylinder does not work. Check thecylinder not to work, find out the reason
not to work, and repair
3. Black smoke
rises.
7. Fuel quality is too bad. Replacethespecified brand fuel
1. Engineload is too heavy. Reduceload
2. Engineoil is too low or too high. Raiseor drop engine oil level according to
specification
3. Air leakageis serious. Check, clean or replacepiston ring
4. Engineoil cooler interior is blocked, bypass valve
pressureis wrong, and shell is blocked by dirt.
Check and clean, adjust bypass valveunlock
pressure
Engine
temperatureis
too high.
5. Air filter is dirty. Check or replace

Maintenance manual
Fault analysis

118

Continued
6. Air filter indicating deviceor indicator light is out of
work.
Check
7. Air intakepipeis leakage. Check or replaceair intakepipe
8. Water pump is leakage. Check or replace
9. Radiator is dirty. Check and clean
10. Fan does not work/belt is broken or seized up. Check and replacebelt
11. Fuel injector is damaged. Check and replace
12. Engineoil filter is damaged. Replace
13. Coolant level is too low. Check and fill coolant
14. Temperatureregulator does not work. Check and replace
15. Fan clutch leak siliconeoil, does not engage. Check and replace

16. Fan is mounted reverse, and vanes arebroken. Check and replace
1. Fuel pressurewarning switch is damaged. Replace
2. Engineoil level is too low. Fill fuel to specified oil level
3. Engineoil gradeis wrong or viscosity is not right. Check engineoil trademark, temperatureand
whether fuel is diluted.
4. Pumping oil of engineoil pump is insufficient. Check and solve
5. Collector gauzeand filter areblocked, or engineoil
cooler is blocked.
Clean or replace
6. Pressurelimit valveor pressureregulating valveare
damaged or seized up.
Replacethepart or handle
7. Engineoil pipelineis blocked or leakage, filter framepad
is mounted reverse.
Check and handle
8. Clearancebetween sections is over big. Check and handle
9. Centrifugal engineoil filter rotor splits and is damaged. Replacerotor assembly
10. Clearance between crankshaft axleneck and main bush
connecting rod is too big.
Replaceabraded bush or crankshaft
11. Engineoil filter or engineoil cooler is blocked. Replacerotor assembly
Engineoil
pressureis
insufficient
12. Engineoil pump gear, bearing and body caseplaneare
abraded.
Replaceengineoil pump
1. Water thermometer or sensor is ineffective. Check and replace Coolant
temperatureis too
high.
2. Coolant is insufficient: fan belt is looseor broken; water
pump supply water is insufficient.
Fill enough coolant according to theprovision,
adjust belt tension

Maintenance manual
Fault analysis

119

Continued
3. Cylinder pad is leakage. Replacecylinder pad
4. Enginewater cavity passageway begriming is too much,
radiator heat sink or copper pipehavedirt, and water
thermometer or sensor does not work.
Clean water furring, dirt, to makepassage
unimpeded.
5. Temperatureregulator is ineffective. Check and replace
6. Water pump has leakage. Check and replace
7. Fan clutch does not engage, leak siliconeoil, ineffective. Check and replace
8. Fan vanes arebroken. Check and replace
9. Engineload is too big. Reduceload
Coolant
temperatureis too
high.
10.Central cooler is blocked, and thereis dirt on thesurface Check and clean

1. Compressor impeller and its passageway are
contaminated.
Clean compressor impeller and its passageway
2. Turbine impeller and its passageway arecontaminated. Clean turbineand its passageway
3. Bearing is abraded seriously. Replacebearing

1. Seal ring is abraded seriously or broken. Replaceseal ring
2. Crankcase interior pressureis high. Check diesel and remove
3. Oil return pipeis blocked. Clean and dredgepipeline
4. Compressor front vacuumdegreeis too big. Clean air filter and pipe
5. Thrust sheet is abraded seriously. Replacethrust sheet

1. Compressor surges. Clean air intakeand exhaust pipes
2. Impeller vanes arefragmented. Replacecorresponding impeller
3. Bearing is abraded seriously whilevanes furbish. Replacebearing
Supercharger fault
1. Efficiency
reduces.

2. Spill oil

3. Others
4. Air inlet and outlet and central cooler pipelineare
leakage.
Check whether air intakeand exhaust pipes split,
and all pads aresealed.
Note: theprofessional of specialized factory, to avoid destroying supercharger train dynamic balance, must replace supercharger train parts.
1. Crankshaft and bush block. Check crankshaft and bush, if necessary, replace Engineflameout
suddenly
1. Crankshaft does
not rotateafter
flameout.
2. Piton and cylinder jacket block. Replacepiston and cylinder jacket
1. Fuel systemis blocked or condensed. Remove
2. Air filter is blocked. Clean or replacefilter cylinder
2. Crankshaft can
rotateeasily after
flameout.
3. Fuel injection pump does not feed fuel. Check and remove

Maintenance manual
Fault analysis

120

Continued
1. Fuel delivery pump piston spring is broken or valveseat
is abraded.
Replacespring or repair check-valveand seat
2. Plunger is abraded. Replaceplunger
Fuel delivery
pump feeding is
insufficient.
3. Fuel feeding screw is leakageor pipelineis blocked. Replacepad, tighten screw; clean block

1. Thereis air in fuel feed system. Dischargegas
2. Fuel-out valvespring is broken. Replacespring
3. Fuel-out valvesealing surfaceand encirclesurfaceare
abraded.
Replaceparts or repair
4. Plunger pair is abraded or spring is broken. Replaceparts
5. Foreign makes plunger pair block. Clean and replace
6. Fuel feeding pressureis too low. Check fuel delivery pump and filter
1. Fuel-out valveis leakage.

Repair or replace
2. J oint leaks fuel. Check and repair
3. Plunger is abraded. Replacethepart
1. Fuel delivery pump has fault. Check and remove
2. Fuel intakepipehas air leakage. Find out fault and remove
Fuel injection
pumps feed fuel
unevenly and
insufficiently or
do not feed.
1. Fuel feeds
unevenly.

2. Fuel feeding is
insufficient.

3. Do not feed
fuel
3. Fuel-out valvespring is broken. Replacespring

1. Thereis air in fuel-way. Dischargeair
2. Needlevalveand valvebody scuff Replace
3. Clearancebetween needlevalveand valvebody is too
big.
Replace
4. Fuel feeding systemhas serious fuel leakage. Tighten, replacethepart
5. Fuel injection pump feeding is abnormal. Debug fuel injection pump on fuel injection pump
test table
1. Pressureregulation screws areloose. Adjust pressure
2. Spring deforms. Replacespring
1.Needlevalveclips Repair and replace
2. Fuel holeis blocked. Dredgeand clean
Fuel injector
injection is
abnormal.
1. Fuel injection is
littleor not any.

2. Fuel injection
pressureis low.

3. Fuel injection
pressureis too
high. 3. Pressureregulation spring pressureis too high. Readjust
1. Needlevalvedeforms or is abraded. Replacethepart
2. Needlevalveand valveseat surfaceareabraded or
burnout.
Replacethepart
3. Injection holeis blocked. Dredge, clean
4. Atomization is
not good.

4.Needlevalveclips Repair or replace

Maintenance manual
Fault analysis

121

Continued
1. Engineoil level is too high. Decreaseoil level
2. Filter is dirty or supercharger has fault. Check or replace
3. Air filter indicating deviceor indicator light does not
work.
Check
4. Low-speed fuel reduction deviceis damaged. Check
5. Air intakepipehas leakage. Check and replace
6. Fan does not work /belt is broken or clips. Check and replace
7. Valveclearanceis not right. Adjust valveclearance
8. Fuel injector is damaged. Check and replace
9. Thereis air in diesel oil system. Check and discharge
10. Fuel coarsefilter or fuel finefilter is dirty. Check, clean or replace
Operation
condition is not
good.
11. Fuel does not conformto standard. Check and replace
1. Fan does not work/belt is broken or seized up. Check and replace All cylinders do
not work. 2. Fuel injector is broken. Check and replace
Engineoil
consumption is
too high
1.Engineoil level is too high
2. Engineoil gradeis not right or viscosity is wrong.
Decreaseoil level
Replaceengineoil
1. Friction plateis smeary. Clean
2. Friction plateis abraded, cannot engagecompletely. Adjust pedal freetravel; if abrasion is over big,
replacedriven disk assembly
3. Friction plateabrasion is over much, not enough to
transfer enginepower.
When total friction of tow surfaces of friction
plateexceeds 3mm, replace
Clutch creeps
4. Driveoperation is not proper, to makeclutch over hot,
causing friction to beburnout and deteriorated.
Repair or replaceaccording to actual condition.
Clutch is not
completely
separated.
Improper driving operation makes clutch over-hot, friction
sheet deformation, even fragmentation.
Correct driven disk assembly: When positioning
by spline, end pulsation amount at clutch driven disk
assembly flangemust beless than 0.8mm, if cannot
engage, replace.

Maintenance manual
Fault analysis

122

Continued
1. Damping spring of driven disk assembly is damaged. Replacedriven disk assembly
2. Releasebearing or thefirst bearing of transmission is
abraded or burned through.
Replacebearing
Clutch makes
noise.
3. Fit clearanceof thesplineslot and first splineis larger
than 0.6mm.
Replacedriven disk assembly
1. Clutch is not completely separated.
2. Control mechanismadjustment is improper.
Correct or replacedriven disk
Check and adjust control mechanism
Transmission
gearshift timeis
long or gearshift
is difficult.
3. Synchronizer, engagebush and transmission fork are
seriously abraded.
Check, replaceabraded parts
1. Clutch interior parts aredamaged or fixtureparts are
loose.
Check clutch parts, replacedamaged parts or
fasten looseparts
2. Lubricating oil viscosity is too low or oil is insufficient. Useproper gradelubricating oil, and fill it to
specified oil level height.
Transmission
makes noise
when shifting
gear.
3. Bearing and gears aredamaged or seriously abraded.
4. Universal joint is seriously abraded.
Replacedamaged parts or abraded parts.
Replaceabraded parts.
1. Combined teeth is abraded or self-lock spring force
weakens.
2. Control mechanismis installed improperly or is seriously
abraded.
Self-lock spring freeheight is 30mm. if thespring
rigidity reduces, replaceit.
Check, adjust control mechanismor replace
abraded parts.
3. Engagebush is seriously abraded. Replaceabraded parts
4. Transmission for is seriously deformed or severeabraded. Correct transmission fork or replaceit
Transmission is
out of gear
automatically in
running.

5. Bearing is seriously abraded.

Replacebearing

Transmission
leaks oil
1. Seal parts are ineffective.
2. Tightening parts areloose.
3. Vent-plug is blocked.
Replaceoil sealing
Check, tighten looseparts
Check clean or replacevent-plug
1. Lubricating oil is over much. Check, dischargeexcessivelubricating oil
2. Lubricating oil deteriorate. Replacedeteriorating lubricating oil
3. Compatibleclearanceof running parts is over small. Check, adjust compatibleclearance or replace
parts
Transmission oil
temperatureis
over high.
4. Gear and bearing are seriously abraded. Check, replaceabraded parts
Handleis not
obvious when
selecting gear
Halt forceof reversegear shifting guideshoeassembly or
gear 5 and gear 6 shifting guideshoes is not enough.
If theforcethat polesuppress ball steel back off
less than 200-500n, need to replacespring

Maintenance manual
Fault analysis

123

Continued
Steel platespring is
broken along center
hole.
Steel platespring U-bolt is not screwed down according to
specified torquefor along time.
Screw down according to specified torque
Steel platespring
sheet is broken
early.
1. Vehicleis long overload, or continuous impact.
2. Spring cramp or bolts arelost.
3. Maintenanceor and lubrication arenot doneaccording to
thespecification.
4. Buffer block is drop out.

Steel platespring
ear is broken.
1. Vehicleworks long in overload state.
2 .Start running improperly, start or braketoo fast.

Avoid long overload
Start and brakesmoothly
1. Steering wheel freetravel is over large. Adjust
2. Steering armfixing nut is loose. Tightening torqueis 200-300Nm
3. Clearancebetween steering universal joint fork, slidefork
and universal joint pin is over large; universal joint pin
needlebearing is abraded.
Adjust with thickening elastic retainer
ring; replaceuniversal joint pin or bearing
Steering is not
smooth.

4. Steering universal joint and slidefork arenot on thesame
plane.
Readjust to make themon thesameplane
1. Clearancebetween brakeshoefriction vaneand brake
drumis over big.
2. Brakeshoefriction sheet is smeary or is burned out.
Brakedrumroundness is very abnormal, brake shoeplate
does not joint well.
3. Brakevalveis not adjusted properly; drawing armtravel is
too small.
4. Brakeshoebobbin or brakecambracket is rusted and
seized.

Braking foreis
insufficient.
5. Brakechamber packing cup, pipelineand joint have
leakage.
Adjust braking clearance

Clean with gasolineor buck, remove
friction sheet surfacedust with No.2 coarse
emery cloth or saw blade
Carry out Boring and honing, circleerror
should not belarger than 0.35mm
After releasing
brakepedal,
braking cannot be
relieved in
time(exhaust is
slow)
1. Brakevalveexhaust clearanceis over small.
2. Brakevalveseat rubber stamp deforms or drops out.
3. Brakevalveguidebaseis rusted and blocked.
4. Brakeshoesheet bobbin is rusted and blocked.
5. Brakevalvemoving parts areblocked.
Adjust exhaust clearanceto 1.20.2mm

Maintenance manual
Fault analysis

124

Continued
Air pressure
within
Gasholder
drops.
1. Gasholder unilateralismvalvelocked, it cant beopened.
2. Gasholder discharging water switch isnt closed.
3. Air pressureregulator valvehas leakageor is improperly
adjusted.
Knock unidirectional valvebody or air pipe with
spanner.
Air pressure
drops sharply
when braking
1. Brakevalveis seized.
2. Braking pipelineor membraneis broken up suddenly.

1. AC generator magnetic field winding circuit is cut-off or
thecontact is not good.
Check and repair generator

2. Voltageregulator is broken. Replaceregulator
Generator
doesnt generate
electricity.
3. Magnetic field fuseis broken. Theyellow wireon generator magnetic field
winding binding post first is dismantled, ground
binding post with wireor screw drive, start the
generator. When rotational speed is 1000r/min, if
generating electricity or charging current increase,
which is regulators fault, if not, it is generators
fault.
1. Generator belt creeps. Check and adjust Current meter
hand swings
excessively.
2. Generator brush section contact is not good. Check and maintain
1. Regulation voltageof regulator is over high. Reducetheresistancevalueof regulating
resistanceproperly, align voltagedrops (when
generator rotational speed is 1000r/min, switch in
headlight high beam, regulation resistanceshould be
27.8-29.2V)
Charging
current is over
big.
2. Regulator is damaged. Replace

124

Data manual

Data manual
Main bolt and nut tightening torque

125
No. Name Tightening torque
(N m)
Quantity
1 Cylinder head bolt(M14,M15) 225.4
+9.8
-29.4

24015(M15)
26
2 Cylinder head bolt(M10) 34
+6.86
-9.8
6
3 Connecting link bolt 14515 12
4 Main bearing bolt 294
+9.8
-29.4
14
5 Flying wheel bolt 275
+9.8
-19.4
7
6 Shock absorber bolt(M14), rubberizing 18010 8
7 Air compressor gear clamp bolt 157
+4.9
-24.5
1
8 Camshaft gear tightening bolt 206
+9.8
-19.6
1
9 Water pump pulley bolt(M10) 20-30 4
10 Intake manifold fixing bolt 20
+5
-7
18
11 Exhaust manifold fixing bolt 34
+6.86
-9.8
4
12 Fuel injector fixing nut 19.61.96 12
13 Injection pump support fixing bolt 43
+7
-10
4
14 Injection pump fixing bolt 251.96 4
15 Injection pump driving gear tightening nut 157
9.8
-19.6
1
16 Gear chamber cover plate fixing bolt 34
+7
-10
7
17 Engine oil filter fixing bolt 30-40 7
18 Engine oil pump tightening bolt 30-40 3
19 Rockshaft support fixing bolt 43
+8
-10
6
20 Front oil seal retainer bolt 59
+8
-12
5
21 Rear oil seal retainer bolt 20
+5
-7
5
22 Clutch cover assembly fixing bolt 60-70 8
23 Clutch shell fixing bolt 35-45 12

Data manual

126

(N m)
Quantity
24 Transmission first shaft bearing cap bolt 40-50 6
25 Transmission rear cap bolt 50-60 10
26 Transmission second shaft flange locking nut 300-480 1
27 Transmission upper cap fixing bolt(CQ1501035) 40-50 18
28 Transmission top cap fixing bolt 28-39 4
29 Transmission and clutch housing connection bolt 229-298 6
30 Transmission filling and discharging oil screw-plug 130-150 1 for each
31 Middle transmission shaft flange nut 200-300 1
32 Transmission universal joint flange fork tightening nut 130-150 2
33 Universal joint pin needle bearing carrying sheet nut 20-25 12
34 Differential shell tightening bolt 90-180 12
35 Differential bearing cap tightening bolt 43020 22
36 Rear axles drive bevel wheel flange nut 200-350 1
37 Half shaft tightening bolt 120-160 142
38 Rear axle oiling and oil discharging nut 60-100 1 for each
39 Rear wheel hubs bearing locking nut 250(pre-tighten) 2
40 Front wheel hubs bearing locking nut 100-150 2
41 Front plate spring center bolt and nut Not less than 100 2
42 Rear plate spring center bolt and nut Not less than 100 2
43 Auxiliary plate spring center bolt and nut Not less than 100 2
44 Plate spring lifting ring pin nut 9010 22
45 Front plate spring U-bolt 350-450 22
46 Rear plate spring U-bolt 500-600 22
47 Shock absorber oil tank nut 8020 2
48 Steering longitudinal pull-rod ball pin locking nut 185-270 22
49 Knuckle upper arm tightening nut 350-410 1

Data manual

127

Continued
(N m)
Quantity
50 Left and right knuckle arm tightening nut 350-410 2
51 Steering arm fixing nut 200-300 1
52 Wheel bolt tightening nut 450-500 104
53 Power steering gear fixing bolt 390-450 4
54 Steering wheel tightening nut 100-120 1
55 Steering universal joint fork tightening bolt 32-42 3
56 Brake shoe bobbin locking nut 380-420 24
57 Connecting rod of spare tire riser 10010 1

Data manual
Bearing table

128
Bearing table
No. Type Name Quantity
1 1602130-680 Clutch release bearing assembly 1
2 Transmission first shaft front bearing 1
3 NUPK311NRV4 First shaft rear bearing 1
4 NUP311EN Second shaft rear bearing 1
5 NJ K309V1 Transmission middle shaft front bearing 1
6 NUPK309NRV3 Transmission middle shaft rear bearing 1
7 49245/27 Reverse gear idler needle bearing 2
8 K687630 Reverse gear roller bearing 1
9 Propeller shaft middle support bearing 1
10 Propeller shaft universal joint needle bearing and
spider assembly
3
11 27709K Rear axle drive bevel gear front bearing 1
12 27210E Rear axle drive bevel gear rear bearing 1
13 32014 Differential bearing 2
14 (32310) Front wheel hub outside bearing 2
15 (30613) Front wheel hub inside bearing 2
16 (33216X2) Rear wheel hub inside and outside bearing 4
17 3404040-15 Steering universal joint bearing 8
18 (6204-2LS) Steering shaft ball bearing 1
19 (6208) Air compressor crankshaft rear bearing 1

Data manual
Oil seal table

129

Oil seal table
No. Drawing No. Name Quantity Remark
1 6110-1005050 Engine crankshaft front oil seal 1 Framework rubber oil
seal
2 6110-1005060 Engine crankshaft rear oil seal 1 Framework rubber oil
seal
3 2202145-01 Propeller shaft middle support oil seal 2 Rubber oil seal
4 2201065-01 Dust cover and felt oil seal assembly 1
5 2402055-5K1DA1Rear axle drive bevel gear oil seal 1 Rubber oil seal

130

CA5083 XXYPK2L1A80 Operation Manua GF-6000l

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