Use and Maintenance Manual For HOVA Series Internal Combustion Towing Tractor

Prompt: before the tractor comes into use, please read the Manual carefully and keep it properly
for looking up at any time.
CNHTC Use and maintenance manual for HOVA series internal combustion towing tractor
(Version I)
China National Heavy Duty Truck Group Jinan Special Vehicle Co., Ltd.
1
Preface
Thank you for choosing HOVA series internal combustion towing tractor. The series tractor has 2 driving forms (4×2, 6×4), two transmissions (automatic
gearbox and mechanical gearbox) and 20 basic types and it is applicable to drop and pull operation of bulk cargo terminal of the port, apron container
transshipment, roll-on-roll-off ship operation, and other operation conditions can used in container logistics park, iron and steel company, etc.
The Manual is the manual for series products and introduces the operation, routine maintenance and tractor maintenance of the internal combustion towing
tractor for port, and relevant safety regulations during the tractor use process.
The user shall read corresponding performance, structure, use, maintenance and other aspects information in the Manual according to chosen tractor type.
Before new tractor is put into operation, please read the Manual carefully and give necessary maintenance of the tractor appropriately in strict accordance
with stipulated contents in order to guarantee normal life of the tractor and obtain good economic benefit. The loss caused because of violating the
provisions hereof should be borne by the user.
The tractor pictures in the Manual may be not completely consistent with the tractor that you buy in view of various tractor models; those illustrations are the
typical examples only. The Company reserves the right to improve the shape, configuration and technical performance of the tractor.
In case of any tractor failure, contact the local branch or maintenance station of CNHTC as soon as possible, and we will provide you with timely and
effective “home” service.
Wish you a safe, comfortable and pleasant driving journey!
Do not reprint, copy, translate or excerpt the Manual without the written approval from China National Heavy Duty Truck Group Jinan Special
Vehicle Co., Ltd.
China National Heavy Duty Truck Group Jinan Special Vehicle Co., Ltd.
August 2015
2
Tractor No.
For the purpose of convenient tractor maintenance, please fill out the correct and complete tractor No.:
Tractor No.:
VIN No.:
Engine No.:
Date for purchase:
Note: 1. The nameplate with tractor No. is on the right platform at the rear of the cab.
2. VIN No. is printed on longitudinal beam web of the frame in the center line of the front axle.
3. Motor No. is printed on the motor body under the air compressor.
VIN Name Engine No.

Nameplate
3
Special tips
1. The tractor is the interior special motor vehicle used in the factory area and other special areas stipulated in the Rules on Safety Supervision of Special
Equipment.
2. Before the tractor is put into operation, please read the Manual carefully and strictly perform the use and maintenance requirements in use, and check and
maintain the tractor regular. The loss caused because of violating the provisions hereof should be borne by the user.
3. At the time of parking for a long time, shut down the main switch of the tractor supply source after shut down the engine, and the parking brake must work
to avoid the accident.
4. At the time of electric welding on the tractor or nearby, do disconnect the battery supply and unplug all plug connectors connecting with the electron
components.
5. Only pure fuel oil up to quality requirement can be used for the tractor. The engine oil, lubricating oil (grease), hydraulic oil, power oil, long-term antifreeze
and other working media shall meet the brands stipulated in the Manual. Filling those with brands not stipulated herein makes the tractor unusable.
6. In case of any tractor failure, contact the local branch or maintenance station of CNHTC as soon as possible, and we will provide you with timely and
effective “home” service. In case of leakage of fuel oil, power and fire operation is strictly prohibited.
7. Drive the tractor in strict accordance with relevant traffic laws.
8. In need of docking tractor (trailer), it shall have parking function and that shall meet full-load parking efficiency stipulated in GB7258.
9. Tel.: 400 6012806, 053187506388; e-mail: TZCJSFW@CNHTC.CN.
The Manual is subject to the change because of continuous improvement of the product without notice.
4
Table of contents
Part I: Tractor use............................................................................................................................................................................................................................1
I. External devices of the cab..........................................................................................................................................................................................................1
(I) Use the door switch outside........................................................................................................................................................................................................2
(II) Use the door switch inside.........................................................................................................................................................................................................4
(III). Opening and closing of engine hood.......................................................................................................................................................................................5
(IV). Cab front shield.......................................................................................................................................................................................................................6
(V). Cab turnover.............................................................................................................................................................................................................................7
II. Internal devices of the cab..........................................................................................................................................................................................................9
(I). Internal devices.........................................................................................................................................................................................................................9
(II). Instrument board.....................................................................................................................................................................................................................11
(III.) Summary sheet of symbols of signal lights...........................................................................................................................................................................12
(III). Graphic symbols of rocker switches......................................................................................................................................................................................18
(IV). Power switch.........................................................................................................................................................................................................................21
(V). Combination switch................................................................................................................................................................................................................22
(VI). Operation of fog lamp and interior lighting............................................................................................................................................................................25
(VII). Seat......................................................................................................................................................................................................................................27
(VIII). Transmission shifting...........................................................................................................................................................................................................29
(IX). Parking brake........................................................................................................................................................................................................................33
(X). Unlocking control button of traction seat................................................................................................................................................................................33
(XI). Saddle lifting..........................................................................................................................................................................................................................34
(XII). Seatbelt................................................................................................................................................................................................................................35
(XIII). Air conditioning....................................................................................................................................................................................................................36
1
(XIV). Other internal devices.........................................................................................................................................................................................................37
III. Preparations before driving......................................................................................................................................................................................................38
(I). Routine check before driving every time.................................................................................................................................................................................38
(II). Engine start.............................................................................................................................................................................................................................45
(III). Stalling of engine...................................................................................................................................................................................................................47
IV. Starting and gear shit...............................................................................................................................................................................................................48
(I). Starting.....................................................................................................................................................................................................................................48
(II). Running and gear shift............................................................................................................................................................................................................48
(III). Power take-off (PR70 power take-off can be added for 4×2 tractor with ZF mechanical gearbox).......................................................................................51
(IV). Clutch control.........................................................................................................................................................................................................................52
(V). Stopping.................................................................................................................................................................................................................................54
V. Vehicle brake.............................................................................................................................................................................................................................55
(I). Energy supplying device..........................................................................................................................................................................................................55
(II). Service brake..........................................................................................................................................................................................................................55
(III). Emergency and parking brake...............................................................................................................................................................................................56
(IV). Auxiliary brake.......................................................................................................................................................................................................................56
(V). Trailer brake............................................................................................................................................................................................................................57
(VI). Precautions for use of brake system.....................................................................................................................................................................................57
VI. Winter operation.......................................................................................................................................................................................................................58
(I). Cooling system........................................................................................................................................................................................................................58
(II). Braking device........................................................................................................................................................................................................................58
(III). Battery....................................................................................................................................................................................................................................58
VII. Wheel replacement and tire pressure.....................................................................................................................................................................................59
VIII. Running-in of new vehicle......................................................................................................................................................................................................60
2
Part II: Use and Maintenance of Principal Assembly...............................................................................................................................................................61
I. Steering system..........................................................................................................................................................................................................................61
(I). Mechanical steering.................................................................................................................................................................................................................61
1.1.1. Steering system fault diagnosis..........................................................................................................................................................................................62
1.1.2. Maintenance of steering system.........................................................................................................................................................................................65
1.1.3. Methods for replacement of hydraulic oil............................................................................................................................................................................65
(II). Fully hydraulic steering...........................................................................................................................................................................................................67
III. Clutch control system (mechanism case)................................................................................................................................................................................70
(I). Operating principles.................................................................................................................................................................................................................71
(II). Operating parameters.............................................................................................................................................................................................................71
(III). Adjustment of clutch control system......................................................................................................................................................................................72
(IV). Precautions............................................................................................................................................................................................................................73
IV. Transmission control system....................................................................................................................................................................................................74
(I). Automatic gearbox...................................................................................................................................................................................................................74
(II). Mechanical gearbox................................................................................................................................................................................................................76
(III). Power take-off........................................................................................................................................................................................................................80
V. Axle............................................................................................................................................................................................................................................82
(I). Front axle.................................................................................................................................................................................................................................82
(II). Drive axle................................................................................................................................................................................................................................87
VI. Brake system...........................................................................................................................................................................................................................92
(I). Brake system structure requirements......................................................................................................................................................................................92
(II). Main structure of brake system...............................................................................................................................................................................................92
(III). Brake system fault and solution.............................................................................................................................................................................................94
VII. LNG supply system.................................................................................................................................................................................................................96
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(I). LNG introduction......................................................................................................................................................................................................................96
(II). LNG safety overview...............................................................................................................................................................................................................96
(III). Principle of LNG supply system.............................................................................................................................................................................................98
(IV). Fuel filling............................................................................................................................................................................................................................102
(V). Fuel supply...........................................................................................................................................................................................................................104
(VI). Gas output...........................................................................................................................................................................................................................107
(VII). Adjustment of economical valve.........................................................................................................................................................................................107
(VIII). Daily maintenance.............................................................................................................................................................................................................109
VIII. Central control system..........................................................................................................................................................................................................111
(I). Overview of central control system........................................................................................................................................................................................112
(II). Description of central control system function......................................................................................................................................................................114
(III). New-type digital CAN instrument.........................................................................................................................................................................................114
(IV). Central control unit (CBCU).................................................................................................................................................................................................116
(V). Electrical junction box assembly...........................................................................................................................................................................................119
Part III: Vehicle Maintenance....................................................................................................................................................................................................122
I. Maintenance category..............................................................................................................................................................................................................122
(II). Interval mileage of routine inspection and maintenance......................................................................................................................................................123
III. Daily maintenance items........................................................................................................................................................................................................123
IV. Table of maintenance items of all classes..............................................................................................................................................................................125
V. Assembly oil-changing interval mileage..................................................................................................................................................................................129
VI. Lubricating grease lubrication points.....................................................................................................................................................................................130
Part IV: Appendixes...................................................................................................................................................................................................................133
(I). Braking schematic diagram...................................................................................................................................................................................................133
(II). Steel plate spring specifications...........................................................................................................................................................................................135
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(III). Service data of commonly used vehicles............................................................................................................................................................................136
(IV). Table of tire pressure parameters........................................................................................................................................................................................137
(V). Table of wheel parameters...................................................................................................................................................................................................138
(VI). Main structure description...................................................................................................................................................................................................139
5
Part I: Tractor use
I. External devices of the cab
Warning: do not drive before close the door!
Back sliding
door
Left side
Figure 1.1
1
(I) Use the door switch outside
1 Left door (as shown in Figure 1.2)
Open the door: the door is in “fully closed” position but not locking status, directly pull the handle down and outward to open the door; if the door is in locking
status, use the key to turn the key cylinder clockwise about 60°and then pull the handle down and outward to open the door.
Close the door: slam the door to make it in “fully closed” position. If lock the door, use the key to turn the key cylinder anticlockwise about 10° and then pull
the key out. Pulling the handle cannot open the door now.
Open
Lock
Figure 1.2
2
2 Back sliding door (as shown in Figure 1.3)
Open the door: the door is in “fully closed” position but not locking status, directly pull the door locking handle to the left and then push the handle of back
door soon to the left to open the door; if the door is in locking status, use the key to turn the key cylinder anticlockwise about 180°and then pull the door
locking handle again to open the door.
Close the door: slam the door to make it in “fully closed” position. If lock the door, use the key to turn the key cylinder clockwise about 180° and then pull the
key out. Pulling the handle cannot open the door now.
Warning: do not directly pull the door locking handle when open and close the door, or otherwise, it easily causes the premature damage of
door lock.
Door lock
handle
Lock
Handle
Open
Figure 1.3
3
(II) Use the door switch inside
1 Left door (as shown in Figure 1.4)
Open the door: pull the inside lock handle outward to open the door lock, and then push the handle outward to open the door.
Close the door: slam the door to make it in “fully closed” position, and the door is closed. If lock the door completely, use the key to lock it outside.
2 Back sliding door (as shown in Figure 1.5 and 1.6)
Open the door: put the inside lock knob of the back door in “U” position, pull the handle to the left to open the door lock, and then push it to the right to open
the door.
Close the door: put the inside lock knob of the back door in “U” position, slide the door to the left to close to make it in “fully closed” position, and the door is
closed. If lock the door completely, put the inside lock knob in “L” position in “fully closed” position, and pulling the handle cannot open the door now.
Inside lock
knob
Handle
Inside lock
handle
Figure 1.6
Figure 1.4 Figure 1.5
4
(III). Opening and closing of engine hood
1 Opening of engine hood (as shown in Figure 1.7)
(1) Grasp and pull the handle up to open the engine hood.
2 Closing of engine hood (as shown in Figure 1.8)
(1) Grasp and pull the handle down to close the engine hood, and the hood is automatically locked.
Handle
Engine hood
Air spring
5
(IV). Cab front shield
(1) The front shield is inside of the cab and close to the right side of the instrument board (as shown in Figure 1.9). Pull it outward to open the front shield;
Pull it down to close the front shield, and the shield is automatically locked (as shown in Figure 1.10).
(2) The electrical appliances box is on the right side of the front shield, open the shield, and see the box (as shown in Figure 1.11).
Note: only right set tractor has the front shield, while the left set tractor does not have one.
Front shield
Figure 1.9 Figure 1.10 Figure 1.11
Electrical
appliances box
Front shield
switch
Air spring
6
(V). Cab turnover
1． Cab turnover operation Button of lifting oil Oil plug
pump
1.1 Park the tractor on the flat road and take out the unsecured articles in the cab before turnover.
(as shown in Figure 1.12) Figure 1.16
1.2 Nobody can stand nearby in front of the cab at the time of turnover! (as shown in Figure 1.13)
1.3 Pull the switch handle of lifting oil pump to “↑” position, and press the button of lifting oil pump
(as shown in Figure 1.16) to turn over until the cab is turned over completely by dead weight
(straighten it with limit drawstring). (as shown in Figure 1.14)
1.4 Turn the cab back to original position: pull the switch handle of lifting oil pump to “ ↘” position,
and press the button of oil pump to turn the cab back (as shown in Figure 1.15) until the locking pin
inserts into the hydraulic lock piece and continue pressing it until the cab do not move any more,
and keep the switch handle in “↘” position.
Figure 1.12 Figure 1.13 Figure 1.14 Figure 1.15
Warning: the cab shall be turned over completely every time, that is, exceed the top dead center, and then the operation after cab turnover
can be carried out.
Nobody can enter the cab when the cab is in turnover state!
Because the oil cylinder has the automatic drop at the drop end point, when the lock pin is 40 － 100mm from the hoop, the cab automatically
7
drops.
8
2. Refueling and exhaust of turnover system
2.1 Open the oil plug (as shown in Figure 1.16) to fill the stipulated hydraulic oil.
2.2 Turn over the cab with hand pump as continue to fill the oil.
2.3 Make the cab fall and meanwhile let excess oil overflow.
2.4 Turn back the cab to original position with the oil pump, check and refill the oil until fill it up.
2.5 Screw up the oil plug finally.
Warning: refueling and exhaust of turnover system can be carried out after the cab is turned back to original position.
Hydraulic oil uses No. 10 aviation hydraulic coil about 0.4L. Before filling the oil, do check whether the hydraulic oil and the required oil can be
filled.
3. Function check of turnover system
3.1 Turn the cab forward to the top dead center, and check the cab fall condition after exceeding the top dead center; if the system works normally, the cab
shall fall slowly under the damping condition, without impact phenomenon.
3.2 Turn the cab over about 30º, the cab shall keep in this position for 20 min and not go down.
9
II. Internal devices of the cab
(I). Internal devices
Figure 2.1
10
1. Rocker switch area 2. Transmission oil temperature gauge 3. Steering wheel 4. Combination instrument 5. Engine speed per hour 6. Gearbox shifter
7. Air-conditioning air outlet 8. Air-conditioning control panel 9. LNG liquidometer 10. Parking brake handle 11. Electric cigarette lighter 12. Saddle air
lock switch
11
(II). Instrument board
9
1
2 7
3 5 6
4
1. Speedometer 2. Water temperature gauge 3. Fuel gauge 4. Small mileage/ small mileage fuel consumption reset button 5. Information display screen
6. Barometer 1 7. Barometer 2 8. Engine speed meter 9. Signal light
Figure 2.2
12
(III.) Summary sheet of symbols of signal lights
No. 1 2 3 4 5 6 7 8 9 10 11
Symbol
Color Red Red Red Red Red Red Red Red Red Blue Flash green
fety belt loc . Charging i Water tempe Steering oil Warning an Brake air pr Brake air pr Engine oil p High beam Left steerin
Name Cab locking
king ndication rature position d stop essure 2 essure 1 ressure indication g
No. 12 13 14 15 16 17 18 19 20 21 22
Symbol
Color Flash green Flash green Red Yellow Yellow Green Yellow Green Green Green Green
Wheel diffe Axle differe
Right steeri Trailer steer Parking brak Air filter blo Common al Front fog la Rear fog la Power take All-wheel dr
Name rential indic ntial indicati
ng ing e cking arm mp mp off ive
ation on
No. 23 24 25 26 27 28 29 30 31 32 33
Symbol
Color Green Green Yellow Yellow Yellow Yellow Yellow Yellow Red Yellow Green
High gear s Low gear s ASB of main Air suspensi Low fuel oil Auxiliary ga Exhaust br
Name Trailer ABS Lifting shaft ASR Retarder
ection ection vehicle on level s ake
No. 34 35 36 37 38 39 40 41 42 43 44
Symbol
Color Yellow Yellow Color Color Color Color Color Color Color Color Color
Flame preh Standby Standby Standby Standby Standby Standby Standby Standby
Name EDC failure Standby
eating
13
Function specifications of signal lights
No. Name Remarks No. Name Remarks

It goes out after fasten the seatbelt (not Power takeoff indicator Indication of power takeoff operation
1 Seatbelt indicator light 19
available temporarily) light (optional for some types)
Indication of operation of wheel
Indicator light of wheel
2 Charging indicator light It goes out after the engine works 20 differential valve (not available
differential valve
temporarily)
Indication of operation of axle
Water temperature Indicator light of axle
3 Water temperature alarm 21 differential valve (optional for some
indicator light differential valve
types)
Steering oil level Steering oil level alarm (not available All-wheel drive indicator Indication of operation of all-wheel
4 22
indicator light temporarily) light drive (not available temporarily)
Warning parking Indicator light of high
5 5 failure types of engine racing 23 Indication of high gear section
indicator light gear section
Cab locking indicator Confirmation of locking switch (not available Indicator light of low gear
6 24 Indication of low gear section
light temporarily) section
Brake air pressure 2 Indicator light of main Indication of action of ABS (main
7 Alarm of brake air pressure 2 25
indicator light vehicle ASB vehicle) (not available temporarily)
Brake air pressure 1 Indicator light of trailer Indication of action of ABS1 (trailer)
8 Alarm of brake air pressure 1 26
indicator light ABS (not available temporarily)
Engine oil pressure Air suspension indicator Indication of air suspension (not
9 Oil pressure alarm 27
indicator light light available temporarily)
High beam indicator Indicator light of Lifting indication (not available
10 Indication of the high beam lit 28
light supporting axel lifting temporarily)
Left steering indicator ASR anti-sideslip It lights up when ASR system acts (not
11 It lights up with left steering light 29
light indicator light available temporarily)
Right steering indicator Indicator light of low fuel
12 It lights up with right steering light 30 Remind timely refueling
light oil level
Trailer steering It lights up with left or right steering light in Auxiliary gas indicator Indication of low pressure of auxiliary
13 31
indicator light case of a trailer (not available temporarily) light gas loop
14
Parking brake indicator Indication when pulling down hand brake Exhaust brake indicator Indication of use of exhaust brake of
14 32
light valve light the engine
Air filter blocking Indication of use of retarder (not
15 Alarm of air filter blocking 33 Retarder indicator light
indicator light available temporarily)
Common alarm EDC failure indicator
16 It lights up in case of minor failure 34 Indication of EDC failure
indicator light light
Front fog lamp Flame preheating Indication of use of flame preheating of
17 Indication of the front fog lamp lit 35
indicator light indicator light the engine (not available temporarily)
Rear fog lamp indicator Indication of the rear fog lamp lit (not available
18
light temporarily)
Signal switch and function (excluding rocker switch):
15
No
Signal function Remarks
.
1 Intermittent wiper (combination switch Switch on (with 15#) means the function is enabled
31B)
2 Washer pump (combination switch 56) Switch on (with 15#) means the washer pump in operation
3 4 key gears (starting signal) Switch on (with 15#) means the function is enabled
4 D+ signal, making the engine in Effective at high potential (>12V)
operation
5 S9 exhaust brake switch Switch on (equivalent to shell overlapping) is effective
6 S30 spring energy storage switch Switch on (equivalent to shell overlapping) that the “parking brake indicator light” on the instrument board
lights up
7 S31 air pressure signal switch Switch on (equivalent to shell overlapping) that the “auxiliary gas indicator light” on the instrument board
lights up
8 S51 water temperature alarm switch Switch on (equivalent to shell overlapping) that the “water temperature alarm indicator light” on the
instrument board lights up
9 S69 steering oil level switch Switch on (equivalent to shell overlapping) that the “steering oil level indicator light” on the instrument
board lights up
10 S27 cab locking switch Switch on (equivalent to shell overlapping) that the “cab locking indicator light” on the instrument board
lights up
11 S28/1 brake air pressure 1 signal Switch on (equivalent to shell overlapping) that the “brake air pressure 1 indicator light” on the instrument
switch board lights up
12 S28/2 brake air pressure 2 signal Switch on (equivalent to shell overlapping) that the “brake air pressure 2 indicator light” on the instrument
switch board lights up
13 S32 oil pressure alarm switch Switch on (equivalent to shell overlapping) that the “oil pressure alarm indicator light” on the instrument
board lights up
14 S29 air filter blocking switch Switch on (equivalent to shell overlapping) that the “air filter blocking indicator light” on the instrument
board lights up
15 S10 brake lamp switch Switch on (with 15#) means function confirmation
16
16 S15 reverse gear switch Switch on (equivalent to shell overlapping) means in reverse gear
17 S24 power takeoff in-position switch Switch on (equivalent to shell overlapping) that the corresponding indicator light on the instrument board
starts flashing to full brightness
18 S20/S21 wheels differential in-position Switch on (equivalent to shell overlapping) that the corresponding indicator light on the instrument board
switch starts flashing to full brightness
19 S22 axle differential in-position switch Switch on (equivalent to shell overlapping) that the corresponding indicator light on the instrument board
20 S25 all-wheel drive in-position switch Switch on (equivalent to shell overlapping) that the corresponding indicator light on the instrument board
21 S33 *** Front range box switch Switch on (equivalent to shell overlapping) that the “indicator light of high gear section” on the instrument
board lights up
22 S26 creeper gear switch Switch on (equivalent to shell overlapping) that the “indicator light of low gear section” on the instrument
board lights up
23 S48/S49 horn switch Switch on (switch equivalent to shell overlapping) that the horn (klaxon or air horn) sounds
24 S14 neutral position switch Switch on (equivalent to shell overlapping) means the “ neutral position”
25 ABS_1 signal Switch on (equivalent to shell overlapping) that the “ indicator light of main vehicle ASB1” on the instrument
board lights up
26 ABS_2 signal Switch on (equivalent to shell overlapping) that the “ indicator light of trailer ASB2” on the instrument board
lights up
27 Cab opening signal Switch on (equivalent to shell overlapping) is effective
28 ECAS1 Switch on (equivalent to shell overlapping) means the function is enabled

29 ECAS2 Switch on (equivalent to shell overlapping) means the function is enabled
30 S40 pressure switch of hydraulic Switch on (equivalent to shell overlapping) means the function is enabled
pipeline
31 High beam switch (combination switch Switch on (equivalent to shell overlapping) means the function is enabled
S3-56a)
17
32 Low beam switch Switch on (equivalent to shell overlapping) means the function is enabled
(combination switch S3-56b)
33 Left steering switch (combination Switch on (equivalent to shell overlapping) means the function is enabled
switch S3-6)
34 Right steering switch (combination Switch on (equivalent to shell overlapping) means the function is enabled
switch S3-7)
35 support shaft mode switch Switch on (equivalent to shell overlapping) means the special mode function is enabled
18
(III). Graphic symbols of rocker switches
No. 1 2 3 4 5 6 7 8
Front fog lam Emergency alarm Emergency warnin Axial differenti Work light swit Power
Name Light switch Switcher
p switch switch g light switch al switch ch takeoff
Graphical si
gn
Symbol and Dual green L Dual green L Red cover, dual Dual green LE Yellow LED lig Dual green LE Red LED li
Dual red LED light
color ED light ED light red LED light D light ht D light ght
No. 9 10 11 12 13 14 15
Engine brake Saddle lifting Engine diagno Gearbox diagnosti Engine diagno Instrument me
Name Power switch
switch switch stic switch c light stic light nu knob
Graphical si
gn
Symbol and Dual green L Green LED li Dual yellow LE LED Red and Dual yellow LE
Red LED light
color ED light ght D light yellow LED light D light
Function specifications of rocker switches (indicator lights included. Unless otherwise stated, the key start switch in gear 1 is
19
invalid )
No Statu Function Remarks

Name
. s
Turn off headlight and
0
position light
Turn on position light When the key is in gear 2, 3 and 4, the instrument lighting drive is valid; high beam
1 Light switch 1
/turn off headlight inching is invalid
Turn on position light / High beam inching is valid, and the combination switch of high and low beams is valid
2
headlight
0 Turn off front log light
2 Front fog light
1 Turn on front log light Precondition: gear 1 of light switch is opened
0 Close emergency alarm
Emergency alarm
3 Open emergency alarm It is valid when key switch is in gear 1, 2, 3 and 4; see following specifications for
switch 1
function functions in details
Klaxon is selected and Press the horn button on the steering wheel to use
0
used
4 Horn switcher
Air horn is selected and Press the horn button on the steering wheel to use
1
used
Close emergency
0
Emergency warning warning light
5
light switch Open emergency
1
warning light
0 Function closed
Axial differential
6 Function opened ** The axial differential magnetic valve is driven, if the axial differential switch is not in
switch 1
position, the corresponding indicator light flashes; if it is in position, the light is lit fully
0 Turn off work light
7 Work light switch
1 Turn on work light The work light is driven
8 Power takeoff 0 Function closed
20
Power takeoff Press the rocker switch after step on the clutch pedal for about 6s
1
combination
0 Close the engine brake
9 Engine brake switch
1 Open the engine brake
0 Function closed
10 Saddle lifting switch 1 Saddle lifted
2 Saddle fallen The button works only at the time of double acting lifting cylinder
0 Turn off main power
11 Power switch
1 Turn on main power
Engine diagnostic 0 Function closed

12
switch 1 Function opened
0 All lights go out Gearbox works normally
Transmission
1 Yellow light lights up In case of minor failure of gearbox, stop the tractor and repair it timely
13 diagnostic light
2 Red light lights up In case of major failure of gearbox, stop the tractor and repair it immediately
Engine diagnostic 0 Diagnostic light goes out The engine works normally
14
light 1 Diagnostic light lights up In case of engine failure, stop the tractor and repair it timely
Instrument menu Rotate or press it to operate the display contents on information display screen of the
15
knob instrument board
Description: ** when the axis difference switch is pressed, the axis difference signal light on the instrument flashes, if the axis difference lock
signal switch has a feedback signal within 5s, the axis difference signal light is lit; in case of no feedback signal, check the drive output of axis
difference magnetic valve, if the drive output is normal, the axis difference signal light is lit. The lamp may have fogging with big humidity change
and fog disappears if the light is on.
21
(IV). Power switch
1. Main power switch (Figure 2.3) Figure 2.3
Main power switch
Main power switch is outside the battery compartment (getting-on ladder) of the left longitudinal beam of the frame.
Note: when the tractor stops for a long time, turn off main power switch to avoid an accident.
2. Key start switch (Figure 2.4 and 2.5)

The key start switch is arranged on the right of the instrument desk.
Turning position Usage Remarks

1 (LOCK) Outage of whole tractor The key can be pulled out now
2(ACC) Connect the electric equipment when the tractor stops
3 (ON) Driving position
4 (START) Start the engine Automatic reset to gear 3
Figure 2.4
Key start switch Figure 2.5
22
(V). Combination switch
1. Operation of turn light:
Left steering Right steering
1. Up is the
indication of right
steering
2. Down is
indication of left
steering

Note: when the turn light works, the steering indicator light on the instrument board flashes meanwhile. When the turn light bulb is damaged
(total power of the bulb is less than 21W), the flashing frequency is increased (work in frequency multiplication), the steering indicator light also
gives the indication of frequency multiplication, and meanwhile, the information screen displays the failure.
2. Emergency alarm Emergency alarm
switch
Turn on the main power switch, press the emergency alarm switch (as shown in Figure 2.6), and all turn lights and steering
indicator lights flash.
Figure 2.6
23
3. Headlight operation:
Light switch Overtaking
Headlight
Low beam
High beam
The combination switch handle is in neutral position, the key switch is in gear 3, the light switch (as shown in Figure 2.7) is in gear 2, the low and high beams of
the headlight (as shown in Figure 2.8) are lit. Now, the combination switch handle is pulled up to 4 degrees, the high and low beams are completely lit and can
be as instantaneous light of night overtaking or passing; the handle is pulled up continuously to 10 degrees, the changing light is available: the high beam
becomes the low beam or the low beam becomes the high beam. Let go the handle and
At the time of day overtaking or passing, the handle is pulled up to 4 degrees, the high beam is lit and let it go and it is automatically reset.
4. Wiper operation
0—Closed position J-- Wiper intermittent gear
I-- Wiper slow gear II-- Wiper fast gear
Press -- windshield washing system.

Figure 2.9
5. Horn button
Horn switcher
Horn button
喇叭按钮
The tractor is equipped with the klaxon and electrically controlled air horn and they are switched by horn switcher (as shown in Figure 2.10).
The horn button (as shown in Figure 2.11/2.12) is on the steering wheel. In case of use of electrically controlled air horn, press the horn switch (rocker switch)
and horn button on the steering wheel successively.
(VI). Operation of fog lamp and interior lighting
Front fog
lamp
Front fog lamp switch
Front fog lamp
1. Operation of front fog lamp
The light switch is in gear 1;
Press the front fog lamp switch (as shown in Figure 2.14) and the front fog lamp (as shown in Figure 2.13) is turned on. Meanwhile, the front fog lamp indicator
light on the instrument board is lit (as shown in Figure 2.15).
Note: the front fog lamp can be operated only when the light switch is turned on.
2 Interior lighting
Interior lighting
switch
Figure 2.16
(1) Turn on the interior lighting switch (as shown in Figure 2.16)
Press the left or right side of the switch on the interior light, and the interior lighting system will be lit always.
(3) . Turn off the interior lighting switch
Put the switch on the interior light in neutral position.

(VII). Seat
1. Air suspension seat
The optimization, matching and combination of air spring and hydraulic damping are made
for the seat. 2
The suspension seat consists of the air spring, leveling valve, hydraulic damper, metal
member, breakdown prevention elastic parts, etc. 5
1
The seat height can be adjusted according to the people weight and road situation, which
greatly improves the comfort of the seat.
Technical parameters
Seat width: 500mm 4 3
Seat height: 865mm (maximum)
Height adjustment: 7 gears within the range of 0 - 65mm
Forward and backward adjustment: 5 gears within the range of 0 - ±75mm
Backrest angle adjustment: 0° - 41.4°(backward from the plumb line) and 0° - 60° (forward
from the plumb line)
Use method
1) Adjustment of backrest elevation
Figure 2.17
Pull the handle 1 up to turn the backrest to required degree, loosen the handle, and lock the backseat position.
2) Adjustment of rear-end height
Softly pull the handle 2 up, meanwhile apply appropriate force upward (downward) to the rear end of the seat to make the rear end go down (up) to required
position, and loosen the handle.
3) Adjustment of rear-end height
Softly pull the handle 3 up, meanwhile apply appropriate force downward (upward) to the rear end of the seat to make the rear end go down (up) to required
position, and loosen the handle.
4) Adjustment of anteroposterior position
Pull the handle 4 up to move the seat forward and backward to required position, and loosen the handle.
5) Height locking handle
The seat will be in the lowest position when the airbag or other damping component is damaged or invalid; for the convenience of driving, the seat can be lifted
to appropriate height, the handle 5 is turned from horizontal position to vertical position (bottom seat plane as datum plane) and locked to keep the seat at fixed
design height.
Note: in case of air spring seat, pay attention to the height locking handle on front lower part of the seat, the horizontal position is inflating position
and vertical position is lock position.
(VIII). Transmission shifting
1. Push-button gear selector (automatic gearbox is as shown in Figure 2.18)
Current gear at running
(1)
Highest gear set
Figure 2.18
Forward gear s switch (press Button D)
When speed it up, the gearbox will automatically rise from available lowest gear to top gear in order;
When slow it down, the gearbox will automatically change gears down;
(2) Reverse gear switch (press Button R)
When selecting the reverse gear, the tractor must stop completely, the engine returns to the idle state, switch to the reverse gear through neutral gear, and now
the shifter displays “R”;
(3) Neutral gear switch (press Button N) R- Reverse

gear
In the neutral gear state, the selector displays “N”. N- Neutral gear
D- Forward
gear
(4) Gear shift mode switch
According to different road conditions and loads, the economic mode and power mode can be selected;
In power mode, the display screen will display “MODE”.
Economic mode: default operation mode, the fuel consumption is low but the power take-off is relatively
poor;
Power mode: at the time of operation in power mode, more power take-off is available,
but shifting point is relatively delayed and the fuel consumption is increased.
Note: the power mode is recommended only when the tractor seriously lacks of power,
or goes up the slope, or is supercharged.
(5) After selecting gear D, manual upshift or downshift can be realized by pressing the upshift button ↑ or
downshift ↓.
Figure 2.19
(6) Read the oil level of the gearbox by the shifter
Entry mode: press both upshift button ↑ or downshift ↓;
Exit mode: exit the oil level check mode by pressing the neutral gear button N;
Conditions for oil level check:
① The tractor is parked on level road;
② The engine is in idle running state;
③ The gearbox is in neutral gear state; O L O K Normal oil level
④ The rotational speed of output shaft is zero;
⑤ Tense the parking brake; Oil level is 2 quarts lower than

O L L O 0 2
standard oil level
⑥ The oil level of the gearbox is stable;
⑦ The oil temperature of the gearbox is in Oil level is 3 quarts higher than
normal measurement range of 60－104℃. standard oil level
O L H I 0 3
Note: see the Allison Operation Manual attached for detailed operation process.
2. Shifting handle (mechanical gearbox as shown in Figure 2.20 and 2.21)
The shifting handle of the transmission feels good, simple in operation, and greatly reduces the driver’s labor intensity. It is installed on the cab floor, seldom
has gear off problem, and does not affect the cab turnover.
1. Control mechanism
The control mechanism of ZF transmission (S6-120) is mechanical soft-axes control and simple in gear shift. There are six forward gears and one reverse gear.
Two pictures above show the position chart of shifting handle of the shifting mechanism and transmission position (position of guide block of top cover).
(IX). Parking brake
(1) Position in Figure 2.22 is the parking brake position.
(2) Loosen the hand brake, push the handle forward and upward successively in the direction of driver
(you can hear the louder deflated sound)
(3) Parking brake, pull the handle down (you can hear inflation sound)
(X). Unlocking control button of traction seat

Using the traction seat can make the tractor go up and down, and this is automatic reset gas-controlled Figure 2.22
switch (as shown in Figure 2.23)
Press the traction seat to unlock; the internal mechanism in the traction seat is automatically locked
under the forward impact of traction pin.
Note: please don’t press on driving.
Figure 2.23
(XI). Saddle lifting
1. Type of lifting cylinder
1
There are three types of lifting cylinder for saddle-lifting tractor:
Single-stage double-acting cylinder (lifting height of 405);
Double-stage double-acting cylinder (lifting height of 705);
Double-stage single-acting cylinder (lifting height of 705);
2
2. Saddle lifting operation
Saddle lifting operation: switch on the power, the key start switch is in gear 2
(ACC) or 3 (ON), long press “1” face of the rocker switch (Figure 2.23), and
the saddle is lifted;
Saddle lowering operation: switch on the power, the key start switch is in
gear 2 (ACC) or 3 (ON), long press “2” face of the rocker switch (Figure
2.23), and the saddle is lowered;
(XII). Seatbelt
1. Fasten the seatbelt
Pull the lock catch for the seatbelt (as shown in Figure 2.26) bypassing the shoulder, put the latch into the
buckle until they are meshed.
2. Unfasten the seatbelt
Press the red button on the lock catch for the seatbelt in the direction of arrow, pull the latch out, and make the
seatbelt automatically return to original position.
Note: please fasten the seatbelt before driving every time! Check the situation and function of seatbelt
every day.
3. Seatbelt alarm description
2.3.1. Turn the key switch to the driving position, and if the seatbelt is well fastened, the seatbelt lock signal
light on the instrument board is out; if not, the signal light is always lit and the buzzer does not ring.
2.3.2. After the engine starts, and if the seatbelt is not well fastened, the seatbelt lock signal light is lit, and the
buzzer rings at low frequency and stops ringing after 6s; after the seatbelt is well fastened, the signal light
goes out and meanwhile the buzzer stops ringing. Figure 2.26
2.3.3. During the engine operating process, if pull the seatbelt out, the signal light will be lit and the buzzer will
ring at low frequency for 6s.
(XIII). Air conditioning
1 Panel description (as shown in Figure 2.27)
1 Temperature adjustment knob 2 Wind speed adjustment knob 3 Water valve knob
2 Use instructions
1. If use the warm air, turn the water valve switch knob pointing to ON; if use the cold air, do not
turn and keep it in OFF.
2. When the wind speed adjustment knob points to gear 0, the air conditioning is in off state; turn
it pointing to gear L, M and H (L - Low speed, M - Medium speed, H - High speed), and the air
conditioning is on.
3. Turn the temperature adjustment knob to adjust the temperature, the closer to HOT the pointer
is, the higher the temperature; the closer to COOL the pointer is, the lower the temperature is.
3. Precautions for use
3.1. Please maintain the air conditioning system regular.
3.2. Gently wipe the panel surface with soft dry cloth if the panel is dirty; do not do that Figure 2.27
with wet cloth or hard dry stuff, or otherwise it easily damages the panel, key or display
screen.
3.3. Do not touch the display screen with finger, oily content, or hard dry stuff, or otherwise, it causes the indistinct display, stroke display or
damage.
3.4. The refrigerant feeding mouth is on the compressor and pipeline. In case of poor refrigeration for lack of refrigerant, please contact the
professionals to feed the refrigerants.
3.5. If the system failure is confirmed, please go to designated special maintenance station, and the professional serviceman services it.
(XIV). Other internal devices
1 Cup base (as shown in Figure 2.28 and 2.29)
The cup base is in the left side of the cab and close to the instrument desk: pull outward to open the cup base to place the cup, and return to original position if
it is not used.

III. Preparations before driving
Warning: keep the tractor in good condition, and do not drive with failure!
Main power
switch
(I). Routine check before driving every time

1. Switch on the tractor power
Rotate the red handle (as shown in Figure 3.1) 90 degrees anticlockwise to open the main power
switch.
2. Check the working condition of entire circuitry (self-test of system)
After the key switch is turned on (in ON), that is, KL15 is connected, the bus system carries out the
self-test.
Actions of various devices are as follows hereafter:

Figure 3.1
All instruments: the pointer of the instrument rotates to the full scale from mechanical limit within 2 s
after power on. Later, the odometer and engine tachometer return to zero position, and the
barometer, fuel gauge and water temperature gauge indicate the measured value of current system.
All indicator lights: all are lit for 1s and then return to actual state.
LCD: 2s interval, display LOGO of CNHTC and normal travel page successively (display the voltage and engine oil pressure).
After completion of self-test, if any current axle and wheel differential lock switches and all-wheel drive switch is closed, the differential lock indicator page will
be displayed;
If the differential lock is not closed and the system has a failure, the page displays the error information;
If both situations above do not occur, while the indicator of other working indicator pages works, the system will jump to the indicator page;
If three situations above do not occur, the system stays the normal travel page.
Note: it is strictly prohibited to cut the connection between the storage battery and central computer before the ignition key and other input powers
with wakeup function are turned off! Or otherwise, it may damage the electronic control unit, wiring harness and electrical and electronic
components of the systems of the tractor in the aspect of hardware, even cause the severe consequence of loss of system data!
3. Check the coolant, fuel oil and engine oil
(1) Check the coolant
The expansion tank is in the engine maintenance chamber and the coolant can be filled after
open this chamber.
Check the level of coolant in the expansion tank (as shown in Figure 3.2), and if the level is
too low, the coolant with stipulated specification shall be filled until reaching the stipulated
scale mark.
The pressure relief valve can keep the cooling system have a certain pressure to
atmosphere to increase the boiling point of the coolant.
The pressure relief valve plays a more important role in the plateau area and cannot be
replaced and damaged at will.
When the engine is in the high temperature state, the coolant shall be filled by two steps:
Step 1: the high pressure is relieved at the feeding mouth;

Figure 3.2
Step 2: open the cover and fill it up with coolant when the engine is at idle speed.
Warning: do not feed the coolant when the engine is in the high temperature state!
(2) Check the fuel oil quantity Dip
stick oil level
sensor
Turn on the key switch, check the fuel oil quantity on the fuel gauge or by taking out the dip stick in
the fuel tank (as shown in Figure 3.3).
If finding the indication of fuel gauge is incorrect, please check the fuel gauge and oil level sensor.
Figure 3.3
(3) Check the engine oil quantity
The tractor is parked on the level road, after the engine cooling, pull out the dipstick (as shown in
Figure 3.4), and the engine oil level shall between the upper and lower scale marks (the oil quantity between upper and lower scale marks is about 3L). If the
level is lower than the lower scale mark, the engine oil with stipulated specification shall be filled until reaching the stipulated level and cover the oil filler cap
tightly.
Dip stick
Engine
oil filler
port
Figure 3.4
(4) Fill the spray liquid
The spray liquid filler port is on the left pedal of the cab (as shown in Figure 3.5). Uncover the outer cover, pull out, rotate and adjust the filler port as shown in
the figure, and fill the spray liquid.
Spray liquid
Warning: please fill the spray liquid with designated brand, or otherwise, filler port
the wash line will be blocked.
4. Check and drain the water in brake system air cylinder

Figure 3.5
After the tractor is parked, pull the water drain valve (as shown in Figure 3.6) down or up to drain the water in collected in air cylinder (as shown in Figure 3.7).
If finding the oil-water mixture is discharged, it means that the air drier fails, its drying cylinder shall be replaced immediately.
Water drain
valve Water
drain
Figure 3.6
Figure 3.7
5. Check the tire pressure
The tire pressure must be normal during the tire use process.
The wheel and tire size required of the tractor are used.
The tire is aging gradually because of sunniness and environmental factors. The tire (spare tire) shall be replaced once every six years at least after use for six
years.
6. Check the leak of lubricating oil, coolant and gas circuit
7. Check the engine intake system
(1) Check the pre-filter
Check whether the pre-filter inlet is blocked with foreign matters to prevent the too high negative pressure of the air intake system; check whether the pre-filter
impeller rotates freely, or otherwise, the pre-filter shall be maintained or replaced to prolong the maintenance period of the air intake system.
(2) Check the air filter
Check whether the pipe between the pre-filter outlet and supercharger inlet is damaged, if so, it shall be blocked timely and replaced with new pipe, or
otherwise, it will causes serious early wear of the engine.
(3) Check the indicator light of air filter blocking alarm
Check whether the indicator light of air filter blocking alarm (as shown in Figure 3.8) gives an alarm and it is lit if the air filter is Filter blocking
blocked. In case of an alarm, do check timely whether the metal and paper filter elements are blocked, and they shall be
maintained or replaced timely.
Figure 3.8
8. Check whether there is people or obstacles around the tractor before starting and driving
(II). Engine start
Main power switch (as shown in Figure 3.9) Main power
switch
Main power switch is outside the battery compartment (getting-on ladder) of the left longitudinal beam of the
frame.
Key switch (as shown in Figure 3.10)
Figure 3.9
Turning position Usage Remarks
Outage of whole tractor The key can be pulled out
1 (LOCK)
Key switch
now
Connect the electric
2(ACC) equipment when the tractor
stops
3 (ON) Driving position
4 (START) Engine start Automatic reset to gear 3
1. Turn on main power switch
Turn the key switch to position 4 (STAT) to start the engine.

Figure 3.10
Note: during the driving process, do not turn off the key switch, that is, the key switch is in position 3 (ON) in the
driving.
2. Starting process
Connect up the hand braking. The gear shift lever is put in the neutral position. Turn the key switch to start the engine.
The charging indicator light goes out after the engine starts.
Note: 1. If it fails the first time the engine starts, the key switch shall be put in gear 2 again to restart.
2. Every starting time is not more than 15s and the interval between two starts is not less than 30s.
3. Engine oil pressure after starting
After the engine starts, observe the pressure value of the oil pressure gauge and meanwhile the oil pressure indicator light shall go out.
Warning: never make the cold engine runs at high speed! If the oil pressure gauge does not work after the engine starts, the engine shall stall
immediately and maintain it.
4. Use of the supercharger
The superchargers of different engines are located at different positions. MC07/MT07 engine supercharger is in middle of the right side of the engine,
，WD615/WT615 and D10/T10 engine superchargers are installed at upper back of the engine. The supercharger consists of the turbine component and pump
pulley component. The exhaust gas from the engine blows the turbine to rotate and drive the coaxial pump pulley to rotate at high speed, to deliver the
compressed air into the engine intake duct to boost the intake pressure so as to increase the engine power. The speed of rotor in the supercharger is high, and
the lubrication of rotor bearing is forced lubrication and the pressure-feed lubrication is provided by the main oil duct of the engine. The engine shuts down and
the oil supply stops.
Attention should be paid at the time of operation:
①. The engine shall run at idle speed for 3-5 min at the time of start; do not slam on the accelerator; apply the load after the engine oil pressure and
temperature are normal (especially start in cold day), or otherwise it easily causes the early wear of the bearing and sealing ring for lack of oil.
② At the time of stalling, the engine shall run at idle speed for 3-5 min and can stall after the supercharger speed is reduced. Particularly note that
do not slam on the accelerator before stalling, the supercharge will be realize high speed for the engine speed suddenly rises for slam on the
accelerator, the engine stalls suddenly now, the engine oil pump stops oil supply, the supercharger rotor still runs at high speed because of inertia,
the rotor spindle, bearing and sealing ring will be burnt up for lack of oil.
③ The pre-lubrication must be conducted for the supercharger before the engine restarts after a long-term shutdown. The pre-lubrication is realized
by disassembling the inlet tube of the supercharger and pouring appropriate clear lubricating oil from oil inlet, or otherwise, the initial start will
have early wear for lack of oil.
(III). Stalling of engine

Turn the key switch to LOCK position and the engine stalls. Turn off the main power switch after stalling.
Note: The engine temperature is high after overloading work, so it stalls after running 3-5 min. When the pressure does not reach the required
pressure value, the engine cannot stall normally (this is normal phenomenon), the engine can stall normally after the pressure reaches the required
pressure value.
IV. Starting and gear shit
(I). Starting
After the engine starts, if the air pressure is low and warning light is lit, do not start. After the charge pressure reaches 0.55MPa and the warning light goes out,
loosen the hand brake handle and ready to start. Before the air pressure in the air cylinder (read from the double-pointer barometer) reaches 0.7Mpa, the
tractor does not completely reach the state suitable for running; only after that, the brake can reach the required brake performance.
(II). Running and gear shift

1. Basic operation
(1) At the time of starting, gently step on the accelerator.
(2) The tractor must stop completely from forward gear to reverse gear or in reverse.
(3) The sliding in neutral gear is strictly prohibited, or otherwise, it seriously damages the gearbox.
(4) Pay attention to supervision of the temperature of the engine and gearbox at the time of running.
(5) When the tractor is dragged because of failure, especially it is dragged for a long distance for engine stalling, the transmission shaft shall be disconnected
or make the driving wheel off the ground. The gear shift lever is in neutral gear when the tractor with mechanical gearbox is dragged.
(6) In case of worse road conditions, the tractor runs by adjusting the gearbox to the gear 4 or less.
2. Precautions
(1) Precautions of the tractor with automatic gearbox
1). Check whether the gear selector displays the neutral gear when the tractor starts, that is, the gear selector displays N;
2). The idle speed of the engine shall be about 600RPM, and too high or low idle speed may cause that the transmission cannot put into gear;
3.) Under any condition, when the tractor with automatic gearbox keeps in the neutral gear, do hold the brake to prevent the accidental movement of the tractor;
4). When change the direction and gear, the tractor must stop completely, switch the gear through N gear and the gear selector shall display corresponding
gear;
5). When carrying out the gear shift operation, if the code of selected gear is flashing, it means that the current operation is suppressed and the gearbox is still
in previous gear before this operation;
6).If the tractor has the gear locked during the running process, do not stall the tractor right immediately and keep the current gear to drive it to appropriate
parking position or repair plant;
If stall the tractor now, the tractor may be unable to select the gear when it restarts;
Oil saving tips
a. When the tractor starts, gently step on the accelerator and do not slam on it, which can save the fuel oil.
b. At the time of pit stop or stopping at a red light for a long time, shift the gearbox gear to neutral gear, which can help saving the fuel oil.
c. Loosen the accelerator to let the tractor slide before stop or stopping at a red light, avoiding the brake stop, which can save the fuel oil.
d. Do step on the accelerator and do not slam on it during the running process, which can shift the gear faster and save the fuel oil.
e. Guarantee correct oil level of the gearbox, which can improve the gear shift performance and save the fuel oil.
(2) Precautions of the tractor with mechanical gearbox
1). At the time of gear shift, the clutch is released completely, avoiding the gear shift failure and early wear of engaging teeth or synchronizer. Check the correct
clutch release and required padel clearance often.
2). The full-load start must use the gear 1 or creeper gear.
3).The creeper gear is only used for ramp and full-load start or running on bad road. Put into reverse gear and creeper gear only when the tractor is in the stop
state.
4). The gear shift lever must be pulled stably during the gear shift process until the gear is fully engaged.
Saving tips
a. The tractor tries to run at high gear during the running to ensure the engine operating condition in economic speed range.
b. When the tractor accelerates, the “gear skipping” (skip a gear) operation is allowed to make full use of engine power.
c. The tractor shall put into high gear at the time of downhill driving to make full use of engine brake.
d. Pay close attention to road condition, use the neutral gear, and make the tractor run by using the inertial.
e. Do not frequently use the emergency foot braking or suddenly speed up when unnecessary.
(III). Power take-off (PR70 power take-off can be added for 4×2 tractor with ZF mechanical gearbox)
1. Power take-off engagement
Step the clutch pedal, press the power take-off switch to engage the power take-off, and the driver’s display screen will display corresponding information; shift
the gear and loosen the clutch pedal.
2. Power take-off disengagement
Step the clutch pedal, press the power take-off switch and after 3s, and loosen the clutch pedal to disengage the power take-off. Meanwhile, the operation
information of power take-off on the driver’s display screen disappears.
Power take-off
Clutch pedal
Figure 4.2
Figure 4.1
(IV). Clutch control
1. Operating parameters and structure characteristics of clutch control system
(1) Operating parameters:
Operating medium: air and brake fluid;
Operating pressure: brake fluid of 4MPa and air pressure of 0.8Mpa;
Operating temperature: －40℃ - ＋80℃;
Brake fluid: SAE 116/DOT3;
Pedal travel: 200mm; free travel: 40mm;
Pedal effort: 190N with power-assisting and 590N without power-assisting.
(2) Structure characteristics:
The clutch control system uses the hydraulic control and pneumatic power-assisting mechanism, as shown in Figure 6.1 and it is simple in operation.
When step on the clutch pedal, the piston of hydraulic master cylinder moves backward, the brake liquid in liquid chamber enters the liquid chamber of power
cylinder along the oil pipe, and the brake liquid acts on the working piston as the working pressure and on the air pressure control valve as control pressure to
separate them, make the compressed air enter the air chamber of the power cylinder, jointly push the working piston to act on the track bar to drive the clutch
release lever, and drive the release bearing by release fork to separate the clutch.
2. Assembly and adjustment of clutch control system
(1) Check and adjust the clearance between the master cylinder push rod and piston.
At the time of assembly, gently screw the pull rod with hands to adjust the length until reaching the piston, and then screw it back for a thread to guarantee the
clearance between the push rod and piston of 0.7mm - 1mm, and the tighten the nut. The clearance shall not exceed 1mm, or otherwise, it will reduce the
effective stroke of master cylinder, affecting the clutch release result.
(2) Check and adjust the free stroke of push rod of power cylinder
The clutch release bearing shall have a free stroke of 2mm - 3mm to prevent the bearing from long-term press work and early damage, so the push rod of the
power cylinder shall have a free stroke of 6mm - 8mm. At the time of assembly and adjustment, the return spring is not installed, the piston and push rod are
pushed by the preloaded spring in the power cylinder to reach the clutch release lever, now adjust the limit bolt to keep the clearance between the bolt top and
holder of 1mm, tighten the jam nut, and then install the return spring.
(3) Exhaust the air in the hydraulic system.
There is air in the hydraulic system of the clutch, the effective stroke of piston push rod of power cylinder will be reduced, so the clutch release is not thorough
and the gear engagement is difficult. At the time of assembly or disassembly of oil pipe, loosen the vent valve of power cylinder first, feed the brake liquid with
required brand in the oil storage tank, feed it as step on the clutch pedal until the liquid overflows from vent valve, and then tighten the vent valve. To fast and
thoroughly exhaust the air in the system, the sectioning exhaust method is used. Exhaust the air in the front end of oil pipe, fast floor the clutch pedal 2 or 3
times and keep it at the time of exhaust, unscrew the union nut of master cylinder, the air in the front end is exhausted here, tighten the joint nut and loosen the
pedal, and just repeat the above actions 4 – 6 times. The aforesaid method can be used to exhaust the air in the rear end of oil pipe at the vent value of power
cylinder.
Special remarks:
1. Note that loosen the pedal after the vent valve or union nut is tightened during the exhaust process to avoid suction air. The pedal shall be
lifted to top to help the brake liquid in the oil storage tank filling into the liquid chamber of the master cylinder.
The inspection standard of correct judgment of exhaust of air in the hydraulic system of the clutch is that step on the clutch pedal and the effective
stroke of push rod of power cylinder reaches 20mm - 25mm, and the exhaust continues when the stroke is less than 20mm.
2. The clearance shall be adjusted for the first time of maintenance of new tractor. In the use, the tractor should be checked and adjusted at every
second-class maintenance, that is, the tractor runs 12,000km, and the tractor should be checked and adjusted at every first-class maintenance, that
is, the tractor runs 4,000km. Pull the clutch release lever with hands and there shall be clearance at the end of limit bolt.
3. The working medium of hydraulic system must use “Laike” DOT3 brake liquid produced by Fujian Nan'an Petrochina Chemical Plant. At the
time of disassembly of oil pipe, the union nut and joint are sealed with Loctit572 thread sealant.
4. When replace the brake liquid, the residual liquid in hydraulic system must be cleared away, and use the brake with designated brand and of the
same batch uniformly.
(V). Stopping
(1) The engine temperature is high after overloading work, so it stalls after running 3-5 min.
(2) Directly turn off the key switch at the time of stalling.
(3) The parking brake handle shall be put to 2 “brake” position when the tractor stops.
(4) The operation can be conducted only under normal air pressure of the tractor.
V. Vehicle brake
The brake system of this vehicle includes energy supplying device, service brake (foot brake), parking and emergency brake device (hand brake), auxiliary
brake (engine exhaust brake) and trailer brake.
(I). Energy supplying device

The energy supplying device includes air compressor, integral air dryer with pressure regulating valve, and corresponding air reservoir. The air compressor is a
mechanical device converting mechanical energy into gas pressure energy, and when the engine runs, the air compressor will run together. When the piston
descends, the outside air firstly enters the intake air filter, then is inhaled into the air compressor cylinder through air inlet and inlet valve. When the piston
ascends, the air in the cylinder is compressed; the pressure rises, and gets over the spring pre-tightening force of outlet valve, thus making the gas valve open;
then the compressed air is charged into the gas tank through outlet. The double-cylinder air compressor is provided with the unloading gear and pressure
regulating valve. When the pressure in the air reservoir exceeds the pressure required by the pressure regulating valve, the air is inhaled and exhausted
alternately between the two cylinders to make the air compressor in the state of unloading operation.
When the ponding occurs in any air reservoir, the drying tank needs to be replaced.
List of total gas storage capacity of each model
Front driving axle Rear driving axle Parking brake Auxiliary air consumption Total gas storage capacity
Welded frame model 30L 30L 20L - 80L
Riveted frame model 30L 30L 20L 20L 100L
(II). Service brake

Pedal control, dual circuit compressed air brake, the operating pressure and the switching-off pressure of pressure regulating valve are 0.85MPa (8.5 bar). The
primary circuit functions on the rear axle (or dual rear axle) wheel, and the secondary circuit functions on the front axle wheel. Once the air reservoir pressure
of either circuit drops below 0.55MPa, the low brake pressure alarm indicator light of corresponding circuit will be on. At this moment, stop the vehicle
immediately and find out the cause for pressure leak.
In a short time, the continuous multiple fully braking may also cause the pressure drops below 0.55MPa.
Leakage inspection: After the engine stops, and the hand brake is connected, the pressure drop is at most 0.05MPa within 2 hours or at most 0.0lMPa within
30 minutes.
(III). Emergency and parking brake
The hand brake can serve as emergency brake and parking brake concurrently, which functions through the spring storage brake cylinder on the rear axle (or
dual rear axle). The parking brake is realized by manipulating the hand brake valve handle. When the brake system fails, driven by the energy storage spring,
the emergency brake can be realized automatically.
Only when the brake system pressure reaches 0.55MPa and after the hand brake signal light is off can the spring brake be fully released.
When the vehicle is in the traveling process, if the main brake suddenly fails, the parking brake handle may be lifted immediately. The brake strength varies
with the handle lifting angle, which can realize “cadence braking”.
Before the engine start, the hand brake valve must be put in the braking position. Otherwise, after the brake system pressure rises, the original
parking brake function will disappear.
The hand brake handle is set on the instrument panel at the driver’s right side.
(IV). Auxiliary brake

Press the exhaust brake switch (as shown in Figure 5.1), then the engine exhaust brake will run. Engine brake switch
At this moment, the traveling vehicle may use engine energy as the auxiliary brake.
When descending the long slope, be sure to use the exhaust brake. Using exhaust brake on the
icy, snowy, muddy pavement may reduce sideslipping. The exhaust brake may be used when
passing each other, passing the poor section, etc. to decelerate in advance.
Using exhaust brake can reduce the main brake use frequency, reduce the wear and heating of
tire and wheel brake, extend its service life, reduce the fuel consumption, and improve the driving
safety.

Note: 1. When the transmission is in the neutral position, the auxiliary brake does not
work. When the gear is low, the exhaust brake efficiency is high.
(V). Trailer brake
The red, yellow spiral air tube , red air source tube 1, yellow signal tube 2, seven-hole trailer socket 3 are
respectively in corresponding connection with the connectors in the front end of trailer. When the spiral tube is
not connected to the trailer, it shall be hung on the right rear support of cab. The connected trailer itself shall 3
have brake function; the brake chamber model shall be 30 and above, and the trailer axle shall be 3-axis and
above.
(VI). Precautions for use of brake system

1. Emergency release of spring brake cylinder
When the pipe connecting the spring brake causes self-braking due to leakage, the brake may be released
when the bolt on the cylinder is screwed out to release position.
Note: 1. Before releasing the spring brake cylinder, engage 1 gear and check whether the service brake
(foot brake) is normal. Figure 5.3
2. When releasing the spring brake cylinder on the inclined pavement, choke the wheel to prevent the
vehicle sliding.
2. Use of gas-charging connector
The gas-charging connector is set on the tail beam air reservoir (Figure 5.3). Gas-charging
connector
Screw up the charging hose on the gas-charging connector, then it can charge air for tires, and can also
charge air for the vehicle through the external air source.
3. Maintenance of brake pipe:
The welding, cutting or drilling near the plastic pipe for braking shall conform to the following provisions:
 Firstly let off the gas in the pipe;
 Cover the pipe for fear of damage from spark, flame and burning cuttings;
Figure 5.3
 The maximum temperature of allowable heating of pressure less pipe is 130C, and the duration is 1 hour.
Warning: You must firstly disconnect the battery power and try to unplug the electrical connectors connected with electronic components (master
control, drive, instrument and ECU, etc.)!
VI. Winter operation

(I). Cooling system
The long lasting anti-freezing, anti-corrosion cooling liquid for cooling system can keep no freezing above -35 C. If the vehicle runs under the environment
below -35C, the concentration of cooling liquid may be increased appropriately.
Note: Using two different varieties of anti-freezing liquid is not allowed. Figure 6.1
To replace the anti-freezing liquid of different varieties, the cooling system shall be cleaned thoroughly.
(II). Braking device
The water gathered in the air reservoir shall be let out promptly to prevent freezing, and the attention shall be paid to checking the
operating condition of air dryer (as shown in Figure 6.1).
Under normal circumstances, the service life of desiccant in the dryer is two years. If there is water pollution discharge in the air reservoir,
this means that the desiccant has lost efficacy, and the drying cylinder shall be replaced immediately.
(III). Battery
The liquid level and proportion of battery electrolyte shall be checked for every three months. The liquid level shall be 10- 15mm higher
than polar plate, and the proportion shall be above 1.24g/cm 3. If the vehicle is not used for long time, and the temperature is low, the battery
may as well be taken down and put in the warm interior. When the vehicle travels for every 500km, the inspection shall be made to confirm
whether the connecting clamp of battery electrode pile and wire is loose and whether the battery condition is normal.
VII. Wheel replacement and tire pressure
1. The attention shall be paid to consistence of tire tread and forwarding direction during the wheel replacement (as shown in Figure 7.1).
2. The attention shall be paid to no bumping of thread on the wheel bolt during the wheel replacement.
3. The paint, lubricating grease and other dirt must not be pasted on the fitting surface of brake drum and rim.
4. The clamping surface of wheel nut shall be clean, without dirt or oil stain.
5. Before the wheel mounting, the wheel alignment hole and the outer circle matched on the
wheel rim reducer casing shall be wiped clean, and shall be applied with a little grease.
6. A little grease, oil or other anti- occlusion agent shall be applied on the thread of wheel
bolt and wheel nut.
7. All the thread of wheel nut shall be right-hand thread. After mounting the wheel, tighten
the nut according to the diagonal cross sequence under the condition of wheel suspension,
then put down the wheel, and tighten the nut at the torque of 550-600Nm. (The wheel nut
sleeve is WG9100850002)
8. After every tire remounting, the wheel nut shall be tightened again after traveling 50km.
Later, the wheel nut re-tightened shall be checked after every traveling of 1,000km.
Figure 7.1
VIII. Running-in of new vehicle
1. The running-in period requires that total engine operating hours reach 100 hours.
2. Before running-in, make the routine inspection to ensure the vehicle in the normal operating condition.
3. The vehicle shall travel on the flat and good pavement in the running-in period.
4. The new vehicle shall not tow heavy-duty trailers within the running-in period.
5. Check and control the engine oil pressure and normal temperature of cooling liquid.
6. Pay attention to the temperature of transmission, rim and brake drum. In case of serious heating, find out the cause and adjust or repair immediately.
7. After the completion of running-in of new vehicle, tighten the wheel nut again after traveling 25 hours.
88. After the traction pedestal hydraulic lifting system is equipped with gooseneck, it shall rise and fall at idle speed for 5 to 10 times.
Part II: Use and Maintenance of Principal Assembly
I. Steering system
(I). Mechanical steering
The steering operation system is composed of steering wheel, steering shaft, universal joint
and steering column assembly. The diameter of steering wheel is Φ450mm.
The steering gear is ZF8098 power steering gear. ZF8098 is an integral hydraulic power
steering gear, and the control valve is rotary valve structure. It adopts the variable-speed
ratio transmission and can automatically adjust the hydraulic steering limit valve. It is
provided with a built-in pressure safety valve, and the adjustable pressure is 170+13 bar,
which can effectively protect the steering pump and steering system, and improve the
service life of steering system parts.
1. Steering wheel 2. Combined switch 3. Steering column holder 4. Steering shaft
5. Universal joint 6. Steering shaft sheath 7. Clamp 8. Steering telescopic shaft
Figure 9.1
1.1.1. Steering system fault diagnosis
Fault phenomenon Fault cause Fault removal

Oil make-up
Low oil level in the oil tank
Leakage repair
Abnormal sound of steering pump Air aspiration Steering system exhaust
Repair and replacement of damaged parts
Damage of transmission parts in the steering pump
Replacement of steering pump
Spool replacement
No pressure of steering system Jamming of control spool in the steering pump
Replacement of steering pump
Low pressure of steering system Jamming of control spool in the steering pump Spool replacement or steering pump replacement
Jamming of control spool, spring failure in the steering
Discharge deficiency of steering pump Spool cleaning, spring replacement
pump
Damage of steering pump sealing element Replacement of steering pump sealing element
Oil leakage of steering pump
Damage of steering pump casing Replacement of steering pump
Oil make-up
Low oil level in the oil tank
Leakage repair
Steering system exhaust
Air aspiration Oil make-up
Slightly hard for turning to left, right
directions Leakage repair
Repair or replacement of jammed steering
Jamming of steering column or steering linkage
transmission parts
Blocking of filtering element in the oil tank Replacement of filtering element and oil
Damage of steering pump Repair or replacement of steering pump
Improper adjustment of steering limiter Readjustment of steering limiter
Hard for one-sided turning
Poor steering gear Repair or replacement of steering gear
Hard for fast turning at idle speed Leakage repair
Matching of small steering pump or internal wear of
Matching of appropriate steering pump
steering pump
Low oil level in the oil tank Oil make-up
Leakage repair
Abnormal sound of steering gear
Leakage repair
Damage of steering pump Repair or replacement of steering pump
Damage of steering gear Repair or replacement of steering gear
Damage of peripheral sealing elements Replacement of peripheral sealing elements
Oil leakage of steering gear
Damage of internal sealing elements Repair or replacement of steering gear
Repair or replacement of jammed steering
Jamming of steering column or steering linkage
Poor steering automatic return transmission parts
Damage of steering gear Repair or replacement of steering gear
Steering deviation Poor steering linkage or suspension positioning Repair or replacement of related parts
Low oil level in the oil tank Steering system exhaust
Oil make-up
Leakage repair
Large inward turning clearance of steering gear Repair or replacement of steering gear
Special attention: As the judgment and solution of the above fault phenomena require professional knowledge and special tools, it is
recommended that you should go to the service branch recognized by China National Heavy Duty Group Co., Ltd. to handle this work. Pay special
attention to any operations involving the safety or safety system that must be carried on in the specialized repair shop.
1.1.2. Maintenance of steering system
▼ Check the hydraulic oil level in the oil tank
Firstly, the oil tank and its periphery shall be cleaned to prevent being mixed with dirt. The attention shall be paid to scale on the oil level indicator during
inspection, and the oil level height during the engine operation shall be between upper and lower scale of oil level gauge. When the engine does not run, the oil
level shall be slightly high.
▼ Replace the hydraulic oil
Quality grade
Assembl Quantit First replacement of interval Replacement of interval
Oil name and viscosity Remarks
y y mileage or time mileage or time
grade
ATFⅢ
Steering Steering 25,000km or 5 months, whichever 25,000km or 5 months,
automatic 5L
gear fluid comes first whichever comes first
steering fluid
▼ Keep the hydraulic oil clean
Check the oil level height and the hydraulic oil cleanness once every month.
▼ Check the rotating components
The clearance of each rotating component shall be checked for every maintenance, such as steering tie rod, straight rod joint. The component shall be
replaced in case of too large clearance. The lubricating grease shall be filled in each part during maintenance.
1.1.3. Methods for replacement of hydraulic oil
① Support up the front axle.
② Open the oil tank cover, and unscrew the oil return pipe on the steering gear.
③ Start the engine for idle running of about 10 seconds; meanwhile, turn the steering wheel to left, right directions to the limiting position for many times to
discharge oil in the oil tank, power steering pump, steering gear.
④ Tighten the oil return pipe (pay attention to keeping clean to prevent dirt, foreign bodies entering the oil line system) again, and clean the oil tank, fueling
filter and filtering element. A new filtering element shall be replaced every time you change the oil.
⑤ After fully filling the hydraulic oil in the oil tank, run the engine at idle speed, and turn the steering wheel to left, right directions repeatedly; meanwhile, make
up oil constantly until the oil level in the oil tank does not drop and produces no bubble. The oil level height shall be within the marking range.
(II). Fully hydraulic steering
1. Steering schematic diagram
1 Hydraulic oil tank 2 Steering oil pump 3 Steering gear Hydraulic schematic
diagram
4 Left steering oil cylinder
5 Right steering oil cylinder
2. Hydraulic schematic diagram
(1) System unloading pressure 175Bar
(2) Rated discharge 60LPM
(3) Maximum operating temperature 93℃
(4) Allowable temperature difference with the system 28℃
(5) Maximum allowable manual steering torque 136NM 图 9.2 图 9.3
Steering system
schematic diagram
Figure 9.2
Figure 9.3
3. Precautions for use
Guarantee clean to prevent dirt entering the hydraulic system.
(1) The oil pipe connector shall not adopt Teflon tape, etc. for sealing.
(2) The input end of steering gear shall avoid bearing axial force.
(3) The liquid level of oil tank shall be checked frequently, and the filtering element and hydraulic oil shall be replaced regularly.
(4) The steering wheel may reach the terminal point after is turned to left, right for 2-3 circles, indicating that the fully hydraulic steering device has no steering
return function.
4. Hydraulic oil
1. Replace the hydraulic oil
Quality grade
Assembl Quantit First replacement of interval Replacement of interval
Oil name and viscosity Remarks
y y mileage or time mileage or time
grade
The filtering element needs
to be replaced when
Steering Steering 46＃ anti-wear 25,000km or 5 months, whichever 25,000km or 5 months, changing the hydraulic oil
35L
gear fluid hydraulic oil comes first whichever comes first
The oil discharged shall not
be used any longer
2. Oil discharge specification
(1) Jack up the front axle, and loosen the oil inlet pipe and oil return pipe on the steering gear.
(2) Start the engine for short-time operation (at most 10 seconds) to suck oil out of the oil pump and oil tank.
(3) Use a container to hold the oil discharged.
(4) Reconnect the oil inlet pipe and oil return pipe.
(5) Open the oil return hole bolt at the steering gear bottom.
(6) Turn the steering wheel repeatedly until no oil discharge.
3. Keep the hydraulic oil clean
Check the oil level height and the hydraulic oil cleanness once every month.
4. Check the rotating components
The clearance of each rotating component shall be checked for every maintenance, such as steering tie rod, straight rod joint. The component shall be
replaced in case of too large clearance. The lubricating grease shall be filled in each part during maintenance.
III. Clutch control system (mechanism case)
The clutch matched for this series model is φ420 periphery-mounted spiral spring clutch. This clutch is a push-type clutch, and Figure 11.1 is the push-type
clutch control device figure.
Figure 11.1
1. Clutch pedal assembly 2. Return spring 3. Clutch drive cylinder push rod 4. Clutch oil tank
5. Clutch drive cylinder 6. High-pressure oil pipe 7. Clutch booster cylinder 8. Booster cylinder holder 9. Disengaging swing arm
(I). Operating principles
The clutch control system uses the hydraulic control and pneumatic power-assisting structure. When the clutch pedal is pressed down, the drive cylinder
pushes the piston to move forward, then pushes the brake fluid to enter the hydraulic control chamber of the clutch booster cylinder along the oil pipe. On
one hand, the brake fluid functions on the piston as operating pressure, and on the other hand, it serves as the control pressure to regulate and control the
air pressure of the booster cylinder air chamber. When the compressed air enters the booster cylinder air chamber, the pneumatic power-assisting is
produced, then to push the piston together to make the booster cylinder push rod move, push the rotation of disengaging swing arm, thus separating the
shifting fork to drive the backward motion of release bearing so as to separate the clutch.
The clutch drive cylinder, clutch oil tank and clutch pedal assembly, etc. are arranged on the front periphery of cab. The drive cylinder is connected to the
clutch booster cylinder arranged on the chassis through the high-pressure hose. The clutch control part shares one holder with the brake control part. The oil
tank is directly installed on the clutch drive cylinder, and the brake fluid can be filled outside the cab when the radiator cover is opened.
(II). Operating parameters

1. Operating medium: compressed air, brake fluid
2. Maximum operating pressure: brake fluid of 4MPa, compressed air of 0.85MPa
3. Operating temperature: -40℃～+80℃
4. Brake fluid: conforming to DOT3 standard
5. Pedal travel: maximum travel of 200mm, free travel of 35-40mm, pull type of 25mm
6. Pedal force: 190N with pneumatic power-assisting, 590N with no power-assisting

(III). Adjustment of clutch control system
1. Check and adjust the clearance between master cylinder push rod and piston:
When adjusting, push the pedal gently by hand to feel that the master cylinder push rod is jacked up to the master cylinder piston, and adjust the position of
upper stopper bolt to make the clearance between upper stopper bolt and clutch pedal reach about 1mm, then tighten the nut at the stopper bolt. Guarantee
a clearance of 0.5mm-1mm reserved between push rod and piston. This clearance shall not exceed 1mm, otherwise the effective travel of master cylinder
will be reduced, and the clutch disengaging effect will be affected.
2. Adjust the clutch brake control valve
Press down clutch pedal to the end; at this moment, the operating travel of the clutch master cylinder push rod assembly shall not be less than 32mm, and at
this moment, the clutch pedal assembly shall have pushed the clutch brake control valve to make it move 3-5mm. Fix the clutch brake control valve, and
tighten the bolt at the clutch brake control valve, then adjust the stop screw on the combination pedal bracket to make its head against the clutch pedal
assembly (when pressing down clutch pedal to the end so as to prevent the clutch brake control valve falling off from the combination bracket due to carrying
force separately.
3. Check and adjust the clearance at the release bearing (push-type clutch)
There shall be a 2mm-3mm clearance at the clutch release bearing to guarantee that the release bearing will produce no burning loss or clutch semi-
disengaging due to long-time operation under stress within the next maintenance period. When adjusting, push the disengaging swing arm to the clutch
disengaging direction until unable to be pushed forward by hand, and adjust the booster cylinder push rod to make its tail contact with the booster cylinder
piston, then adjust the push rod locking nut to make the clearance between it and the push rod forkhead keep within 3-5mm, finally rotate push rod to make
the nut contact with the push rod fork, and tighten the nut.
4. Fully exhaust air in the hydraulic system:
If there is air in the hydraulic clutch system, the effective travel of booster cylinder push rod will decrease, causing incomplete clutch disengaging and
difficulty in engaging a gear. When assembling or dismounting the oil pipe, firstly release the booster cylinder venting valve, add the brake fluid of specified
brand in the oil tank, make up the brake fluid when pressing down the clutch pedal until spilling over at the venting valve, and tighten the venting valve. Then
press down the clutch for no releasing after quickly pressing down it for many times, release the booster cylinder venting valve until no air escaping out, and
tighten the venting valve. Repeat the above steps for 2-3 times, and this can fully discharge air in the hydraulic system.
(IV). Precautions
1. In the exhaust process, the attention shall be paid to no releasing of pedal before the venting valve or union nut is tightened for fear of air aspiration. The
pedal shall be lifted to the maximum height so that the brake fluid in the oil tank can be made up to the master cylinder hydraulic chamber. The inspection
standard to correctly judge that the clutch hydraulic system air has been fully discharged is to press down the clutch pedal, with the effective travel of booster
cylinder push rod reaching 25mm. The air discharge shall continue when the effective travel is less than 25mm.
2. It is recommended that the operating medium of hydraulic system use “Laike” DOT3 brake fluid. During the assembly and disassembly of oil pipe,
Loctit572 thread sealant may be used to seal the place of union nut and joint.
3. During the replacement of brake fluid, the residual liquid in the hydraulic system shall be fully removed, and the brake fluid of specified brand shall be
uniformly replaced.
(V). Common faults and removal methods
Fault Cause Removal method

1. Remove the oil stain on the clutch pressure plate, driven plate
1. The friction disc is pasted with oil stain.
and flywheel.
2. The driven plate friction disc becomes thin due to serious wear,
Clutch slipping and make disengaging lever contact tilt backward. The tilt amount is 1. Adjust the pedal free travel as required.
greater than free travel, and the disengaging lever is under stress, 2. If the friction disc is damaged, adjust the effective length of
thus offsetting some pressure of the pressure spring. Therefore, stopper bolt. If the adjustment does not work, replace the friction
although the pedal is fully released, the clutch cannot be fully disc.
engaged.
1. The free travel of clutch pedal is too large, and the operating
1. Adjust the pedal free travel as required.
travel is insufficient.
Incomplete
clutch 2. Improper adjustment or deformation of the clutch disengaging 1. Calibrate the disengaging lever, and replace if necessary.
disengaging lever causes deflection of the pressure plate, and local wear of the 2. Check wear conditions of the friction disc, and repair or replace
friction disc. depending on the situation.
IV. Transmission control system
(I). Automatic gearbox
1 Main structure
Connecting surface
Air plug
with engine
Power take-off port

cover
Oil filler pipe mounting port
Nameplate
Main oil pressure measurement

port
Output speed sensor
Cooling oil access
Figure 12.1
2 Gearbox oil
(1). Gearbox oil and fueling
a. Oil standard: It is recommended to use the synthetic oil dedicated for Allison transmission jointly researched and developed by Allison Company and
Castrol Oil Company: standard of TranSynDTM.
b. Oil filling: The oil consumption for this series transmission varies with the change of oil pan depth and external piping, and will be finally confirmed
according to the oil level inspection procedure.
c. Fueling procedure: Unplug the oil scale in the oil filler pipe, and place it in a clean place Fill the qualified gearbox oil to be within the oil gauge range, then
check the oil level.
Note: Do not bring sundries in the gearbox when fueling and checking the oil.
Oil gauge
(2). Oil level inspection
Oil filler pipe
a. Oil gauge: For the oil gauge scale as shown in Figure 12.2, the range between characters of COLD
ADD and CALD FULL is oil level of cold oil level, in the lower part of the oil gauge, while the range
between characters of HOT ADD and HOT FULL is hot oil level, above the cold oil level.
Hot oil level
b. Cold inspection: The so-called cold inspection is the oil level inspection when the gearbox oil
temperature is ambient temperature (16-49℃). The purpose of cold inspection is to have sufficient
gearbox oil for hot inspection. The steps are as follows:
1) Park the vehicle on the level ground.
2) Place the gearbox in the neutral position to start the engine.

Cold oil level
3) The engine returns for idling after running 1 minute at the speed of 1000-1500r/min. The gearbox
enters the forward gear for running 1 minute again. At this moment, the oil temperature shall be within
16-49℃.
4) Wait for a period of time to make the oil level balanced, take out the oil gauge, and check to
confirm the oil level in the cold position, namely between COLD ADD and CALD FULL. Otherwise add or
discharge to make it reach this position. Oil gauge scale
Figure 12.2
c. Hot inspection: The so-called hot inspection is to check the gearbox oil level when the gearbox oil temperature reaches 71-93℃ for the first time. At this
moment, take out the oil gauge, and the oil level shall be in the hot position, namely between HOT ADD and HOT FULL. Otherwise add or discharge to make
it reach this position.
Warning: ※ The oil level shall be checked when it is in the “not tighten” or looseness position to ensure the oil gauge is stretched into the oil
pipe bottom. ※ If the gearbox “stalling” method is adopted to speed up the oil temperature rise, the vehicle brake shall be confirmed to be
enough to prevent vehicle motion, thus to ensure safety. ※ Before the oil level is confirmed to meet the requirements, the gearbox shall avoid
long-time running during the hot inspection to prevent the gearbox damage due to insufficient lubrication.
3 Use maintenance
1 To avoid personal injury or causing equipment fault and damage, please operate the transmission according to the specified procedures.
2 When starting, press down the accelerator gently.
3 When engaging the reverse gear from the forward gear or engaging the forward gear from the reserve gear, completely stop the vehicle.
4 Prohibit sliding at neutral gear, otherwise the gearbox may be damaged badly.
5 When traveling, pay attention to monitoring the temperature of engine and gearbox.
6 The engine idle speed shall be about 600RPM, and too high or too low idle speed may cause the transmission is unable to engage the gear.
7 The accelerator sensor interruption may cause the transmission is unable to engage the gear.
(II). Mechanical gearbox

1 Installation and adjustment of flexible axle control system
1. When the flexible axle is arranged on the vehicle, its being radius is not less than 300mm, and the operating temperature range of flexible axle is between
-40℃ and +100℃.
2. The connection of flexible axle with gear change, gear selection swing arm shall meet the following requirements:
(1). The flexible axle and swing arm shall form a 90° angle.
(2). The guide sleeve, sleeve joint of flexible axle shall be in the same straight line with the push rod spatially.
3. The gear selection and gear change flexible axle shall be respectively installed on the controller.
Note: The ball joint thread of two flexible axles shall be screwed to the bottom.
4. After installing, place the control lever in the neutral position, and measure whether the transmission end flexible axle dimension meets the requirements.
If failing to meet the requirements, the connection length of flexible axle ball joint and pull rod shall be adjusted to adjust the installation dimension of flexible
axle.
5. After completing installation, the gear change and selection operation shall be made to check that all gears are available. The installation dimension of the
gear selection flexible axle of transmission end shall be checked and adjusted according to the previous article.
6. The flexible axle is specifically adjusted as follows: (Figure 12.3)

(1). After the completion of assembling, when finding that the front gears are not engaged in place during test run, unscrew ① nut (or ⑤ nut), and rotate ④
ball joint (or ⑥ ball joint) properly in counterclockwise direction. On the contrary, if the rear gears are not engaged in place, unscrew ① nut (or ⑤ nut), and
rotate ④ ball joint (or ⑥ ball joint) properly in clockwise direction (shortening). Repeat the above steps to adjust until all gears are engaged in place.
(2). After the completion of assembling, when finding that the low gears are not engaged in place during test run, unscrew ② nut (or ⑦ nut), and rotate ③
ball joint (or ⑧ ball joint) properly in counterclockwise direction (lengthening). On the contrary, if the high gears are not engaged in place, unscrew ② nut (or
⑦ nut), and rotate ③ ball joint (or ⑧ ball joint) properly in clockwise direction (shortening). Repeat the above steps to adjust until all gears are available.
左侧车架
Figure 12.3
2 Transmission oil
1. Lubricating oil brand
The transmission must be filled with 85W/90 vehicle gear oil.
2. Correct oil level position
The oil level shall be ensured to parallel with the oil filling port. With the oil level checked through the cone-shape oil filling port on the shell flank, the oil level
may be filled to the hole where the spillover occurs.
3. Operating temperature
The maximum temperature of transmission during continuous operation shall not exceed 120℃, and the minimum temperature shall not be lower than -40℃.
When the operating temperature exceeds 120℃, the lubricating oil will be decomposed, and the transmission life will be shortened.
4. Oil changing period
When the new transmission travels 2,000-5,000km, the lubricating oil must be replaced.
The oil level height and leaking conditions of lubricating oil shall be checked to make up at any time for every traveling of 10,000km
The lubricating oil shall be replaced for every traveling of 50,000km.
5. Dragging or sliding
During the transmission operation, the transmission shaft and gear rotate constantly, which can provide adequate lubrication for the transmission. But when
the vehicle is dragged under the condition of rear wheel landing and transmission system connection, the countershaft gear and main shaft gear of main tank
do not rotate, and the main shaft is driven by rear wheel for high-speed rotation, which may cause serious damage to the transmission.
The same consequence may be also produced when the transmission is engaged in neutral gear for sliding.
When the vehicle needs dragging, the half shaft may be drawn out or the transmission shaft may be disengaged, and the driving wheel may be dragged
away from the ground.
3 Use maintenance
a. To avoid personal injury or causing equipment fault and damage, please operate the transmission according to the specified procedures.
b. Before the vehicle start, the driver shall sit on the driver seat, place the gear lever in the neutral position, and use the hand brake.
c. When leaving the cab before the vehicle operating or during the engine operation, he shall place the gear lever in the neutral position, and use the hand
brake to lock the wheels.
d. When parking the vehicle or leaving the cab, he shall place the gear lever in the neutral position, and use the hand brake.
e. The hand brake must not been released for gear changing operation under the circumstance where the vehicle air pressure does no rise to the correct
level.
f. Long-distance sliding is forbidden when the transmission is in the neutral position.
g. During the power turn-off control, firstly press down clutch pedal to the end, then press the power take-off switch, wait for a moment, and release after
the power take-off is normal.
(III). Power take-off

1. Overview
The power take-off is a set of transmission gears, also known as power output device, which provides power for the equipment requiring extra power. The
power take-off for port vehicles is mainly used for saddle lifting system, and services as the power source of
lifting pump. Generally the engine rear power take-off method is adopted. PR70 power take-off is optional for
ZF mechanical transmission model.
2. PR70 power take-off (Figure 12.4)
1) Output location: upper right output
2) Speed ratio of power take-off: 2.12×0.789=1.673
3) Output speed: 2,300rpm (rated engine speed)/1.673 (total speed ratio)=1,375rpm (output transmission
speed of power take-off)
4) Rotating direction: left-handed rotation (viewing from the output end of power take-off), in the same direction
with engine
5) Output mode: internal spline, major diameter of 25mm, minor diameter of 20.1mm, tooth space width of
6mm
Figure 12.4
6) Rated output torque: 700Nm
7) Recommended oil pump: CB-HJH series gear pump (Xuzhou Construction Machinery), the users may
choose as needed, and direct connection is available.
3. Engine rear power take-off (MC07) (Figure 12.5)
1) Output location: engine rear upper output
2) Speed ratio of power take-off: 0.82
3) Output speed: 2,300rpm (rated engine speed)/0.82 (total speed ratio)=2,805rpm (output transmission
speed of power take-off)
4) Rotating direction: left-handed rotation (viewing from the power take-off output end), in the same direction
with engine
5) Rated output torque: When the engine speed is lower than 1,900r/min, the maximum allowable output
torque of power take-off is 500Nm. When the engine speed is higher than 1,900r/min, the maximum
allowable output torque of power take-off is 600Nm.
Figure 12.5
4. Use maintenance
When the gear meshing of transmission mechanism connected with the power take-off is poor, and the related connecting bolts of power take-off is loose,
the abnormal sound will occur. Check the fastening bolt of each component; meanwhile, pay attention to viewing the conditions of lubricating oil, clean the
dirt promptly, and keep each component clean, intact, without collision, scratch. In addition, check the connecting pipe between power take-off and oil pump
frequently, and if there is looseness, damage, falling, fracture, replace promptly.
V. Axle
(I). Front axle
1. Structure overview
Figure 13.1
The front axle (as shown in Figure 13.1) is a fist type I-shape rigid special front axle, which is mainly composed of the middle front beam and the knuckle and
hub, etc. hinged at both ends of the front beam. The front beam is the integral forging fist-type I-shape beam, and its middle part adopts the concave curve
structure. The titling both ends on the front beam present the fist shape, and the round hole on it is used for installing master pin, thus the inclination angle of
master pin is guaranteed.
2. Maintenance of front axle
1. The front axle shall be maintained regularly for every traveling of 15,000km or for every six months. The following fasteners shall be tightened regularly
according to the required tightening torque:
Tightening torque of main bolts and nuts
Part name Tightening torque (Nm) Part name Tightening torque (Nm)
Knuckle arm nut 280-350 Sliding pin hex socket cheese-head screw 200-240
Steering tie rod nut 280-350 Tie rod clamping nut 40-60
Wheel nut 550-600 Steering stopper bolt locking nut 70-90
Hub end cover bolt 21-25 Steering tie rod arm ball pin nut 180-280
Brake chamber fastening nut 160-200 Brake block clamp fixing bolt 160-200
2. Check the rotation conditions of hub bearing, and replace the lubricating grease; meanwhile, check whether the hub bearing can be used continuously,
and adjust or replace if necessary. The lubricating grease for hub bearing, brake camshaft and master pin, tie rod ball pin, brake clearance adjusting arm,
etc. is the general purpose lithium base grease for automobile.
3. Usage of lubricating grease:
(1) Usage of lubricating grease for each hub: a total of about 0.6kg for hub inner chamber, two bearings;
(2) Usage of lubricating grease for each brake camshaft and master pin: about 0.2kg, use an oil gun to fill until spillover of bracket hole;
(3) The tie rod ball pin, brake clearance adjusting arm, etc. shall be fully filled with lubricating grease.
4. The following items need to be checked regularly, as shown in Table 1. The parameter requirements are shown in Table 2.
Table 1 Regular inspection items
New vehicle Traveling of 3,000- Every 3 months Every 12 months Replacement with new
5,000km parts for brake pipe
Adjustment of brake pipe / Check / Adjust Check / Adjust
valve (no dismounting (no dismounting of tire)
of tire)
Brake force distribution of Check / Adjust Check / Adjust
trailer / tractor (no dismounting of tire) (no dismounting of tire)
Visual inspection of brake Check (no dismounting
block wear loss of tire)
Visual inspection of brake Check (no dismounting
disc of tire)
Sliding function of sliding Check (tire dismounting)
pin
Sliding pin sheath Check (tire dismounting)
Piston sheath Check (tire dismounting)
Table 2 Parameter requirements
Inspection items Requirements

Minimum thickness 3mm
Brake block
Maximum uneven friction loss 1mm
Brake disc Minimum thickness 37mm
Maximum wear thickness of each side 4mm
Maximum radial runout 0.5mm
Maximum thickness difference 0.1mm
Sliding pin Maximum clearance 1mm
Sliding function Maximum sliding resistance 100N
5 Common fault phenomena, causes and removal methods
Fault Fault cause Removal method

phenomenon
Inflexible knuckle rotation Lubricate the knuckle master pin, and check the clearance of
knuckle and front axle
Hard steering
Insufficient lubrication Lubricate the knuckle master pin and steering linkage ball pin
Improper toe-in adjustment Readjust the toe-in
Improper pretightening of hub bearing Readjust the pretension of hub bearing
Loose steering Looseness or wear of steering linkage ball pin Fasten or replace the ball pin
Knuckle bushing wear Replace the knuckle bushing
Improper pretightening of hub bearing Readjust the bearing pretension
Looseness or wear of steering linkage ball pin Fasten or replace the ball pin
Wheel oscillation
Knuckle bushing wear Replace the knuckle bushing
Too large clearance of knuckle and front axle Readjust the clearance
Whether the brake block is polished of one side Replace the brake block
Whether the clearance of brake block and brake disc is correct Make initial adjustment and function inspection
Braking deviation Whether the brake block can move freely in the fixing bottom plate Remove the brake block, and clean the brake block, fixing
bottom plate and brake caliper
Whether the air exhausting plug of brake chamber is removed Remove the air exhausting plug of brake chamber
Brake scuffing Whether the clearance of brake block and brake disc is correct Make initial adjustment and function inspection
Whether the brake block can move freely in the fixing bottom plate Remove the brake block, and clean the brake block, fixing
bottom plate and brake caliper
Whether the function of brake caliper sliding function is normal Replace the sliding pin and bushing
Whether the air exhausting plug of brake chamber is removed Remove the air exhausting plug of brake chamber
Whether the brake block is polished Replace the brake block
Whether the clearance of brake block and brake disc is correct Make initial adjustment and function inspection
No or poor
braking effect Whether the brake disc is good Replace the brake disc
Whether the pressure of brake chamber is normal (measure the Implement remedial measures according to the vehicle use
chamber pressure with a barometer) requirements
(II). Drive axle
1. Rear axle overview
The Steyr ST16 rear drive axle is the central one-level reduction and wheel planetary
reduction two-stage drive axle, with the total speed ratio of i=10.77. According to different
drive types, there are also duplex drive axle and single rear axle two kinds. The steel plate
punched axle housing makes the drive axle and vehicle have better matching attribute.
2. Rear axle maintenance
1. Fueling and oil changing
After traveling 5,000km, replace the lubricating oil filled when assembling, and
check the oil level once for every traveling of 5,000km or for every month;
Replace the lubricating oil once for every traveling of 150,000km or for every year;
Replace the lubricating grease for brake adjusting arm and camshaft once for every Figure 13.2
traveling of 150,000km or for every year.
Oil name: GL-585W-90 gear oil; oil filling: 23L (middle axle), 20.5L (rear axle).
2. Axle maintenance
a. Clean the dirt, dust on the rear axle breather plug frequently.
b. Check the oil filler plug and oil drain plug frequently, and if there is oil leakage, tighten or replace the sealing washer promptly.
c. As the half axle flange transmission torque is torque, and there exists the impact load, check the fastening condition of half axle bolts to prevent looseness
and fracture of the half axle bolts arising therefrom.
d. For every traveling of 2,000km, fill 2＃ lithium base grease in each grease nipple, clean the breather plug, and check the gear oil level height in the axle
housing (open the oil filler plug on the axle housing rear cover for inspection).
e. For every traveling of 5,000km, check the brake clearance.
f. For every traveling of 8,000-10,000km, check the fastening condition of brake bottom plate, and check the looseness of hub bearing. Check the wear
condition of brake pad, and if the wear of brake pad exceeds the limiting pit, replace the brake pad. Check the quality of gear oil in the axle housing, and if
there is deterioration or thinning, replace with new oil promptly. The initial oil changing mileage is 8,000km; later, replace the gear oil for every traveling of
24,000km.
3 Inspection and maintenance:
Inspection, maintenance period (mileage and time, whichever comes first)

Inspection and maintenance item
Initial inspection Regular inspection and maintenance
After 1,500km After 15,000km
Every 60,000km Every 120,000km
Regular inspection item After the first Every three
Every six months Every year
month months
Check the wear, sealing and damage conditions of moving parts, ○ ○ ○ ○
check the wear of brake friction disc, check the easy return of
camshaft, check the function of adjusting arm, and check the function
and tightness of brake chamber
Check the safety (daily)
Check the correct adjustment of brake ○ ○ ○ ○
Check the braking operation of the brake ○ ○ ○ ○
Maintenance item
Tighten the bolt again according to the required torque ○ ○
Clean the brake ○
Apply anti-blocking agent in the brake shoe fulcrum pin and rolling ○
wheel
Check the rotating condition of hub bearing, and adjust or replace the ○ ○
hub bearing if necessary
Notes: 1. When the vehicle runs under bad operating conditions, the maintenance period shall be correspondingly shortened.
2. After the new wheel is installed or the wheel is changed, after it travels 50km, tighten the wheel nut according to the required tightening torque, and after it
travels 150km, tighten the wheel nut again according to the required torque.
4 Tightening torque of main fasteners

No. Fastening part Tightening torque (Nm)
1 Fastening bolt for left and right shell of differential bevel gear 300-420
2 Fastening bolt of driven bevel gear 265-355
3 Oil filler plug and oil drain plug 35-45
4 Fastening bolt of main reducer shell bearing cover 650-810
5 Fastening of reducer nut, bolt 245-310
6 Hexagon slotted and castle nut on the main cone 1350-1670
7 Brake assembling bolt 300-360
8 Hub bolt fastening nut 550-600
9 Bearing block fastening bolt on the main cone 95-150
10 Half axle fastening bolt 245-310
11 Bearing block fastening bolt at the driving cylindrical gear 100-129
12 Bearing block fastening bolt of transfixion shaft 47-68
13 Fastening bolt of axle differential front and rear shell 60-75
14 Fastening bolt of transfixion shaft end 610-881
15 Bearing block fastening bolt of middle axle input shaft 100-145
16 Hexagon slotted and castle nut on the input shaft 815-1085
4 Tightening torque of main fasteners
Fault symptom Cause analysis Treatment method

1. Improper gear clearance of differential gear Replace the thrust washer or gear
2. Too large clearance of driving, driven gear Replace the thrust washer or gear
Abnormal sound of
3. Too small pretension of driving gear bearing Adjust the pretension
transmission
4. Wear of half axle gear, planetary gear and cross axle washer, etc. Calibrate or replace the defective parts
5. Too low oil level Fill sufficient lubricating oil
1. Wear, looseness, damage of oil seal Replace the oil seal
2. Looseness of reducer fastening bolt Tighten according to the required torque
3. Sealing ring damage Replace the sealing ring
Leakage of 4. Looseness of bearing block fastening bolt Tighten according to the required torque
lubricating oil
Tighten the plug according to the required torque or
5. Looseness of oil drain plug or liner damage
replace the liner
6. Axle housing deformation due to overloading Calibrate or replace the axle housing
7. Blocking or damage of breather plug Clean or replace the breather plug
1. Too large pretension of hub bearing Adjust the pretension
Hub bearing
2. Lack of lubrication or incorrect lubricating grease for the bearing Fill or replace the lubricating grease
obstruction
3. Bearing pasted with dust Clean and fill the lubricating grease
Insufficient brake 1. Ineffective camshaft rotation Check the operating conditions of camshaft
force
2. Improper adjustment of brake chamber push rod travel Adjust the travel
3. Overheating or deterioration of brake friction disc Replace the friction disc
4. Improper fitting of brake friction disc Calibrate the fitting position of friction disc
Fault symptom Cause analysis Treatment method
Press down the pedal gently when traveling to drain the
5. Water inflow of brake drum
water
6. There is lubricating grease on the friction disc and brake drum Remove the grease or replace the friction disc
7. Insufficient brake pressure or insufficient gas volume Check the pneumatic piping and each gas valve
1. The wear of friction disc makes the bolt protrude Replace the friction disc
2. Friction disc surface hardening or deterioration Replace the friction disc
Abnormal sound of 3. Uneven wear or unstable installation of brake drum Calibrate, replace the brake drum or tighten the bolt
brake 4. The contact of brake shoe and friction disc is not close Replace the brake shoe and lining assembly
5. Wear of hub bearing Replace the hub bearing
6. Brake drum deformation Calibrate or replace the brake drum
1. Improper installation of brake shoe Reassemble
2. Damage of return spring Replace the return spring
Brake instability
3. Oiliness or deterioration of friction disc Clean or replace the friction disc
4. Damage of brake bottom plate Replace the brake bottom plate
1. Poor lubrication of camshaft or no return of adjusting arm Calibrate the defective part
Wheel unsmooth
2. Breaking or fatigue of brake shoe or chamber return spring Replace the defective part
VI. Brake system
(I). Brake system structure requirements
1 Functions required for the brake system: service brake, parking brake, emergency brake;
2 The service brake must be dual circuit system.
3 The service bake must function on all the wheels, with even braking effect.
4 The brake control must have the function of gradual advance.
5 There must be an audio (or) optical alarm device structurally.
6 If one circuit fails, the other circuit pressure must be protected to make the residual brake force can effectively stop the vehicle.
(II). Main structure of brake system

1. Air compressor
The air compressor is air source for the entire vehicle gas path. At present, Sino Truck equips with WABCO double-cylinder air compressor that has the
synchronous level with Europe’s most advanced heavy-duty truck engine, and under the Europe’s service conditions, its service life reaches 1500,000KM.
The single-cylinder air compressor is in the high load operating state for long time due to small discharge capacity, thus easily causing break of crankshaft,
linkage of air compressor and large expelling of engine oil. The double-cylinder air compressor has large discharge capacity and short operating period,
which greatly improves reliability, life of the air compressor itself, thus reducing the power consumption. The temperature and oil expelling of compressed air
are obviously reduced, causing the reliability of various valve components of the truck brake system are promoted greatly, then the safety and
maneuverability of entire vehicle will become better. Under the traveling condition of descending a long slope, the compressed air can be made up promptly
to ensure there is sufficient compressed air in the brake system, and ensure the traveling safety.
2. Air processing unit (APU)
APU (as shown in Figure 9.1) is an assembly of air dryer and four circuit protection valve. The air dryer uses
molecular sieve as desiccant to clean, dry the compressed air from the air compressor. The built-in reflux valve
substitutes the 5L air reservoir, which saves more installation cost and installation space. The reflux valve
allows a certain amount of pressure to blow back the drying cylinder, and the back flowing process is
controlled through accurate pressure difference. The four circuit protection valve is used for restricting and
protecting the system pressure. Therefore, APU provides a complete, simple, effective air processing system
for the automotive air brake system.
3. Main control valve
The main brake valve is a device used to control and manipulate the main brake system work, and to make the
brake pressure and brake controlling force (or pedal travel) form a certain proportional relation. The internal
combustion tractor adopts the double circuit dual-chamber main brake valve. Figure 9.1
4. Brake relay valve
The function of main brake relay valve (as shown in Figure 9.2) is to shorten the brake reaction time, which plays the
role of “fast charge” and fast discharge for the main brake chamber. Figure 9.2
With long axle base, large total capacity of automobile (middle) rear axle brake chamber, and long distance to the
main brake valve, therefore, the brake reaction time from the brake pedal being pressed down to reaching the
corresponding value of chamber pressure is too long. Thus a relay valve is installed in the nearest position to the
(middle) rear axle brake chamber, which is supplied of air directly by the air reservoir through a thick main piping,
then is controlled by the main brake valve through a thin piping.
5. Brake chamber
The function of front brake chamber is to input different pressure and produce different thrust, then through the brake
cam and brake shoe, the brake drum will produce braking of different strength to the front axle. The middle rear axle is a combined brake chamber, and its
function is not only to produce effect on the (middle) rear axle main brake, but also to implement the parking and emergency brake.
(III). Brake system fault and solution
1 Brake failure
Causes and removal methods
1. Insufficient pressure in the gas path:
a. Poor sealing of suction and exhaust valve of the air compressor, gasket damage, replace the valve or spring, and replace the gasket in case of damage.
b. Damage of air tube or air tube joint, replace the air tube or joint.
c. Leakage of four circuit protection valve, after the valve dismantling, clean each machine part, and check the leak tightness after replacing the damaged
part.
d. Leakage of relay valve, after the valve dismantling, clean each machine part, and check the leak tightness after replacing the damaged part.
e. Leakage of main brake valve, after the valve dismantling, clean each machine part, and check the leak tightness after replacing the damaged part.
f. Leakage of parking brake valve, after the valve dismantling, clean each machine part, and check the leak tightness after replacing the damaged part.
2. Poor sealing of suction and exhaust valve of the main brake valve, clean the suction and exhaust valve, and replace if necessary.
3. Poor sealing of suction and exhaust valve of the relay valve, after the valve dismantling, clean each machine part, and check the leak tightness after
replacing the damaged part. If the valve is damaged, replace it.
4. Damage of brake chamber diaphragm, replace the diaphragm.
5. Too large brake clearance, readjust the brake clearance as required, and if necessary, replace the lining.
6. Oiliness or burning hardening of brake lining, replace the brake lining or oil seal, and eliminate the oil leakage phenomenon.
2 No reliving or incomplete relieving of brake
1. Blocking of main brake valve relay piston or slave piston, after dismantling the main brake valve, check the piston, sealing ring and its operating surface,
and replace the piston or sealing ring.
2. Shriveling of plastic pipe from main brake valve to relay valve, causing the air venting obstructed, check the piping of this section, and replace if
necessary.
3. Blocking of relay valve piston or exhaust valve, after dismantling the relay valve, check the piston, sealing ring and exhaust valve, and if necessary,
replace the repair kit.
4. Leakage of hand brake chamber, dismantle, check and repair the hand brake chamber.
5. Leakage of hand brake valve, dismantle and check the hand brake valve.
6. Inhibited air return of main brake valve, relay valve, dismantle, check and repair.
7. Camshaft unsmooth, check the movement condition of camshaft, and if necessary, dismantle and check.
8. Insufficient elasticity of return spring of brake pedal, replace the spring.
9. Too small brake clearance, readjust the brake clearance.
3 Braking deviation
1. The tire pressure does not meet the requirements; check the tire pressure.
2. The tire type is not consistent; install the same type of tire.
3. The brake clearance adjustment is not correct; readjust the brake clearance.
4. The brake shoe wear is uneven; replace the brake shoe, and polish it if necessary.
5. There is oil stain on the brake shoe of some side; clean with gasoline, and replace if necessary.
6. The material, model of each brake shoe are not consistent; replace the brake shoe of the same model, material.
7. The brake chamber of some side does not work normally; repair or replace the brake chamber.
8. The brake drum is out of round; bore the brake drum.
VII. LNG supply system

(I). LNG introduction
LNG is mainly methane (CH4); meanwhile, it includes a small amount of hydrocarbon gas, such as propane (C3H8) and butane (C4H10), etc., and non-
hydrocarbon gas, such as nitrogen, carbon dioxide, hydrogen sulfide and a tiny amount of hydrogen, helium, argon, etc. The LNG formation process in the
various places is quite different, therefore the ingredient is not exactly the same.
As the main ingredient of LNG is methane, and the composition in the various places is different. Its density is generally within 426-470kg/m3. With more
methane content, the density will be smaller. The density of LNG is also the function of temperature, and the higher the temperature is, the density will be.
Therefore, the priority shall be given to methane during the explanation of property. The required accurate physical parameters shall be provided by a LNG
manufacturer.
The high-purity LNG is colorless, odorless transparent liquid. Because of low boiling point, when it is observed, the liquid generally has strong boiling. When
it is exposed to the air, due to condensation of steam in the air, lots of steam cloud will appear.
(II). LNG safety overview

1) LNG exists the risk of fire
The ignition point of LNG is 650℃, higher than the ignition point of gasoline, diesel, LPG, and its ignition energy is also higher than gasoline, diesel,
therefore, it is more difficult to ignite than gasoline, diesel, LPG. The combustion range of LNG is small, generally 5-15%. The LNG steam above -106.7℃ is
lighter than air, which will immediately volatilize once there is leakage, and it is difficult to form the density that produces the combustion and explosion in
case of fire. Therefore, whether LNG or its steam will not explode in a non-closed environment.
When the LNG leaks at ambient environment, it will evaporate rapidly to produce lots of natural gas to form the steam cloud. Therefore, smoking or open
flame is not allowed in the place storing, loading and unloading or using LNG, otherwise the danger, even the personal injury may be caused.
If the LNG leaks in a closed environment or in the space with heat source (without ignition source), as it may become steam, and the volume expands
rapidly, there is also risk of explosion. Therefore, the place for storing LNG shall be open, ventilated as required so that the steam can spread out.
When the density of LNG in the air exceeds 1%, the operating personnel shall evacuate the scene.
LNG fire characteristics: The fire flame propagation velocity is fast, and the mass burning rate is large, about 2 times of gasoline. The flame has
high temperature and strong radiating heat, easily forming the large-area fire. It has recrudescence, repeated explosion, and is difficult to be
extinguished.
Notes: Fire fighting
The purpose of fire fighting is mainly to extinguish the fire source or control the flame propagation. Firstly cut off the leaking source, then control the
combustible, and extinguish the fire source. When extinguishing the fire source, choose correct extinguishing agent, and for LNG, the best extinguishing
agent is dry chemical powder extinguishing agent (potassium carbonate). When using dry powder to extinguishing the flame, it is like thick cloud to cover the
flame to reduce heat radiation. The high temperature makes dry powder let out crystal water or produce decomposition, which can not only absorb some
heat, but also can reduce the oxygen density in the combustion zone.
2) Risk for suffocation
The excessive accumulation of LNG may cause thinning of oxygen density in the air, and people in the environment may suffer coma, injury, even
suffocation. When the oxygen volume in the air is below 20%, the operating personnel shall notice that he shall evacuate when the oxygen content further
decreases.
When the operating personnel loses consciousness due to oxygen deficiency, he shall be excavated from the site immediately, and given with artificial
respiration. If the operating personnel stops breathing, he shall be immediately given with artificial respiration, and sent to the hospital for treatment. When
the oxygen density in the air is ＜10%, and the LNG density is ＞50%, bringing permanent injury to human body, under this circumstance, the staff shall not
enter LNG zone.
3) Low temperature
As the temperature of LNG is very low, if it contacts with body skin, the serious frostbite may be caused due to rapid gasification of liquid, also called cold
burn. If it contacts with room temperature pipes and equipment, the phenomenon of brittle fracture may be caused.
In case of burn, the following treatment methods shall be adopted:
(1) When the skin is bonded to the low temperature surface, use the method of heating by hot water to unfreeze skin, then move away the frozen part, and
send the injured to a warm place (about 22℃).
(2) Remove all clothes that hinder the blood circulation of frozen part.
(3) The frozen part shall receive water bathing, and the water temperature shall be 41℃-46℃. Using the method of drying or direct heating is not allowed. If
the water temperature exceeds 46℃, the injury to body composition of frozen part will aggravate.
(4) The injured shall be immediately sent to the hospital for further treatment.
(5) If the injured have large-area frostbite, and their body temperature has fallen, the injured need to be soaked in the water of 41℃-46℃, then shall be sent
to the hospital as early as possible.
(6) The frozen body part begin to feel pain, swelling after heating, if the injury condition is not serious, the frozen part shall be heated slowly, continuously
until the skin changes from grey white to pink or red.
(7) The injured are not allowed smoking, drinking, because this may reduce the blood volume flowing to the frozen organization. The tetanus vaccine shall
be injected to prevent infection.
4) LNG also has the characteristics of easy evaporation, easy diffusion, flowing, etc.
The boiling point of LNG (methane as an example), with easy evaporation.
(III). Principle of LNG supply system

1) System composition and process
The LNG supply system for vehicle is composed of special vehicle-mounted low-temperature insulated cylinder, filling port, safe flow-limiting device, LNG
vaporizer, regulator, pressure indicating device, etc., and its process is shown in the following figure:
water outlet
Circulating
Circulating
water inlet
Pressure
gauge
Filter disconnector Regulator

Discharge
Pressure
stabilizing tank
Enter the
pipe engine
LNG storage
cylinder
The outlet pressure may be set
Vaporizer within 0.3-1.2MPa
Figure 10.1
Essential conditions for air supply: The pressure in the LNG storage cylinder shall be always 0.2Mpa higher than the intake pressure required for the
engine. The outlet pressure setting of the pressure regulating valve on the air supply pipeline shall be 0.05-0.1Mpa higher than the intake pressure required
for the engine.
The pressure setting of our company’s MT07 series engine regulator is 0.55MPa, and the pressure setting of WT615 series engine regulator is 0.85MPa.
In order to keep the pressure in the cylinder higher than the engine intake pressure, we adopt a gas cylinder with the self-pressurization system:
For the gas cylinder with self-pressurization, the gas filling station does not regulate the temperature of LNG. The pressure of LNG saturated steam shall be
as low as possible, which can facilitate the storage of LNG, and reduce the venting loss of gas station. When the LNG is filled in the vehicle cylinder, it will
carry on self-pressurization until being 0.2Mpa higher than the engine intake pressure, and will carry on automatic pressure regulation. The normal operating
temperature of LNG cylinder is above -162℃. When the temperature of LNG is higher than -130℃, the self-pressurization system can be closed.
• The air supply process is as follows: After the LNG is delivered to the water-bath type vaporizer through the cylinder flow-limiting valve for being
vaporized into gaseous state, and its temperature rises, then its pressure will drop through regulator to the set value to enter the engine
• Supply air temperature control: Generally the required intake air temperature range of the engine is -20℃-40℃. If the intake air temperature is too high
or too low, the water intake of vaporizer hot water may be regulated.
Circulating water
inlet
Circulating water
outlet
Figure 10.2 LNG supply system flow chart

No. Code Name Function
1 V1 Vent valve (manual) Used for gas cylinder pressure relief
2 C2 Filling connector, aeration panel Used for connection of air-charging machine and
gas cylinder
3 V2 Liquid inlet check valve Used for controlling the entering of fuel in the
cylinder
4 V3 Manual stop valve Used for controlling the flowing of fuel out of the
cylinder
5 V4 Restrictor valve Prevent large leakage of fuel when the supply
pipeline fractures
6 V5 Saving valve Used for controlling the internal pressure of gas
cylinder
7 V6 Balance valve Balance the gas-liquid pressure in the tank
8 V7 Pressure stabilizing valve Control the air volume entering the engine
9 V8 Manual self-pressurization stop valve Self-pressurization switch valve in the cylinder
10 V9 Self-pressurization regulating valve Self-pressurization control valve in the cylinder
11 Pr2 Air temperature vaporizer Used for pressurization in the cylinder
12 Pr1 Water-bath vaporizer Change LNG into gaseous natural gas
13 LG Liquid-level meter Display the fuel level in the gas cylinder
14 Pg Pressure gauge Display the pressure in the gas cylinder
15 S1 Primary safety valve Use the pressure relief method to protect the gas
cylinder
16 S2 Secondary safety valve Use the pressure relief method to protect the gas
cylinder
17 Pressure stabilizing tank Maintain the engine air utilization requirements
Caution: The self-pressurization will not be used when the saturated pressure meets the engine air supply requirements, and the stop valve (V8)
shall be closed. The self-pressurization stop valve (V8) may be opened only when the saturated pressure fails to meet the engine air supply
requirements. The stop valve (V8) shall be also closed when the vehicle stops for more than 1o minutes.
(IV). Fuel filling

1. Initial filling
Generally the gas cylinder receiving the initial filling, stopping work for more than two weeks and receiving maintenance is called “hot cylinder”. For the filling
of hot cylinder, the liner temperature of gas cylinder must be cooled to the LNG temperature, which shall be carried on according to the following procedures:
(1) Confirm that the gas filling station or the vehicle installed with gas cylinder has been well earthed.
(2) Open the protective cap of low-temperature liquid inlet and air return joint.
(3) Visually check valve, joint, pipe of the gas cylinder to confirm there is no leakage and no missed component.
(4) Use dry nitrogen to purge (or use clean, dry cotton yarn to wipe) the low-temperature liquid inlet and air return joint to ensure no water, impurity.
(5) If needed, connect the reclaiming nozzle and air return joint, and screw the reclaiming nozzle of 90°.
(6) Confirm that the gas filling hose is matched with the low-temperature liquid inlet, and connect the gas filling hose and low-temperature liquid inlet.
(7) Open the gas filling station pump, and fill liquid in the gas cylinder. When the air-charging machine displays about 30L, stop filling.
(8) Open the gas cylinder vent valve to make the pressure drop to 0.3MPa, then close the vent valve.
Warning: When venting, the attention shall be paid to: The gas vented shall return to the big storage tank in the gas filling station or discharged
to a safe place.
(9) Let the gas cylinder cool for about 10 minutes, and during this period, the pressure of gas cylinder will rise.
(10) Observe the gas cylinder pressure gauge. If the gas cylinder pressure is high, the filling can be carried on only after venting, and the steps shall be in
accordance with the provisions of Paragraph 8 of this article.
(11) Reopen the gas filling station for filling until the air-charging machine stops automatically.
(12) Confirm that the vent valve (VV) has been closed, and dismantle the gas filling hose and reclaiming nozzle.
(13) Cover the protective cap of low-temperature liquid inlet and air return joint.
2. Conventional filling
The conventional filling means that for the gas cylinder normally used, its liner is in the low-temperature state and there is part of liquid when filling.
(1) Confirm that the gas filling station or the vehicle installed with gas cylinder has been well earthed.
(2) Open the protective cap of low-temperature liquid inlet and air return joint (C2).
(3) Visually check valve, joint, pipe of the gas cylinder to confirm there is no leakage and no missed component.
(4) Use dry nitrogen to purge (or use clean, dry cotton yarn to wipe) the low-temperature liquid inlet and air return joint to ensure no water, impurity.
(5) If needed, connect the reclaiming nozzle and air return joint, and screw the reclaiming nozzle of 90°.
(6) Confirm that the gas filling hose is matched with the low-temperature liquid inlet, and connect the gas filling hose and low-temperature liquid inlet.
(7) Observe the gas cylinder pressure gauge. If the gas cylinder pressure is high, the filling can be carried on only after venting. Open the gas cylinder vent
valve to make the pressure drop below the pressure required for air-charging machine, then close the vent valve (when venting, the attention shall be paid
to: the gas vented shall return to the big storage tank in the gas filling station or discharged to a safe place).
(8) Open the gas filling station pump for filling until the air-charging machine stops automatically.
(9) Confirm that the vent valve has been closed, and dismantle the gas filling hose and reclaiming nozzle.
(10) Cover the protective cap of low-temperature liquid inlet and air return joint.
Attention: 1) Before filling, observe whether the gas cylinder surface has the phenomenon of condensation or frosting. It is suggested that the
gas cylinder with such phenomenon should not be filled, and should be returned to the manufacturer for repair.
2) Check whether the gas cylinder has pressure. If the pressure is zero, carry on purging, air-tight test to the gas cylinder, then fill after being
qualified.
Warning: 1) Before filling liquid, check whether there is water, impurity in the low-temperature liquid inlet, and ensure that the water and impurity
has been fully cleaned up when filling liquid.
2) If there is water, when filling liquid, the water may rapidly condense into ice. The ice may block the feeding one-way valve, low-temperature
liquid inlet, and may even enter the cylinder. The blocking causes the low-temperature liquid inlet, feeding one-way valve cannot be closed
tightly, producing leakage, even causing damage to the sealing surface. If the ice enters the gas cylinder inside, it may be blocked at the
discharging one-way valve, causing obstruction of liquid supply, and making the engine have insufficient power, even failure to start.
3) If there is impurity, when filling liquid, the impurity may cause the feeding one-way valve, low-temperature cannot be closed tightly, and may
even cause damage to the sealing surface. Meanwhile, if the engine front end is not provided with a filter, the impurity may cause damage to the
engine.
Attention: For a fully filled gas cylinder, its pressure rises rapidly, which may cause the safety valve open. Therefore, the fully filled gas cylinder
must be used as early as possible, and the long-time storage is forbidden.
Warning: When venting to the atmosphere, the vented air shall be led to a safe place, otherwise the risks of fire and explosion may be caused.
(V). Fuel supply

1. Pressurization
The gas cylinder needs to be pressurized in the following circumstances:
(1) When the gas cylinder is initially used and the pressure is below the engine needs; (2) The gas cylinder is after the calibration of safety valve, pressure
gauge;
(3) The gas cylinder is repaired after venting; (4) The pressure set for the pressurization regulating valve is below the pressure required for engine.
2. Pressurization process
(1) Confirm the use valve and vent valve in the closed state; (2) Open the booster valve, and at this moment, the booster pipeline begins frosting.
(3) When the pressure reaches stable, and at this moment, the booster pipeline begins defrosting. If the pressure at this moment still cannot meet the engine
needs, the pressurization regulating valve needs to be adjusted. If the gas cylinder needs to supply liquid externally, it is not necessary to close the booster
valve.
3. On-line adjustment of pressurization regulating valve
Structure of pressurization regulating valve (as shown in Figure 10.3)
① Adjusting screw ①
②
② Locking nut ③
④
③ Nameplate ⑤
⑥
④ Valve cover ⑦
⑧
⑤ Spring upper pad ⑨
⑩ Gasket A
⑥ Spring A ⑪ Valve
body
⑦ Pressure ring ⑫ Valve
clack assembly Figure 10.3
⑧ Spring lower pad assemblies
⑬ Spring B
⑭ Washer
⑨ Plug ⑮ Plug
(1) Judgment of set value for the pressurization regulating valve
① If the booster coil does not frost, and the pressure of the gas cylinder pressure gauge does not change, with the progress of use, when the pressure drops
to a fixed value, the value displayed on the pressure gauge is the set value for economical valve, which means that the set pressure of pressurization
regulating valve is less than the value displayed on the gas cylinder pressure gauge at this moment.
② If the booster coils frosts, and the pressure of the gas cylinder pressure gauge raises gradually, this means that the set pressure for pressurization
regulating valve is more than the value displayed on the gas cylinder pressure gauge. With the progress of time, when the pressure rises to a fixed value, the
value displayed on the gas cylinder pressure gauge is the set value for pressurization regulating valve.
(2) Adjustment of pressurization regulating valve
Pressure adjusted to high
① Confirm the set value for pressurization regulating valve.
② Unscrew the ② locking nut, then screw the ① adjusting screw clockwise. When screwing, judge the required number of turns according to the difference
of actual value and set value of the pressurization regulating valve.
③ After screwing, the self-pressurization coil will frost, and the pressure of gas cylinder will rise. When observing that the pressure is stable or the frost of
self-pressurization coil becomes cellular or changes into water, the value displayed on the gas cylinder pressure gauge at this moment is the set value for
pressurization regulating valve.
④ If the pressure fails to reach the set value, repeat the above steps. When the pressure reaches the required value, tighten the ② locking nut.
Pressure adjusted to low
① Confirm the set value for pressurization regulating valve.
② Close the pressurization stop valve, then drop pressure to the required set value by using or venting.
③ Unscrew the ② locking nut, then screw the ① adjusting screw counterclockwise.
④ Then open the pressurization stop valve, and observe whether the pressure rises.
If it rises, repeat the above steps until the pressure reaches the required value.
⑤ Screw the ② locking nut.
Reminder: (1) The pressure for one turn increases / decreases by about 0.2MPa.
(2) When the pressurization regulating valve leaves the factory, the set pressure is 0.86MPa.
Attention: (1) It is suggested to screw 1/4-1/2 turn as criterion for every time when screwing.
(2) If the set value after adjustment is higher than the required set value, please carry on according to the steps for being adjusted to low, without screwing
back randomly.
4. Liquid output
(1) Confirm that the set value of pressurization regulating valve and the pressure of gas cylinder meet the engine needs.
(2) If the pressure of gas cylinder is over 0.3MPa higher than the engine pressure, carry on emission treatment to the gas cylinder.
(3) After the pressure of gas cylinder is 0.1MPa higher than the engine pressure, open the use valve slowly.
(4) After the engine is operating normally, the opening of use valve may be enlarged.
Reminder: If the pressure of gas cylinder is too high or the use valve is opened too fast initially, this may cause the restrictor valve off, and engine out.
(VI). Gas output

During the normal use, if the pressure of gas cylinder is higher than the set pressure of economical valve, the economical valve will be automatically opened.
Attention: Under the circumstance of normal supply, the vaporizer is supplied with liquid fuel. But when the economical valve is opened, it is the
gas-liquid two-phase hybrid fuel flow, and the gas occupies a larger proportion.
(VII). Adjustment of economical valve
Economical valve
adjustment flow chart
Part name:
① High-pressure nitrogen cylinder ② Depressurization regulating valve (common regulating valve for high
pressure gas cylinder) ③ Stop valve ④ Pressure gauge ⑤ Economical valve to be adjusted
Figure 10.4
1. Off-line adjustment
Debugging steps:
(1) Connect all valves according to the flow chart.
(2) Confirm all valves in the closed state, and confirm the adjusting screw of ⑤ economical valve to be adjusted in the fully loosened state.
(3) Open the high-pressure nitrogen cylinder valve slowly, then open the pressure of ③ stop valve for test, and check the leakage of pipeline.
(4) Open the high-pressure nitrogen cylinder valve, and adjust the outlet pressure of ② depressurization regulating valve to equal to the economical valve
pressure to be set.
Reminder: The economical valve pressure shall be 0.05MPa-0.1MPa higher than the pressure of pressurization regulating valve.
(5) Screw the economical valve adjusting screw clockwise until no gas produces from the economical valve outlet. At this moment, the pressure displayed on
the pressure gauge is the set pressure of economical valve.
2. On-line adjustment
During the on-line adjustment, firstly judge the set value of economical valve, then adjust the adjusting screw according to the pressure needing to be
adjusted.
(1) Unscrew the ② locking nut, then screw the ① adjusting screw counterclockwise / clockwise.
(2) When screwing the adjusting screw, the amplitude shall not be too large, and it is suggested to screw 1/4-1/2 turn as criterion.
(3) Screw the ② locking nut.
Reminder:
(1) The pressure for one turn increases / decreases by about 0.2MPa.
(2) When the pressurization regulating valve leaves the factory, the set pressure is 0.86MPa.
(3) It is suggested to choose the off-line adjustment method when adjusting.

(VIII). Daily maintenance
The gas cylinder user shall prepare a detailed maintenance plan, and shall implement as planned to ensure the gas cylinder safety in use.
1. Daily maintenance requirements
Maintenance content Maintenance interval Maintenance method Maintenance Date

time person
Connecting nut of gas cylinder and 15 days Screw the nut
bracket
Connecting nut on the gas cylinder Before the vehicle Visually check whether there is leakage
pipeline dispatching of each time
Vaporizer 6 months Clean the limescale on the coil
Valve Frequently Whether there are untight closing and
leakage
Safety valve 12 months Sent to local technical supervision
department for checking
Pressure gauge 12 months Sent to local technical supervision
department for checking
Vacuum degree of gas cylinder 12 months Pressure test
Leakage detecting Frequently Air-tight test or leakage detecting
2. Leakage detecting
A portable methane detector may be used to detect the natural gas leakage point of the gas system (it shall be correctly used in accordance with the
detector manufacturer’s instructions). To ensure the normal operations of vehicles, the system leakage detecting shall be carried on regularly, and any
leakage points found shall be immediately repaired. When it is difficult to judge the leakage points with the detector under some special conditions, the soap
solution may be used to detecting the leakage points.
3. Parts replacement
Any fuel leakage must be repaired once found:

If the pipe thread leaks, remove the connection, clean the connecting surface, and use Teflon tape for sealing.
If the pipe fitting leaks, dismantle it and check strictly. If the nut and sleeve appearance has no damage, use continuously, reinstall the pipeline and screw
the nut, finally make the pressure leak test.
In case of valve leakage, carry on in accordance with Valve Structure and Maintenance.
Warning: During the repair and replacement of valves, pipe threads and pipe fittings, the safety measures described in the requirements of Safety
Summary and Safety Protection must be met, otherwise personal injury may be caused.
4. Vacuum failure
Generally, with the vacuum failure, the gas cylinder may appear the phenomenon of cylinder body frosting or sharp pressure rise in the cylinder, etc. But for
a new cylinder or a gas cylinder unused for long time, as its liner temperature is high, the pressure also rises fast when filling liquid, and this phenomenon
should be normal.
The excessive pressure rise may be taken as one of the basis to judge the vacuum failure of gas cylinder. The gas cylinder shell is provide with a vacuum
plug, and in case of vacuum failure of the gas cylinder, the vacuum plug will become loose (normally, the vacuum plug is compressed tightly by atmospheric
pressure). In normal times, the vacuum plug outside is covered with a plastic protective cap. Do not open the protection cap or vacuum plug. When finding
the vacuum failure of gas cylinder, please send to the manufacturer for repair.
VIII. Central control system
Warning:
a) Keep the vehicle in good condition, and do not drive the defective vehicle!
b) When installing this control system, ensure that the circuit system is well earthed.
c) When operating, extremely avoid the hot plugging behavior.
When carrying on welding work on the vehicle or nearby, disconnect the battery power and unplug all electrical connectors, such as CBCU, electrical
junctions’ box, instrument, ECU of engine and ECU of ABS, etc.
(I). Overview of central control system
Combination instrument
Traffic detector
Menu knob
Information Informa
tion
Control 6 meters, all Used for menu
Travel speed, total odometer, time, control of LCD
indicators, LCD information
short mileage are sent to the
instrument through CAN through CAN
Off-line
Vehicle body central diagnosis
computer Read all fault codes
from controller and
program download
Start Vehicle electrical control
Others Gearbox Engine Light Windshield

wiper spray
All Sensor
system switches
Figure 11.1
The HOWO VDO bus control system structure chart is as shown in Figure 11.1, and the constituting components include vehicle body central computer
(CBCU), menu knob / switch, combination instrument (CMIC), travel detector (VDR) (optional).
The vehicle body central computer can be connected with other modules with the CAN communication function, such as power bus conforming to SAE-
J1939. The function of externally connected nodes can be extended according to the future loading need.
System advantages: The combination instrument can be controlled flexibly through the vehicle body central computer, all functions can be completed
through PLC programming, and the customer personalized requirements can be realized easily. The system has high reliability.
Operation cautions:
The charged assembly and disassembly of the instrument is strictly prohibited! Otherwise the instrument, wiring harness may be damaged (such as causing
the terminal burning, and causing the data loss).
 The sufficient protection must be provided for cable layout.
 The line on CBCU must be disconnected during welding, etc.
 Turning off the power switch is strictly prohibited during the engine operation.
 CBCU opening, flushing and measuring are strictly prohibited.
 The supply voltage must be kept within the range of operating voltage.
 Before the battery line is firmly connected, connecting power and starting engine are strictly prohibited.
 The battery electrolyte boiling is strictly prohibited.
 Touching the CBCU terminal with hand or other conductor is strictly prohibited.
 All operations that may produce too high instantaneous induction voltage due to load discharging are strictly prohibited.
 Pay attention to good earthing connection.

(II). Description of central control system function
1. When the vehicle is traveling (vehicle speed of more than 15km/h), if the cab door is not tightly closed, the buzzer will send high-frequency alarm for 30
seconds; meanwhile, the display screen flickers constantly, displaying “please shut the door”.
2. After the power master switch is connected, and when the key is not inserted, all pointers return to zero, and the driving screen flickers a time. The buzzer
will not chirp, and all indicator lights will not be lit.
3. After the 15# power supply is connected, all signal lights on the instrument will flicker, and the buzzer will chirp, about 1 second. After the engine start, D+
generation, when the ordinary alarm indicator light is lit, the buzzer will not alarm.
If any one of engine oil pressure alarm light, cab lock-up signal light, engine overspeed alarm (more than 2,500r/m), brake pressure 1 signal light, brake
pressure 2 signal light, brake pressure 3 signal light is lit, the buzzer will send high-frequency alarm continuously.
4. During the engine operation, turn off the 15# power supply, and the buzzer will send high-frequency alarm; meanwhile, the display screen will display
“please stop the engine”.
5. Description of safety belt alarm
A.14 on the central control unit (CBCU) is input terminal of the safety belt alarm signal. When the safety belt is not inserted well, there is earth signal input,
and after the safety belt is inserted well, the input terminal dangles.
a. After the 15# power supply is connected, if the safety belt has been inserted well, the safety belt lock-up signal light on the instrument panel will not be lit.
If the safety belt is not inserted well, the signal light will be always lit, and the buzzer will not alarm.
b. After the engine starts, if the safety belt is not inserted well, the signal light will be lit, and the buzzer will send low-frequency alarm for 6 seconds, then
stop. After the safety belt is inserted well, the signal light will be off, and meanwhile, the buzzer will stop alarming.
6. During the engine operation
If the safety belt is pulled out, the signal light will be lit, and meanwhile, the buzzer will have a 6-second low-frequency alarm reminder.
7. Description of air filter blocking alarm
After the 15# power supply is connected, if D.37 of the central control unit (CBCU) detects the air filter blocking alarm signal, this alarm light on the
combination instrument will be always lit until the key switch 15# is closed, then recheck after power-on. The buzzer will not alarm.
(III). New-type digital CAN instrument
The new-type digital CAN instrument is mainly composed of engine tachomerer, speedometer, barometer 1, barometer 2, fuel gauge, water thermometer,
information display panel, signal light and knob.
The combination instrument is connected with the vehicle body central computer, recorder through instrument bus (ICAN) to display traveling information,
error alarm, etc. of the vehicle, then the instrument will display directly on the dial after receiving these signals.
The combination instrument internally is set with a buzzer, and it can send alarm when the system fails. During steering or operation of the danger alarm
switch, the buzzer also beeps.
The instrument surface has a button used for zero clearing of trip distance.
No. Function No. Function

1 Speedometer 5 Trip distance zero-clearing button
2 Engine tachomerer 6 LCD
3 Engine water thermometer 7 Brake circuit 1 pressure gauge
4 Fuel gauge 8 Brake circuit 2 pressure gauge
Figure 11.2
(IV). Central control unit (CBCU)
Figure 11.3
1. Main tasks of central control unit (CBCU) are as follows:
 Through CAN port, receive, process and distribute data;
 Diagnosis function applicable to driver, owner, service personnel;
 Diagnosis port for the overall electrical network;
 Special gateway for CAN bus system;
 Input / output, error handling;
 Switch digital input and status signal;
 Frequency input;
 Sensor analog input;
 Input of multi-function selector switch;
 Output to incandescent light bulb and relay;
 Output of 8V, 5V power for sensor;
 Input and output error monitoring;
 Monitoring of CAN bus error information;
 KWP2000 port used between the vehicle body central computer and KIBES-32 software;
 Diagnosis information storage;
 Control instrument (CMIC), including the display content of LCD, etc.
2. Advantages of central control unit (CBCU):
 The KIBES-32 software may be adopted for flexible programming. KIBES-32 is a highly graphical software based on KIBES-32, and the product
developer may make the system programming simply.
 Without needing to change the CBCU source program, the programmer may realize all functions directly.
 The customer may realize the system integration.

 KIBES-32 platform is established with CAN, gateway, etc. function, thus, using CBCU, the function extension of future system can be realized easily.
 All functions of the instrument are completed through PLC programming, and the professional design to customers can be realized easily.
 The flexible configuration of all system within the port defined range can be realized.
Attention:
 The central computer shall be installed in the cab.
 The central computer shall not be operated in the inflammable and explosive environment.
The charged assembly and disassembly of central computer is extremely prohibited, otherwise the damage to the central control unit (CBCU) and wire
harness may be caused (such as causing the burning of terminal in the connector assembly, etc.).
(V). Electrical junction box assembly
The electrical junction box assembly integrates the relay, diode, safety, etc. used on the vehicle:
Fuse link clip
Spare safety plate
Figure 11.4
The definition of each component of the electrical junction box is as follows:
24 diod
Definition of electrical junction box assembly WG9716580021/1:
e
20: Diode K4: trailer K11 #
23 diod K6: electric K7: left K10: windscreen wiper
resistance K3: D+ left-position exhaust K1:PCV
e horn distant light interval
components light brake
K13: trailer
22 diod K9:15# power K12: K15: air K16: right K17:ECU15# power
right- K18: spare K2:ECU
e supply 1 working light horn distant light supply
position light
K19:15# K8: air-
21: dio
power supply Notes: K3, K17 are special 5-leg relay for ADR model conditioning
de
2 power supply
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18

5A 5A 15A 15A 10A 10A 10A 15A 15A 25A 10A 10A 2 O 10A 15A 5A 5A 2 OA
A
PC Rock Working Trailer Air Seat 15 # Elect Main Trail Left Righ PCV Windscr Trail Exha EC U1 ECU power
V er light K12 positio drye heati spar ric vehic er A dista t pow een er ust 7 leg K2
coil switc n light r ng e horn le AB BS nt dista er wiper sock brake
K1 h, K4, after after after K6 S light nt supp interval et K11
etc. K13 K9 K9 K9 Air K7 light ly K K10 pow
15 horn K16 1 er
powe K15
r
suppl
y
F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 F30 F31 F32 F33 F34 F35 F36
5A 5A 15A 15A 10A 5A 10A 10A 15A 15A 15A 20A 2 0A 2 0A 15A 15A 10A 25A
Main Trail Combinat Odome VDR CMI CMI Cigar CBC 图 11.5 CBC
CBC CBC CBC CBCU G 30# Key Interna Air-
vehic er A ion ter sen pow C C lighte U G1 U G U G U G U G 6 spar switc l conditionin
le AB BS switch sor er powe pow r 2 3 4 5 e h headli g power
S supp r er ght supply K8
ly suppl supp VDR
y ly casset
te
radio
Part III: Vehicle Maintenance
I. Maintenance category
According to different uses and service conditions of the vehicle, as well as the expected annual traveling mileage, the vehicle maintenance system is
divided into three classes:
Class I: The service condition is poor (cold or hot climate, high dust content, short-distance transportation, off-road use) or the annual vehicle traveling
mileage is less than 20,000km.
Class II: Short, medium-distance transportation, the annual vehicle traveling mileage is less than 60,000km.
Class III: Long-distance transportation, the annual vehicle traveling mileage is more than 60,000km.
(II). Interval mileage of routine inspection and maintenance
Table of interval mileage of routine vehicle inspection and maintenance under the various serious conditions (as shown in Table 1) Unit: 1,000km
Routi Routi Class Routi Routi Class Routi Routi Class Routi Routi Class
Class I Class I Class I Class I
Cate ne ne II ne ne III ne ne II ne ne IV
mainte mainte mainte mainte
gory inspe inspe mainte inspe inspe mainte inspe inspe mainte inspe inspe mainte
nance nance nance nance
ction ction nance ction ction nance ction ction nance ction ction nance
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160
I
165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320
II
330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480
490 500 510 520 530 540 550 560 570 580 590 600 610 620 630 640
15 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320
III
330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480
490 500 510 520 530 540 550 560 570 580 590 600 610 620 630 640
III. Daily maintenance items

1 Check the parking brake and foot brake.
2 Check the lighting and the service conditions (engine oil pressure, air reservoir pressure, air filter maintenance indicator light, charging indicator light, etc.)
of signal system and all kinds of indicator lights.
3 Check the tractor tire pressure and condition.

4 Check the engine oil, transmission hydraulic oil, cooling liquid and fuel level.
5 Check the steering hydraulic oil level, temperature.
6 Check the steering hydraulic oil temperature.
7 Check whether the tractor and trailer connecting device is in normal condition.
IV. Table of maintenance items of all classes
Initial Routine Class I Class II Class III Class IV

Engine
inspection inspection maintenance maintenance maintenance maintenance
Replace the engine oil (at least once every year) ※ ※ ※ ※ ※
Replace the filtering element of oil filter ※ Every time replace the engine oil
Check and adjust the valve clearance ※ ※ ※ ※
Check the opening pressure of oil nozzle ※
Replace the filtering element of fuel filter ※ ※ ※
Clean the rough filter of fuel pump ※ ※ ※
Check the cooling liquid volume and fill up ※ ※ ※ ※ ※ ※
Replace the cooling liquid Every 24 months
Fasten the cooling pipe clamp ※
Fasten the inlet pipe hose and flange connection ※ ※ ※ ※ ※
Check the air filter blocking alarm switch ※ ※ ※ ※
Clean the dust cup of air filter ※ ※ ※ ※ ※
Clean the main filtering element of air filter When the indicator light is on
Replace the main filtering element of air filter When the main filtering element is damaged
Replace the safety filtering element of air filter After cleaning the main filtering element for 5 times
Check and fasten the V-belt ※ ※ ※ ※ ※ ※
Check the booster bearing clearance ※ ※
Check the fuel injection pump ※
Adjust the idling speed ※
Check the connection and fixation of intercooler inlet pipe ※ ※ ※ ※ ※ ※
Transmission Please refer to the transmission accompanied data for inspection and adjustment of transmission part
Check the transmission hydraulic oil level ※ ※ ※
Replace the transmission lubricating oil (at least once every year) ※ ※ ※ ※
Check the connection and fixation of oil pipe from transmission to cooler ※ ※ ※ ※
Check the transmission oil thermometer operating condition ※ ※ ※ ※
Check the throttle sensor operating condition ※ ※ ※
Check the operating condition of the transmission fault indicator light ※ ※ ※ ※ ※
Transmission shaft
Refasten the transmission shaft bolt Retighten the transmission shaft bolt when it initially travels 1,200km, and after that, retighten the transmission shaft
bolt for every traveling of 3,000km.
Axle
Clean the ventilation device ※ ※ ※ ※
Check and adjust the hub bearing clearance Carry on during the first Class-2 maintenance
Check and adjust the bearing clearance Carry on during the first Class-2 maintenance
Replace the hub lubricating grease ※ ※
Cab
Check the wiper action ※ ※ ※ ※ ※ ※
Check oil level of the cab flip oil pump ※ ※ ※
Check the lifting cylinder installation condition ※ ※ ※ ※ ※
Check the operating condition of hydraulic lock and damper ※ ※ ※
Check the service condition of backdoor lock ※ ※ ※
Check the condition of front flip points ※ ※ ※
Chassis
Check the fixation of front axle damper ※ ※ ※ ※ ※
Check and adjust the clearance of the steel plate spring side baffle ※ ※ ※
Fasten the front, rear steel plate spring U-shape bolt and bracket ※ ※ ※ ※
Check the tire pressure ※ ※
Check the fixation of traction gear ※ ※ ※ ※ ※
Check the fixation of wheel nut ※ ※ ※ ※ ※
Check the fixation of battery, air reservoir ※ ※ ※
Check the fixation of fuel tank ※ ※ ※ ※
Check the fixation of fender board ※ ※ ※ ※
Brake system
Drain water from the air reservoir ※ ※ ※ ※ ※ ※
Check the pressure system tightness (barometer inspection) ※ ※ ※ ※ ※
Clean the filtering screen of pressure regulating valve of the dryer ※ ※ ※
Check the thickness of brake friction disc, and adjust the brake clearance ※ ※ ※
Clean the wheel brake ※ ※
Check the easily abraded part of brake pipeline and hose ※ ※ ※ ※
Check the function of brake chamber ※ ※ ※ ※
Check the function of foot brake, hand brake and exhaust brake (carry on during test run) ※ ※ ※ ※ ※

Electrical
Check the operation condition of the electrical system (signal light, headlight, width light, wiper, heating and ventilation device) of tractor and trailer ※ ※
※ ※ ※ ※
Check the liquid level and proportion of battery electrolyte as well as the voltage of each battery cell ※ ※ ※ ※ ※
Check the fixation of battery terminal, and apply lubricating grease on the electrode ※ ※ ※ ※ ※
Check the correctness of electronic tachometer speed ※ ※ ※ ※ ※ ※
Check the correctness of speedometer speed ※ ※ ※ ※ ※ ※
Steering system
Check and adjust the positioning of front wheel ※
Check the oil level height of steering oil tank ※ ※ ※ ※ ※
Replace the oil filer of steering oil tank ※ ※
Check the connection of steering oil pipe ※
Check the fixation of steering oil pipe ※
Check the function of steering system ※ ※
Saddle lifting system
Check the leakage condition of hydraulic pipe connector Once every day
Check the leakage condition of hydraulic cylinder Twice every week
Check or replace the gooseneck front supporting pad Once every half a year
Check the leakage condition of control unit bank Twice every week
Carry on the anti-rust state inspection to the cab for every 12 months, and if necessary, carry on the anti-rust supplementing treatment.
V. Assembly oil-changing interval mileage
Category Engine Transmission Rear axle Steering system Cab lifting system Remarks
Initial inspection ※ ※ ※ ※ ※
Routine inspection ※
Class I maintenance ※
The initial
Class II maintenance ※ ※ ※ ※ ※ inspection is
after the engine
Class III maintenance ※ ※ ※ ※ ※ operating
※ ※ ※ ※ ※ reaches 100h
Class IV maintenance
VI. Lubricating grease lubrication points No Plac
Lubrication part Usage Period Remarks
. es
(I). Lubrication part, usage, period
1 Engine water pump 1 120g Once every 400h
2 Steering master pin 2 As needed Once every 400h
3 Cab damper 3 As needed Once every month
4 Cab hydraulic lock 1 As needed Once every month
5 Cab flip shaft 2 As needed Once every month

h: Engine motorcycle calculated in hour / hour
6 Front axle brake arm 2 As needed Once every 400h
Notes: After the vehicle cleaning, all lubrication points shall
be refilled with lubricating grease. Front axle brake
7 2 As needed Once every 400h
camshaft
Drive axle brake
8 2 As needed Once every 400h
camshaft
Once every half a
9 Cab door hinge 4 As needed
year
Front suspension pin At least once every
10 6 As needed
shaft month
11 Transmission shaft 3 As needed Once every month
Front suspension At least once every
12 2 As needed
damper week
At least once every
13 Hub Each 600g
year
Contact
Traction seat surface
14 1 As needed
junction surface fully
applied
Swing arm rotating
15 2 As needed
point
Cast steel traction
16 2 As needed
seat rotating shaft
Traction seat lifting
17 4 As needed
cylinder
(II). Lubrication point distribution diagram
2.1 4×2 model lubrication point distribution diagram
Swing arm
rotating shaft
Drive axle center

Front axle center
Cab flip shaft
line
line Gearbox
Plate spring Damper Transmission

Brake adjusting arm
Swing arm rotating
pin Brake adjusting shaft
shaft
Engine water arm Hydraulic cylinder
pump shaft Brake adjusting trunnion
arm shaft Traction seat shaft
Steering
master pin
Steering tie
rod
Part IV: Appendixes
(I). Braking schematic diagram
4X2
1. Barometer 2. Brake master valve 3. Air horn 4. Push button valve 5. Hand brake valve 6. Front axle brake chamber 7. Air compressor 8. Main
intake pipe 9. Spiral pipe 10. Trailer connector 11. Fuel cut-off cylinder 12. Air reservoir 13. Traction seat unlocking cylinder 14. Dual-chamber brake
chamber 15. Hand brake relay valve 16. Air reservoir 17. Foot brake relay valve 18. Air reservoir 19. Four circuit protection valve 20. Dryer 21.
Butterfly valve switch cylinder 22. Trailer brake valve 23. Shut-off valve
6X4
1. Barometer 2. Brake master valve 3. Air horn 4. Hand brake valve 5. Front axle brake chamber 6. Air compressor 7. Main intake pipe 8. Spiral
pipe 9. Trailer connector 10. Fuel cut-off cylinder 11. Solenoid valve 12. Air reservoir 13. Differential lock 14. Dual-chamber brake chamber 15.
Hand brake relay valve 16. Air reservoir 17. Foot brake relay valve 18. Air reservoir 19. Four circuit protection valve 20. Dryer 21. Butterfly valve
switch cylinder 22. Trailer brake valve 23. Shut-off valve
(II). Steel plate spring specifications
Model Drive type Position Specification (pieces × thickness × width) mm Remarks

Front 4×22×90
4×2
Rear (9×18×100) +(6×16×100)
Riveted frame
Front 9×16×90
6X4
Rear 12×22×90 Main spring of 4 pieces
Front 9×13×90
4×2
Rear Rigid suspension
Welded frame
Front 9×13×88
6X4
Rear Rigid suspension
Material 50CrVA Generally used for all models
(III). Service data of commonly used vehicles
Assembly Oil product Designation Capacity

Condensation point in
GB252 top-grade No. 0 light diesel
summer0C
Fuel tank Diesel 230L
Condensation point in
GB252 top-grade - No. 20 light diesel
winter-20C
Cooling WD(T)615 Heavy-duty four-season lasting anti-freezing solution 40L

Cooling liquid
system MC(T)07 -35℃ working solution, I type Q/ZZ21007(BASF G48-24-35℃) 25-30L
ZF S6-120 Heavy-duty vehicle gear oil 85W/90 GL-5 11L
Transmissio Allison Allison transmission special oil TranSyndTM 27L
n
Shuangte transmission special
Shuangte Dexron IIIH 28L
transmission fluid
Mechanical ATFⅢ automatic steering fluid
5L
Steering steering
Steering fluid
system Fully hydraulic 46＃ anti-wear hydraulic oil
20L
steering
Saddle lifting system Hydraulic oil 46＃ anti-wear hydraulic oil 40L
Cab flip mechanism Hydraulic oil No. 10 aviation hydraulic oil 0．4L
Clutch Brake fluid DOT3 About 1L
Main reducer Heavy-duty vehicle gear oil 85W/140 GL-5 6.3L
Drive axle
Wheel reducer Heavy-duty vehicle gear oil 85W/140 GL-5 2.4L (each side)
PR70 power take-off Heavy-duty vehicle gear oil 85W/140 GL-5 1.5L
(IV). Table of tire pressure parameters
Model Single tire (KPa) Double tire (KPa)

11.00-20 (Level-18) 910 840
12.00-20 (Level-18) 810 740
12.00-24 (Level-18) 810 740
11.00R20 (Level-18) 930
12.00R20 (Level-18) 830
12.00R24 (Level-18) 830
11R22.5 (Level-16) 830
12R22.5 (Level-16) 830
315/80R22.5 (Level-18) 830
295/80R22.5 (Level-16) 830
425/65R22.5 (Level-18) 760
(V). Table of wheel parameters
Model 8.00V-20 8.5-20 8.5-24 22.5×8.25 22.5×9.00 22.5×12.25

Rim type Two-piece type Two-piece type Two-piece type One-piece type One-piece type One-piece type
12R22.5
Tire 11.00-20/ 12.00-20/ 12.00-24/
11R22.5 315/80R22.5 425/65R22.5
specification 11.00R20 12.00R20 12.00R24
295/80R22.5
(VI). Main structure description
1. Engine: Special engine of Sino Truck.
2. Front axle: Fist-type I-shape special rigid front axle, drum brake.
3. Rear axle: Steyr punching reinforced center, wheel rim two-stage reduction rear axle, total speed ratio of 10.77.
4. Suspension: The front suspension of riveted frame model is a vertical steel plate spring belt drum-type damper, and the rear suspension is a primary,
secondary steel plate spring suspension.
The front suspension of welded frame model is a vertical steel plate spring belt drum-type damper, and the rear is a rigid suspension.
5. Steering system: The welded frame model is mechanical steering, and the diameter of steering wheel is 420mm.
6. Clutch: Single-piece dry type, hydraulic gas control type, 420, it is a periphery mounted spiral spring.
7. Brake system: WABCO brake system, it adopts the Germany’s VOSS quick connector.
8. Electrical equipment: Single-wire system, 24V, negative earth; 2×12V/165Ah battery, headlight, left, right front turning light, front fog light, width light, brake
light, back-up light, interior light, reversing light, combination instrument, transmission oil thermometer (automatic transmission accessory), transmission fault
indicator light (automatic transmission accessory), reserved 24V wireless terminal equipment spare power cord (such as connection of the attached
transformer, variable pressure of 12V), 24V power supply socket.
9. Cab: The cab is a skeleton covering structure, and adopts the VDO electrical system of Sino Truck.

Use and Maintenance Manual For HOVA Series Internal Combustion Towing Tractor

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Use and Maintenance Manual For HOVA Series Internal Combustion Towing Tractor

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Prompt: before the tractor comes into use, please read the Manual carefully and keep it properly

for looking up at any time.

VIN Name Engine No.

I. External devices of the cab

Warning: do not drive before close the door!

Figure 1.7 Figure 1.8

Figure 1.9 Figure 1.10 Figure 1.11

Figure 1.12 Figure 1.13 Figure 1.14 Figure 1.15

No. Name Remarks No. Name Remarks

Signal switch and function (excluding rocker switch):

28 ECAS1 Switch on (equivalent to shell overlapping) means the function is enabled

No Statu Function Remarks

Engine diagnostic 0 Function closed

2. Key start switch (Figure 2.4 and 2.5)

Turning position Usage Remarks

Left steering Right steering

Figure 2.4 Figure 2.5

Light switch Overtaking

Figure 2.7 Figure 2.8

0—Closed position J-- Wiper intermittent gear

I-- Wiper slow gear II-- Wiper fast gear

Press -- windshield washing system.

Figure 2.10 Figure 2.11 Figure 2.12

Figure 2.13 Figure 2.14 Figure 2.15

1. Operation of front fog lamp

The light switch is in gear 1;

(3) . Turn off the interior lighting switch

Put the switch on the interior light in neutral position.

1. Air suspension seat

Seat width: 500mm 4 3

Seat height: 865mm (maximum)

Height adjustment: 7 gears within the range of 0 - 65mm

Forward and backward adjustment: 5 gears within the range of 0 - ±75mm

1) Adjustment of backrest elevation

2) Adjustment of rear-end height

3) Adjustment of rear-end height

4) Adjustment of anteroposterior position

5) Height locking handle

(2) Reverse gear switch (press Button R)

(3) Neutral gear switch (press Button N) R- Reverse

In power mode, the display screen will display “MODE”.

or goes up the slope, or is supercharged.

Entry mode: press both upshift button ↑ or downshift ↓;

Conditions for oil level check:

① The tractor is parked on level road;

② The engine is in idle running state;

③ The gearbox is in neutral gear state; O L O K Normal oil level

④ The rotational speed of output shaft is zero;

⑤ Tense the parking brake; Oil level is 2 quarts lower than

Figure 2.20 Figure 2.21

(X). Unlocking control button of traction seat

Note: please don’t press on driving.

Single-stage double-acting cylinder (lifting height of 405);

Double-stage double-acting cylinder (lifting height of 705);

Double-stage single-acting cylinder (lifting height of 705);

2. Unfasten the seatbelt

3. Seatbelt alarm description

3. Precautions for use

3.1. Please maintain the air conditioning system regular.

Figure 2.28 Figure 2.29

(I). Routine check before driving every time

2. Check the working condition of entire circuitry (self-test of system)