manual_de_servicio_faw_ca4df2-13.pdf

Operation Manual
Model: CA5083XXYPK2L1A80
Cab-over-engine Diesel Truck
Brief manual
Forward
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Welcome to choose FAW Truck
FAW model CA5083XXYPK2L1A80, cab-over-engine cabin truck is a new product
developed by FAW, metal and cab-over engine type cabin, CA6-75 mechanical gearbox,
CA4DF2-13 diesel engine, turbo charging, intercooler, Euro-2 emission. The truck has the
advantage of high performance and low fuel consumption.
For better drive and maintenance of this truck, this manual introduces the detail of
operation, maintenance, adjustment and trouble shooting. Please carefully read this book to
master the driving method to operate the truck properly, to prolong the service life to make
maximum profit.
All of the contents of this manual are latest. The reprint version will contain the changed
content.
The copyright of this manual belongs to FAW. Without permit, any person or unit can’t
duplicate it.
Wish you a pleasant journey!
China FAW Group Imp. & Exp. Corporation
January, 2006

Brief manual
Content
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Vehicle identification·
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Brief technical properties·
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Fuel, lubricating oil·
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Operation mechanism·
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Indicator lights and instruments·
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Switch, button and handle ·
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Correct operation·
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Correct drive·
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New vehicle running-in·
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Regular maintenance·
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·57
Maintenance and adjustment of main assemblies·
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·67
Replacing lubricating oil·
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Lubrication table·
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Emergency treatment·
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Fault causes and solution·
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Main bolt and nut tightening torque·
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Bearing table·
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Oil seal table·
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Brief manual
Outline diagram
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Brief manual
Forward
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1
Vehicle identification
China FAW Group Corporation
Vehicle type CA
Engine type Load kg
Engine power kW TW kg
Chassis number
Engine number
Date of manufacture Y. m. d.
Vehicle model Engine model Loads Gross weight
CA5083XXYPK2L1A80 CA4DF2-13 3570 8200
●Vehicle nameplate lie in outside and middle of right longitudinal beam.
Engine parameters
Engine model
Max.power/rotation
speed kW/(r/min)
Max. torque/rotation
speed N·m(r/min)
Min.fuel
consumption rate
g/kW·h)
CA4DF2-13 96(2500r/min) 390/( 1400-1600r/min) 208
Brief manual
Brief technical properties
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2
车型 CA5083XXYPK2LIA80
General parameters
Chassis curb weight kg 3735
Chassis gross weight kg 8200
Front kg 2150
Gross axle weight (chassis)
Rear kg 1585
Front kg 2700
Gross axle weight
(Full-load) Rear kg 5500
Length mm 7557
Width mm 2385
Overall Dimensions
(chassis)
Height mm 2725(no load)
wheel base (full-load) mm 4250
front mm 1800
Wheel track
rear mm 1740
Front suspension (full-load) mm 1232
Rear suspension (full-load) mm 2075
Distance between cab back and rear axle
center (full-load)
mm 3600
Distance between body geometrical center
and rear axle center (full-load)
mm 3200
Length mm 5400
Width mm 2284
Inner body dimensions
Height mm 600
Min. Ground clearance (full-load) mm 220
Vehicle (full-load) Approach angle 22°

Brief manual
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3
Vehicle (full-load)Departure angle 15°
Camber 1°
Inclination 6°
Front wheel alignment
Caster 1°30＇
Toe-in mm 2～6
Min. turning diameter (by front outside
wheel trace center)
m 17.8
Max turning angle of front inside wheel 40°
dynamic mm 412.5
Wheel radius(full load)
static mm 407
Top speed km/h 90.5
Max. Grade ability % 28
60km/h m ≤36.7
Brake distance(load)
40km/h m ≤33.8
Parking brake on slope(5min) % 18
Fuel consumption L/100km 20
Max. continuous running mileage km 700
Max Noise from outside of vehicle when
accelerating running
dB(A) 83
Minimum speed (high shifting gear) km/h 28
Capacity parameters
fuel tank L 150
Brief manual
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4
Cooling system L
25 (no heater)
26 (Include heater)
Lubricating system (including engine oil
filter and engine oil cooler)
L 14
Gear box oil volume L
8.3（without PTO）
9 （With PTO）
Rear axle oil volume L Around 3.5
Power steering gear and reservoir L Around 3
Shock absorber (each) L 0.74
Clutch hydraulic control mechanism L Around 0.4
Adjustment parameters
intake mm 0.30
Valve clearance (cooling state)
exhaust mm 0.35
Fan belt tension (plus 78N) mm 10-15
Normal temperature of engine coolant 75-95°
Free traveling of clutch pedal mm 35-45
Total traveling of clutch pedal mm 180
Air pressure of brake kPa 784-833
front mm 25±10
Brake chamber push-rod space
rear mm 30±10
Clearance between brake drum and brake
hoof-plate of running brake (measure the middle
shoe plate at brake drum inspect hole)
mm 0.6-0.1
Front wheel kPa 560
Tire pressure
Rear wheel and spare wheel kPa 670

Brief manual
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5
Brief description of structure
Engine
Model CA4DF2-13
Type In-line six-cylinder, four-stroke, water-cooled,
turbocharger, central-cooled, direct-injection
Compression ratio 16.8
Cylinder replacement 4.751 L
Max. torque 390 N·m（at 1400 r/min）
Max. power 96 kW(at 2300 r/min)
Piston space 125mm
Cylinder diameter 110mm
Min. fuel consumption 208 g/(kW·h)
Cylinder ignition
sequence
1-3-4-2
Fuel supply advance angle before upper dead-point 9±1°
Cooling system Pipe radiator, centrifugal water pump, wax temperature
regulator, plastic fan and silicon oil fan clutch, with dilator
Fuel injection bump P7100
Fuel injector P model, 6 spouts
Governor Full speed controller
Fuel delivery pump KS plunger model, fuel delivery pressure is156.8kPa
Fuel filter Double-level rotation type, paper filter’s core (model is
X0710A)
Air cleaner The filter is dry paper filter’s core with safe filter’s core
Clutch φ350
Transmission CA6-75 mechanical transmission, 6 forward gear, 1 reverse
gear,
Brief manual
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6
Gears speed rate
Gear 1
Gear 2
Gear 3
Gear 4
Gear 5
Gear 6
Reverse gear
Over speed gear
6.515
3.796
2.284
1.428
1
0.815
6.060
propeller shaft Open, 2 piece, with 3 universal joints
Rear axle deceleration ratio is 5.43
Frame Boundary beam pressing riveted structure. Longitudinal
beam front is variable section, middle and rear are straight
sections, max. section size is (section height× wing width ×
plate thickness) 237mm × 75mm × 7mm, and longitudinal
beam is infrastructure board connection structure; there are
hooks at front and rear frame.
Suspension Front and rear leaf springs are both longitudinal symmetrical
semi-ellipse leaf spring structure. Rear end is flying rings
structure, front suspension is installed with φ50mm
bidirectional sleeve shock absorber, and rear suspension with
auxiliary plate spring .
Structure parameters Action length(mm)×width(mm)×height(mm)
－ leaf spring number
Front spring 1350×76×11-2 1350×76×10-5
Rear spring 1475×76×11-10
Rear auxiliary spring 1170×76×14-3
Plate spring center space
Front spring
830 mm
Rear spring 1004 mm

Brief manual
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7
Front axle Integral forging forming.
Spare tire riser Catenary “one gear differential” structure, transmission ratio
is 17, it mounted at lower part of frame behind rear axle.
Wheel Rim is 8.25-16 model,
Steering gear Cycle integral power steering gear, gear ratio is 20.48
Braking system Adopt front and rear independent two-way pneumatic brake
system, braking valve is straight-step double-cavity piston
series valve. Equipped with four-loop protection valve,
fast-release valve, relay valve, and exhaust braking valve.
Air compressor Single-cylinder water-cooled type
Running brake Front and rear brakes are all pneumatic drum ones
Parking brake Adopting spring energy-storage braking cylinder,
controlled by manual braking valve, acting on rear driving
wheels; Parking braking system is equipped with fast-release
valve.
Auxiliary braking Engine exhaust braking, engine exhaust braking valve and
control cylinder is equipped in silencer inlet pipe,
electromagnetic valve pneumatic control
Air reservoir The main gasholder is integral double-cavity type (the front
cavity volume is 17L, it is used for front braking; its rear
cavity 23L is used for rear wheel braking. There is a
single-cavity gasholder with 20 L, used for separator water.
Electric system 24V, cathode wire tapping
Battery 6-QAW-120D, two in series
Generator Magnetic field outside wire tapping, silicon rectifier AC
generator, with neutral-point tap, voltage is 28V, electricity is
55A.
Starter Electromagnetism control, max. output power is 6kW
Brief manual
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8
Other electric equipment Heater motor is 24V permanent magnetism, output power is
85W. Wiper motor is permanent magnetism double-speed
DC motor, equipped with combination instrument,
combination switch and warning system linking steering
wheel. Circuit protection system consists of two pieces of
fusible wire and 18-plates fuse box. Circuit control system
consists of 8 relays. Combination switch consists of 8
switches, and set the automatic return unit of turning switch,
and starting switch has the anti-theft mechanism and stop
unit of self-lock steering wheel.
Vehicle body
and accessories
Cab is forward metal closed type, adopts panorama and
curving surface windshield; and equipped with torsion bar
spring booster switching mechanism and safeguard by safety
hook. The interior is equipped with high backrest driver seat
with multiple functions, passenger seat with adjustable
backrest angle, with safety belt. With three-gear electric
wiper; single-arm glass regulator, card type door lock;
windshield syringe, plastic carpet, large sphere rear-view
mirror, air mixed heating system and multi-point injection
defroster, and second-level pedal mechanism, as well as new
headlights, front small light and side turning light. Select
electric door and window.

Operation manual
Fuel and lubricating oil
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9
Fuel
●Must use good quality diesel fuel .
●The user should select proper diesel fuel according to local temperature condition,
in compliance with following.
Air temperature above 0℃ 0－ -10℃ -10 －-20℃ -20－-35℃
Diesel fuel type No.0 No.-10 No. –20 No.-35
●The fuel filled when new vehicle leaves the factory is:
Summer: GB252 grade one No. 0 light diesel
Winter: GB252 grade one No. –35 light diesel
★If the diesel is mixed with fuel such as gasoline and alcohol, fire may occur, so
this case should be avoided absolutely.
Operation manual
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10
Caution
★ Before filling fuel, stop running first, and pay attention to whether there is open
flame, to prevent unexpected thing occurrence.
★ Diesel fuel must be deposited at least 48 hours before it is filled into fuel tank,
not including any impurity and water.
★ The filling container must be clean, preventing dust and impurity from entering
it.
★ Do not fill diesel when engine is running, not spattered diesel outside.

Operation manual
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11
Lubricating oil
● Lubricating oil can be filled into diesel engine after filtering( see on picture) .
● The diesel engine series vehicle type is exhaust-driven supercharger and central
refrigeration turbine diesel, must select engine oil above grade CD.
● Lubricating oil viscosity is influenced greatly by temperature, lubricating oil
should be select according to the stipulation of national standard(GB11122),
based on local temperature.
● If local temperature overstep the utmost, it only start capability but damaged
diesel engine.
● Engine oil must keep clean, not be polluted by dust and impurity.
● The lubricating oil filled when new vehicle leaves the factory is:
General areas whole year: 15W/40 CD(-20℃－ 40℃) grade diesel engine oil.
Summer (south areas): 40CD(0℃－40℃) grade diesel engine oil.
Winter (cold areas):5W/30CD(-30℃－40℃) grade diesel engine oil.
Operation manual
Symbol indication
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12
Symbol indication
Turning symbol Battery charge condition Engine oil pressure
warning
Braking system trouble Parking brake Master switch for
lights
Leg space ventilation
Master power switch
e
Electric and pneumatic
horn conversion switch
Fuel Coolant temperature Cigar lighter Exhaust braking Heating
Cab toplight Differential lock Windshield wiper Working light Engine preheating Vehicle door Cab tilting
Reversing light Lights and lanterns Filter block ABS ADM Fog lamp
Danger signal Parking light Windshield defrost and
defog
Power takeoff indicator
light
Contour light High beam light

Operation manual
Control mechanism
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13
Control mechanism
1-steering wheel 2-turning switch, light switch 3-instrument cluster 4-fog
light switch 5-starting switch 6-wiper switch, washer switch, exhaust brake
switch, danger warning switch 7-air conditioner switch 8- cigar lighter 9-
ashtray 10-heating control lever 11-manual valve 12-gear control lever
13-accelerograph pedal 14-braking pedal 15-clutch pedal 16-glass regulator
handle 17-door lock inside handle 18-steering wheel lock handle 19-horn
button 20-clutch oil tank
Operation manual
Control mechanism
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14
1-voltage meter 2-air pressure meter 3-fuel gauge 4-water temperature meter
5-oil pressure meter 6-warning indication lamp 7-speedometer 8-engine
revolution meter 9-rear fog switch 10-pre-heat button 11-windshiel washer
switch 12-wipper switch , exhaust brake switch and danger warning switch
13-lock knob of ignition switch 14-ignition switch 15-lock handle for steering
wheel 16-horn button 17-light switch, turning light switch 18-front fog light
switch

Operation manual
Indicator lights and instruments
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15
Parking braking indicator light
● The light comes on when parking braking valve (i.e. manual valve) is at braking
position, which remind the driver turn the parking braking valve back the
front( ravel parking braking) in time when the vehicle starts to run; and the light
goes off when fast-release valve pressure reaches 392kPa.
Power indicator light
● Indicate the charging state of generator. The light comes on when the engine
begin starting, showing it has been charged; if the light comes on when the
vehicle is running, it is necessary to check whether the power supply system
trouble occurs.
★ Check whether V-belt has breakdown and V-belt tension is normal.
★ Check whether high current fuse of charged circuit is blown out; if it has been
blown out, replace it.
★ If there is no abnormal in the above two items of check, which shows the
charging system has trouble, remove it in time.
Braking system trouble warning light
★ After brake warning light comes on, braking effect decline obviously, extremely
danger, the vehicle cannot continue running absolutely. If the braking system has
air leakage, the brake shall lose its action.
● When pneumatic braking system has trouble or pipe has air leakage, gasholder
pressure drops to 441kPa, the warning light comes on. When running if the light
is bright, must stop vehicle to check, after the trouble is removed, it can run.
Operation manual
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16
☆ Run the engine in middle rotary speed, until the warning light goes out.
☆ Check whether the match pipes and pipe joint of all sections has air leakage.
☆ If the warning light does not go out, or it comes on soon after it goes out, the
braking system should be repaired.
Start preheating indicator light.
● When starting engine, after starting switch switching in ON gear, press starting
preheating button, the preheating indicator light comes on; release the button,
relieve preheating, the indicator light goes out, preheating system finishes work.
Engine oil pressure and engine oil filter warning light
● When the key switches in power, oil pressure indicator light comes on. After the
engine starts, the indicator light goes out.
● When the engine oil pressure drops to 60±5kPa, the light is comes on. If the light
comes on when running, which shows that the engine oil is deficient or engine
filter is crammed, at that time, must stop vehicle to check, and drive it after the
trouble is removed.
● When it is cold, the warning light still comes on temporarily after the engine
starts sometimes due to the engine oil viscosity rising, this phenomenon is not
abnormal.
● If the light comes on when the engine is running, the vehicle should be parked on
safe place to check.
☆ Check engine oil level, if it is deficient, complement.
☆ Check all section of the engine to see whether there is oil leakage.
☆ The oil level is normal and there is no oil leakages, showing that lubricating
system has trouble, remove it.

Operation manual
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17
Cooling water level/engine over-hot warning light
● When engine coolant is deficient or the engine is over-hot, the warning light
comes on.
● Don’t ignore the warning light; Otherwise the engine temperature rises
excessively, to lead to sinter.
● If the warning light comes on, and water thermometer hand get outside of the red
area, showing that the engine is over-hot, the following operation should be done.
☆ Operate the engine at the rotational speed slightly higher than idle speed, to make
the engine temperature drop.
● If the warning light comes on, but the water thermometer is in normal position,
showing that the coolant is deficient, the following check should be carried out.
☆ Stop the engine until the coolant temperature drops.
☆ Check whether radiator and its match pipe have water leakage.
☆ Open radiator water tank cap, and fill coolant fully.
☆ If finding water leakage, go to garage to repair.
Caution
★ Dilator cap can be reopened until the water temperature drops. When open the
cap, cover it with cloth, slowly unscrew to the first stop, after pressure relief, and
open the pressure cap, to avoid hot water erupting to cause scald.
Operation manual
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18
Air pressure meter
★ Air pressure meter is double-hand type.
● The upper hand indicates the front cavity air pressure of air holder, the front
cavity air is used for front wheel braking.
● The lower hand indicates the rear cavity air pressure of air holder, the rear cavity
air is used for rear wheel braking.
● When vehicle is running, braking air
pressure must keep in the range of
784-833kPa.
Speed odometer
a－indicate vehicle running speed
b－indicate vehicle cumulate total
running mileage
●During the wear away period (2500km),
Max. Speed does not exceed 60km/h.

Operation manual
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19
Fuel gauge
● Indicate the fuel level in fuel tank.
0: show no fuel in the fuel tank.
1: show full fuel in the fuel tank.
★ After close starting switch, the hand still indicates the fuel level in the fuel tank.
● Fuel tanks volume is 300L, this is equipped with conceived fuel tank.
● Continuous running mileage of vehicle is 1000km.
Water thermometer
● Water thermometer indicates engine coolant temperature, scale 110 expresses
high temperature, 50 low temperature, 110-50 expresses normal temperature..
● After the engine is cold started each time, it is necessary to run at low speed to
preheat rising temperature, until the coolant temperature reaches above 50℃, it
can start to run.
● In running, observe carefully water temperature, to make coolant temperature
keep 75-95℃(about at the middle of both scales).
● If the hand is outside of scale 110, it shows that the engine is getting over heat, it
is necessary to stop to check, remove the trouble.
● In normal operation circumstance, radiator curtain is fully open, temperature
controller and fan clutch shall automatically adjust coolant temperature, to make
it at optimal working temperature. When it is particularly cold, lower the radiator
curtain to adjust coolant temperature.
Operation manual
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20
Voltmeter
● Voltmeter reading range is 0-32V. 16-24V and 30-32V are red area, normal
voltage is at middle position.
Engine oil pressure meter
★ Indicate the working pressure of lubricating oil in main oil-way of engine.
● After the engine starts, it is necessary to check engine oil pressure.
● Scale 6 expresses high pressure, 0 expresses low pressure.
◆ In running, often observe engine oil pressure. When the engine runs normally, if
the hand of engine oil pressure meter is 0－6, the pressure is normal. If the
engine oil pressure is over low, the hand does not move or the hand moves
suddenly, must be stop vehicle to check, to prevent parts from burning out. When
the engine is working, the engine oil pressure does not lower than 100kPa.

Operation manual
Switch, button and handle
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21
Combination switch
★ Combination switch includes: light switch, change lights switch, turning signal
switch, wiper switch, washer switch and danger warning switch.
Left handle (light switch, turning signal switch)
★ This switches control lever, at left side of turning column
High beam and low beam conversion
Overtaking dimming
Operation manual
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22
Light switch
◆ To turn the knob at the end of left handle, to make the handle be at OFF
position, turn off all light.
◆ When the left handle turns to position, front and rear small lamps,
instrument light and rear license plate light come on.
◇ Raise the handle, high beam and low beam of headlight comes on
simultaneously, giving overtaking signal; after releasing it, headlight goes off.
◆ When the left handle is turned to position, headlight, front and rear dim
lamps, instrument light and rear license light come on.
◇ Raise the handle to the top, high beam and low beam of the front light come on
simultaneously. Raise the hand to the top again then release, returning low
beam.
◇ Repeat rising and releasing, may send the vehicle meeting signal that high
beam and low beam alternate conversion.
Turning switch
◆ When the left handle is on middle gear position, turning light goes off.
◆ Push the left handle forward, right turning light comes on, at the same time,
corresponding turning indicator light on the instrument cluster flash.
◆ Pull the left handle backward, left turning light comes on, at the same time,
corresponding turning indicator light on the instrument cluster flash.

Operation manual
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23
Right handle (wiper switch, windshield washer switch, danger warning
switch, exhaust braking switch)
★ This switch is control lever, at the right side of turning column.
Wiper switch
Danger warning
Windshield wash
Operation manual
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24
● When right handle is in the middle position (OFF), the wiper not to work.
● When right handle is turned to “LO” position, the wiper works at a low speed.
● When right handle is turned to “HI” position, the wiper works at a high speed.
● When right handle is turned to “INT” position, the wiper works intermittently.
Windshield washer switch
● Windshield washer switch is at the end of wiper switch.
● Press the switch at right handle end inward, detergent will spray on windshield
glass; When loosening, spray stop.
★ When wiper switch turns to “OFF” position, press washer switch, the wiper
should automatically wipe twice.
Caution
★ Washer spray cannot exceed 5 seconds for each time; the interval to next spray
cannot be less than 25 seconds.
Danger warning switch
★ This switch can simultaneously turn on and turn off left and right turning light
power.
★ Use it when vehicle in trouble, or parking at danger place.
● When right handle is raised to the middle position, front, rear, left and right
turning lights flash simultaneously.
● Raise the right handle to the top, after loosening, the right handle falls
automatically, 4 turning lights go off simultaneously.
Exhaust brake switch
● Push right handle forward, at OFF position, exhaust brake does not work.
● Pull right handle backward, at ON position, exhaust brake will work.

Operation manual
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25
Starting switch
★ starting switch key and vehicle door key are
the same one.
● LOCK: Shut off electric circuit
● ACC: Turn the key rightward (clockwise) to
gear 1, switch in accessory gear. When vehicle
stop, if want to use some electric equipment
(radio cassette, etc), turn the key to this gear,
then can operate the corresponding electric
equipment.
● ON: Continue to turn the key to gear II, switch
in electric circuit.
● S: Continue to turn the key to the bottom, start engine, after loosening, the key
returns automatically.
Key locking
● When the key is inserted into the starting switch, turned LOCK position to
ACC position, the lock locking button(white button) will spring automatically,
to make the key not be pulled out, preventing the key from pulling out from
lock hole due to vehicle vibration in running.
Fog light switch
★ Fog light switch is roller type, at steering wheel jacket.
★ Please use fog light when it is foggy or sight is not good in cloudy day.
● Press the switch at ON position, the fog light comes on; The switch is returned,
the fog light goes off.
Operation manual
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26
Electric and pneumatic horn conversion switch
● The vehicle is equipped with electric horn and pneumatic horn, and set the
conversion switch on the instrument cluster, the user can convert them
randomly.
Cigar lighter
● Press down the cigar lighter switch, until
resistance wire is red and hot, it automatically
pops out, at that time, pull out the button to use it.
★ Don’t hold the lighter in to block it pop-up;
otherwise, it will overheat to cause danger.
★ If the lighter doesn’t pop out within 30 seconds,
which shows the lighter in trouble, remove it to
prevent fire.
★ When the lighter doesn’t work well, stop using it.
★ Don’t leave the vehicle when the lighter is
pulled.
★ Deformed lighter cannot pop-up, replace it with
right lighter.
★ Don’t use the lighter socket for plug-in
accessories. They may damage it or cause
electrical accident.
★ When the ignition switch must be in the ON or
ACC position, it can be used.
Ashtray
● Beside the lighter is equipped an ashtray.
● Put Cigar end and match into the ashtray after they are completely.
Was put out; then press the ashtray cover well.
● Don’t put things other than cigar end or be full of cigar end; You may bring a
fire.

Operation manual
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27
Steering wheel locking handle
● Steering wheel locking handle is installed
on the steering post, release the locking
handle can adjust steering wheel and
steering post positions. When adjusting,
raise the locking handle, make the steering
wheel relieve locking, at that time the
steering wheel can slide upward and
downward or swing forward and backward.
The steering wheel can slide upward 40mm,
downward 20mm; swing 5° forward and
backward respectively.
Parking braking control valve (manual
valve for short)
● Manual valve is at the right side of driver
seat.
● When braking, pull the manual valve to the end.
● When relieve braking, lift the pull button 2 of the manual valve, at the same
time push handle 1 forward to the end.
Caution
★ Use the manual valve only for parking.
★ In running, when running braking fails or other dangers occur, the manual
valve is allowed to use, but don’t replace running braking.
Steering wheel
Steering wheel locking handle
Braking position
Relieve braking
Operation manual
Correct operation
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28
Correct operation
Outside unlock of left door:
● Insert the key into lock hole, turn 90°
clockwise then return, pull out the key, then
hold the outside handle, and press strongly
press-button with thumb, pull outward, to
open the door.
Outside locking of left door
● Close the door properly, insert the key
into lock hole, and turn 90° anticlockwise, the
door is locked. The key can be pulled out
after it returns.
★ Right door operation is the same as left
door, but the direction is reverse:
Inside unlocking of door
● Raise lock button, then pull inside handle, to
open the door.
Inside locking of door
● Close the door, press the lock button, to lock the door.
★ Note: When the door is not closed completely, the light inside of cab
comes on; after the door is closed properly, the light goes off.
Outside handle Press-button Lock body
Lock button
Inside handle Inside arm
Glass regulator handle

Operation manual
Correct operation
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29
Cab ventilation
● Natural ventilation is implemented
through air ways on interior and upper
walls of cab, airflow enter the cab
through airways and vent grid,
manually trigger grating to adjust
airflow.
● Forcing ventilation, heating and
defrosting are to send fresh air into the
cab through floor vents, central vent
grating and left and right side defrost
nozzle.
Glass regulator operation
● Left door: Turn handle clockwise, door
glass fall.
Turn handle anticlockwise,
door glass rise.
● Right door: Turn handle anticlockwise, door glass fall.
Turn handle clockwise, door glass rise.
Vent grating
Lock button
Inside handle Inside arm
Glass regulator handle
Operation manual
Correct operation
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30
Central control door lock (optional)
● Press remote device locking button outside of the door, left and right doors
can be locked simultaneously.
● Press remote device unlocking button, left and right doors can be unlocked
simultaneously.
Inside locking of door:
● Close the door, press the locking button inside of left door, left and right
doors can be locked simultaneously; Press the locking button inside of right
door, only right door can be locked. Press the front end of door control switch,
left and right doors can be locked simultaneously.
Inside unlocking of door
● Pull the locking button inside of door, or press the rear end of door controls
switch, the door is in unlocking state, pull inside handle backward, to open
the door.
Operation of electric glass regulator (optional):
● Driver side can control left and right door glass regulators.
● Press the front end of control switch of left door glass regulator, left door
glass rise, release it, glass stop lifting, right door operation is the same as left
door.
● Press the rear end of control switch of left door glass regulator, left glass fall,
but release it, the glass continues falling up to the low stop point.
● Press the rear end of control switch of right door glass regulator, right glass
fall, release it, the glass stops falling.

Operation manual
Correct operation
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31
1
2
3
Left door Right door
1-inside lock button 2-inside handle 3-right door regulator switch 4-left door
regulator switch 5-door lock control switch
Operation manual
Correct operation
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32
Adjustment of driver’s seat
Front and back adjustment:
● When adjusting front and back positions, step
on the floor, pull rightward slide-way
regulation handle, to make the regulation
board take out toothed plate, use the friction
force of the body and seat-bottom to make the
seat slide to necessary position, then release
the handle, to make the regulation plate and
toothed plate fit, restore locking.
● The front and back adjustment of the seat can
be divided into 8 gears, Max. Adjustment
quantity is 140mm.
Backrest angle adjustment:
● When adjustment, pull backward the angle
regulation handle to relieve locking, the
backrest will incline forward automatically
due to spring elasticity, use the body backrest’s pressure to adjust the back to
proper angle, then release the handle to restore locking.
● The original angle of the back is 12°30’; it can be adjust forward to 22°;
backward to 46°, divided into 23 gears.
Slide-way handle
Slide-way regulation handle

Operation manual
Correct operation
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33
Headrest position adjustment
★ Must adjust the headrest to correct position, and fix well.
● When adjusting the driver’s seat headrest position, pull the headrest
regulation lock plate, after open the lock plate, press down or raise the
headrest, to the position you want, then release your hand to lock.
★ Passenger seat: except for the front and back adjustment function, other
functions are as the same as the driver’s.
☆ In running, don’t make the backrest incline
backward, otherwise, when emergency
braking, passenger’s body will slide off the
seat to suffer from serious injury.
★ Middle seat: The back can tilt forward,
behind the back is equipped with a glove
box.
Height adjustment of selecting driver’s seat:
● Pull upward height adjustment handle,
adjust front handle 3, relieve locking, adjust
seat front angle with human body weight,
after adjusting to proper position, release
handle, then lock it again.
● Adjust rear handle 4, relieve locking, adjust
seat rear angle with human body weight,
after adjusting to proper position, release
handle, relock, and finally reach the goal of
adjusting seat height.
1-front and rear adjusting handle 2-angle adjusting handle
3-front handle of height adjustment 4-rear handle of height
adjustment
5-rigidity adjusting handle 6-electric heating pad plug
Unlock
Operation manual
Correct operation
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34
Front and back adjustment:
● Pull upward the front and back adjusting handle 1, relieve locking, adjust seat
assembly forward or backward with human body strength, after adjusting to
proper position, release the handle, relock.
Angle adjustment
● Pull upward the angle regulation handle 2, relieve locking, adjust seatback
angle forward or backward with human body strength, after adjusting to
proper position, release the handle, relock.
Rigidity adjustment:
● Turn rigidity adjusting handle 5 forward or backward, adjust to driver weight
value according to the scale on the handle, so as to adjust the seat mat rigidity
suitable for driver.
Passenger seat adjustment:
★ The height adjustment, front and back adjustment, angle adjustment of
passenger seat is the same as driver seat adjustment, only without rigidity
adjustment.
Seat electric heating unit:
● Turn on the electric heating seat switch on instrument cover, and then the seat
can be heated.

Operation manual
Correct operation
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35
Seat belts (selection)
● In order to reduce the damage occurring in vehicle bumping or emergency
braking, it is very important to use seat belt correctly.
● Before vehicle start to run, make sure all passengers fastening the seat belts.
★ It is extremely dangerous to remove or fasten the seat belts in running, must
do it when vehicle stops.
★ One seat belt is not allowed to used by tow passengers.
★ Note abraded seat belts, this kind of seat belt is not only non-effective, but
also very dangerous.
★ After fastening seat belts, should sit up on the seat, make the back lean
against the seatback. If sitting posture is not upright that will reduce the
protection effect of seat belts.
★ When vehicle is running, don’t over-tilt the seatback, otherwise, when vehicle
bumps, passenger’s body will pull out from the seat belts, to cause
passenger’s neck hanging, suffering from unexpected injury such as cervical
vertebra wreckage.
★ In order to avoid abdomen crush in vehicle bumping, must fasten the seat belt
on bones, also note the shoulder belt position.
★ When fastening seat belts, make sure the seat belts are not twisted up. The
area of the twisted section, which will bring over large pressure on human
body, causing danger.
★ If the seat belts have broken, and burst at the seam, or the belt buckle effect
is abnormal, replace them immediately.
★ When vehicle bumping accident occurs and the seat belts receive impact
force, although the seat belts are not found damage, the seat belts should be
also replaced.
★ Don’t insert impurity into the belt buckle of the seat belts, don’t transform or
take off the seat belts either.
☆ Seat belt cleaning: When the seat belts are dirty, they should be cleaned with
neutral detergent, don’t use bleacher, dye or dry cleaning agent, which can
seriously damage their strength.
☆ Fastening seat belts: sit upright on seat, make the back against the seatback
comfortably, slowly pull out tongue and insert it into buckle until you hear a
click, make sure the seat belts have not twisted section; loin belt is fastened
on bone, the lower the better.
☆ Releasing seat belts: press red button, the belt will automatically wrap, when
the belt is wrapping, hold the tongue until it wraps.
Operation manual
Correct operation
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36
Sundries box
● Don’t put the things that may fall down or roll, or they may roll out to block
safe running when vehicle starts or stops.
● Before vehicle starts, must close the cover.
Outside rear view mirror
● Outside rear view mirror can be adjusted manually to the desired angle, to
reach satisfactory effect.
● Rear view mirror should be wiped to keep mirror cleanness.
Adumbral board
● When driving, if the sun irradiate directly, lower the adumbral board.
● Adjust the adumbral board to proper angle, to guarantee both the driver’s
sight and effective visual field.
● Pull out the adumbral board from the fixed clip, swing to door side, to keep
out sidelight.

Operation manual
Correct operation
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37
Radio/cassette player
★ Dual-track, AM/FM stereo radio cassette tape player, it has LED frequency
and clock display function, high tone and low tone compensation function,
remote and local reception control function, automatic reverse function, etc.
● Power supply (SW), volume (VOL) button: Turning clockwise until you hear
click, showing switch in power, may adjust volume.
● TUNE button: Turn this button, display frequency on LED screen
correspondingly change, may select corresponding broadcasting station.
● Volume output balance (BAL) button: Adjust left and right track volume
balance.
● Tone control button: Adjust high tone and low tone to make tone quality
optimal.
● Frequency/clock selection button: Change the selection of reception
frequency and clock display on LED screen.
● Band (BAND)button: AM and FM switch
● Stereo control button(ST): Normal / Stereo selection.
● Remote/near control button(DX): Remote broadcasting station and near
broadcasting station switch.
● Clock set button(SET): Hour set button (H), minute set button (M): press (H)
button or (M) button, LED will display clock. If the adjustment is need, adjust
“hour” or “minute”.
★ When vehicle stops, if using the radio, first turn the starting switch key to
switch in accessories gear.
Operation manual
Correct operation
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38
Emblem mark
1-TUNE knob (for radio channel selection) 2-power, volume knob 3-tone control
knob 4-clock set button 5-LED display screen 6-cassette holder

Operation manual
Correct operation
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39
Cab tilting forward and return
Cab tilting forward:
● Cab locking control mechanism is at the left side of cab back.
● Pull out safety pin 6 from the pinhole, pull control handle 7 down to the end,
make main hook detach from lock latch assembly 2 (see the right figure in
next page).
● Pull outward pull-rod 5, make safety hook detach from lock latch fixed rack 3,
at that time, the cab can spring upward to one balance position.
● Push upward handrail 12, make cab 11 lift, so as to make support rod
assembly 10 strengthen out, at that time, the cab is balanced, push upward
lock hook, insert linchpin 8 into lock hole, lock the support rod, see the left
figure in next page.
Caution
★ Support rod linchpin must be inserted into the hole actually, to avoid the cab
fall to cause personal injury.
Cab return
● Stand outside of left front wheel, pull out linchpin 8(see the left figure in next
page), turn downward lock hook, at the same time hold handrail 12, pull
downward, to make the can fall.
● When the cab fall, safety hook 4 (the right figure in next page) will lock the
lock latch fixed rack 3, the cab will be advance locked.
● Push upward control handle 7(as the position in the right figure in next
page), to make main hook 1 lock the lock latch assembly 3.
● Insert safety pin 6 into pin hole, at that time the cab is locked.
Operation manual
Correct operation
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40
1-main hook 2-lock latch assembly 3-lock latch fixed rack 4-safety hook
5-pull-rod 6-safety pin 7-control handle 8-slip-pin 9-lock hook
10-support rod assembly 11- cab 12-armrest

Operation manual
Correct operation
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41
Operation of air conditioner (heating, cooling)
1: A/C switch: A/C switch is cooling switch. Cooling equipment is a selection.
● When wanting to operate cooling equipment, press this switch,
compressor begins operation; Want to stop, please press this switch
again.
2: Cooling outlet shift control rod
…Air blows toward selected direction from the central or left and right
outlets.
…Air blows out from the center, left, right or floor.
…All air blows from floor.
…All air blow toward front glass window (frost prevention device).
…Air blows toward the center, left, right and front glass window.
…Air blows toward the center, left, right and front glass window.
3: Interior and exterior air shift control rod
…Interior circulation: make the air within the cab circulate.
… Exterior circulation: input exterior fresh air.
Operation manual
Correct operation
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42
4: Fan switch
OFF stop
Gentle breeze
Mild wind
Normal wind
Strong wind
5: Temperature regulation control lever
Left side (COOL)…blow cool wind
Right side (WARM)…blow warm wind
Operation tips
Heating: When wanting the cab interior become warm, place control lever 3
in interior circulation position

Operation manual
Correct operation
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43
Ventilation: Place control lever 3 in exterior circulation position, other control
lever positions are as shown in the figure.
Defrost: All control lever positions are as shown in the figure.
Caution
★ When using heating, the engine coolant temperature should be above 75℃.
★ When using heating in winter, the heating outlet switch on engine cylinder
head should be opened first.
★ Antifreeze is required to use in cold areas. If antifreeze is not used, when
vehicle stops for a long time, it is necessary to open discharge valve, to
prevent generating ice block in pipeline or freeze heating radiator.
Operation manual
Correct operation
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44
Using tire chain in winter
Tire chain installation
● Tire chain should be installed firmly, to avoid to take off or collide and
interfere other parts in running.
● The tire chain suitable for tire size should be mounted.
● Don’t mount tire chain on front wheel.
● When installing, check whether tire chain and it spring drawstring have
abrasion.
● After running 5-15 minutes, check whether tire chain has looseness or
dropout.
● After install tire chain, driving speed should not exceed 30km/h.
● On the road without ice and snow, don’t use tire chain; Otherwise chain is
easily damaged.
★ The bending section of cross chain should be at outboard.
Cross chain

Operation manual
Correct operation
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45
★ Inside chain is all used to make it become non-residual state and link hook,
pull the cross chain of inside tire outward, to eliminate inside chain looseness.
Outside chain Middle chain Inside chain
Hook
Cross catena
★ The hook that temporary fix outside chain is as shown as the figure.
★ Strain the middle chain as far as possible and connect hook.
Hook
★ Strain both ends of outside chain and connect hook.
Hook
Operation manual
Correct operation
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46
★ Make sure all hooks and tire side-wall become parallel state, at the same time,
make sure all chain has no twisted section.
★ Fix residual chain with wire, to prevent contact other parts.
★ Fasten spring clamp, all sections of spring clamp should face the outside and
evenly installation.
Spring clamp

Operation manual
Correct drive
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47
Correct drive
General starting of engine
● Place gearlever in the neutral position, strain manual valve, then switch in
power with key(turn the key clockwise to ACC position).
● Step on clutch pedal, continue to turn the key to start engine, as soon as the
engine starts, release the key immediately.
● After the engine works smoothly, uniformly release clutch pedal.
● After starting, check engine oil pressure and coolant temperature.
Caution for starting:
● Make sure whether there are people or barriers in the under part, front, left and
right of the vehicle with eyes or rear view mirror.
● Make sure whether there are bright warning lights.
● Make sure manual valve is in relieving braking state.
● When starting, don’t step on accelerograph suddenly, to prevent the engine oil
pressure from rising suddenly, while the engine oil is over viscous, which
cannot reach the friction surface of all parts in time, to accelerate part abrasion.
● Starter is not used for more than 5-7 seconds each time, after each failure,
restarting must be after 2 seconds. If three successive starting fails, check
whether oil pipeline and circuit have trouble, restart after finding the cause and
removing it, and don’t start forcedly.
● After engine starts, don’t step on gas pedal suddenly, to avoid engine running at
high speed.
● After engine starts, first work for several minutes at low speed, until water
temperature reaches 50℃, begin to run, but don’t idle work over long.
● For the vehicles that don’t drive for a long time, or the engine oil and engine oil
filter cylinder are replaced, must start motor first, to make lubricating oil get on
all lubricating surface, then start the engine.
Operation manual
Correct drive
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48
Caution for winter
● When the temperature is lower than 5℃, must particularly maintain the diesel.
● Must use the engine oil and diesel for winter, don’t mix diesel with water, to
avoid block oil-way.
● When replacing low-temperature engine oil, discharge the engine oil in the
original disc and oil injection pump of the diesel completely, and clean engine
oil filter, engine oil disc and engine oil receiver, then fill low-temperature
engine oil into the engine disc and oil injection pump. When diesel working
environment temperature is below -10℃, the replacing oil cycle should be
shortened.
● Before starting, pull down radiator curtain.
● When starting the engine, first the starting preheating button, then start the
engine with key.
● After the vehicle stops in winter, discharge water until the water’s temperature
drops to 40℃-50℃.
● In cold areas, it would be better if the vehicle would not stop in the open,
otherwise, when starting, must warm engine oil disc to make engine oil not
over dense. If the vehicle does not use antifreeze, the water tank must be filled
boiled water, and use heater so as to start easily.
● When starting engine below -35℃ temperature in winter, if using hot-water
heater, the water temperature should not be over high, to avoid cylinder body
crazing.

Operation manual
Correct drive
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49
Engine preheating
◆ After engine starts, first preheat to make temperature rise, during this period, to
observe the working conditions of all instruments, indicator lights and warning
lights.
◆ In the period of preheating, indicator lights come on,
but along with oil and air pressure rise, warning light go off.
◆ When the hand of pressure meter indicates 450kPa, engine oil pressure will
reach 100kPa, and coolant temperature will get above 50℃, at that time, the
vehicle possesses driving condition.
◆ At that time parking braking light still comes on, which remind you
release manual valve before driving.
Notice
Please avoid preheating operation in bad ventilation places is harm to your
health.
Caution
● Don’t operate engine in garage or closed place for a long time, since air cannot
ventilate well, danger occurs easily
● Don’t park vehicle for a long time under the condition of engine working.
Vehicle should be parked in good ventilation places, and adjust A/C system to
make outside airflow into the vehicle.
● Avoid inbreathe engine exhaust, since CO in exhaust is toxic gas,
over-inbreathing will make person be suffocated to death.
● Often to check the exhaust system.
Method of engine starting after long parking
● After the vehicle is not driven for a long time, or engine oil and engine oil filter
cylinder, which will cause lack engine oil in the engine, so before starting the
engine, turn the engine crankshaft with starter according to the following
method, to make engine oil roll into all sections of engine.
● Make the engine crankshaft turn with starting motor, the purpose is not to make
engine start, therefore, don’t step on accelerator pedal.
Operation manual
Correct drive
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50
● After turning the starting key to S position, release it.
☆ Make sure pull manual valve.
☆ Push gearlever into neutral position.
☆ In the state of not stepping on accelerator pedal, turn the starting key to S
position, rotate engine for 15 seconds.
★ Caution: The vehicle with supercharged engine must rotate engine according to
the above-mentioned method before starting.
Starting engine in cab gradient state
● Start engine in cab gradient state in order to check and repair, first take the
following safe measures, then start engine with starting key.
☆ Be sure to apply parking braking, and fix wheel with stow-wood.
☆ Make sure gearlever is in neutral position.
☆ Make sure there is not any person around vehicle.
Flame preheating type low temperature cold-starting
● When surroundings temperature is below 0℃, the system will automatically
work.
● Switch in ignition switch ON position, when engine water temperature is above
0℃, the preheating indicator light will automatically go off after it comes on
2 seconds, the preheating equipment don’t work.
● If the engine water temperature is below0℃, the preheating indicator light
comes on, preheating plug is powered and temperature rises.
● After preheating 26±2 seconds, preheating indicator light will goes off, to give
a hint that driver may start engine.
● At that time switch in START gear, fuel electromagnetic valve operates current,
diesel oil passes through oil pipe to preheating plug, to forming flame, heating
admission.
Caution
★ If don’t start operation within 30 seconds after the indicator light goes out,
preheating unit will automatically stop working.

Operation manual
Correct drive
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51
Vehicle running
● Vehicle can start running only under the conditions that the engine works
normally, all instruments, indicator lights and warning lights are normal.
● Place the manual valve in relieving braking position when starting.
● In running, notice that the engine coolant temperature keep 75-95℃.
● Notice observing engine oil pressure, it is not lower 170kPa in low-speed
running; Doesn’t exceed 490kPa in high-speed running, or stop the vehicle to
check, to avoid burning parts.
● In running, if some section has trouble, for example, if air holder pressure drop,
warning light will come on; At that time, must stop vehicle, strain manual valve,
and after the trouble removal, and the warning light goes out, continue to drive.
● Under general conditions, don’t start rapidly, accelerate suddenly and brake
urgently as far as possible.
● When shifting gears, must boost evenly, and put into gear to the end. If it is
difficult to shift gears, transmission control mechanism should be regulated.
★ In running, don’t put foot on clutch pedal all along, the foot should leave the
pedal after shifting gears.
★ Strictly prohibit shifting gears without stepping on clutch.
★ Vehicle may shift reverse gear only after it stops completely stably.
Operation manual
Correct drive
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52
Driving on hill road
● When driving along long and steep ramp, use exhaust brake, and also can use
engine to brake, that is, put gear control rod in the gear position for same slope.
When braking force is deficient, use foot to increase braking.
● In order to reduce abrasion and heating phenomena in braking, before drive
down on long and steep ramp, first reduce speed and shift to low gear.
Caution
★ When driving downhill, strictly prohibit cutting out engine.
★ When driving downhill, transmission is not allowed to put into neutral position.
● When driving upslope, if vehicle speed gradually decreases, must shift to low
gear in time.
Driving on ice and snow road
● Please use tire chain when driving on ice and snow road.
● Be sure to reduce speed, avoid urgent acceleration and urgent braking.
● Strictly prohibit urgent braking and urgent turning when driving at high speed,
if not, the vehicle will bring about sideslip and uncouple to cause accident.
Driving on rainy road
● When driving on rainy road, the speed should be controlled, the best is not
more than 35km/h.
● When driving in rain, the rain may enter into brake drum to influence braking
effect; Therefore, it is necessary to step on brake pedal, to check braking effect.
● Avoid urgent braking and urgent turning, if not, the vehicle will bring about
sideslip and uncouple to cause accident.

Operation manual
Correct drive
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53
Vehicle stop
● When vehicle stops, first release accelerator pedal, to reduce the speed.
● Step on brake pedal evenly, after the vehicle stops stably, step on clutch pedal
to put transmission into neutral position, then pull the manual valve to the end,
to make it keep braking state.
● Cut off power (turn starting switch key to LOCK position).
Driving in foggy day
● Turn on fog light, drive at low speed, note road centerline and front running
vehicle’s taillight.
● If fog is heavy, stop running, and park the vehicle in safe places, at the same
time, turn on distress warning switch, to make front, rear, left and right turning
lights flash simultaneously.
Economical driving
● Unnecessary high-speed driving, and high-speed driving while placing
gearlever in low gear may both increase fuel consumption.
● After acceleration, shift the gearlever to high gear in time, smoothly release
clutch pedal.
● After shifting gearlever to direct gear or overspeed gear, be sure to keep certain
speed.
● In driving, coolant temperature should keep within normal range.
● The tire without sufficient charge may impair fuel economization.
● Avoid long engine preheating idle.
● Don’t often step on clutch pedal or brake pedal.
● Guarantee accurate orientation of front wheel.
54
Maintenance Manual

Maintenance manual
New vehicle running-in
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55
New vehicle running-in: running period is 2500km
● New vehicle running-in condition has great influence on vehicle life, working
reliability and economical property.
● After receiving new vehicle or vehicle has a big repair, especially, the engine
must carry out running-in compliance with the requirement strictly, then it can
put into operation.
Running requirement
● Within 200km in running-in period, never load; Within 1500km, the load does
not exceed 70% of rating load; after 1500-2500km the load can increase to 90%
of rating load.
● Select smooth and good road surface.
● Correct drive and operate.
○ Smoothly switch in clutch, shift gear in time.
○ Avoid sudden accelerate and rapid braking.
● Often observe the temperature of transmission, rear axle, wheel hub and brake
drum, if it is seriously hot, find out the cause, and remove immediately.
● During running-in period( especially 1500km), all gear speeds are not allowed
to exceed 65% of max. Speed of that gear, all gear speed limits are as follows:
Maintenance manual
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56
Vehicle type CA5083XXYPK2L1A80
Gear 1 Don’t exceed 7km/h
Reverse gear Don’t exceed 7km/h
● In running-in period, particularly notice engine coolant temperature and engine
oil pressure, they must within specified range.
● In load state, check and tighten plate spring U-bolt nut. The tightening torque:
front spring is 350-450N·m, and rear spring is 600-700N·m.
● Check, clean or replace filter element.
● Check coolant level height.
● Check all sections tightening condition, lubricate all sections.
● In thermal vehicle state, replace engine lubricating oil, wash engine oil disc.
● Replace engine oil filter.

Maintenance manual
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57
● Clean the filter core, and joint and filter netting of oil intake pipe of fuel
delivery pump
● Check engine idling rotational speed, V-belt tightness degree.
● Replace the lubricating oil of engine, transmission and rear axle, clean
vent-plug.
● Clean, lubricate and adjust wheel hub.
● Clean battery exterior.
● Clean the filter core in steering oil tank.
● Remove the oil and water in gas holder.
● Check engine suspension component connection.
● Check all sections connection of the body interior and exterior.
● Check and tighten all connection bolts of chassis, especially propeller the
tightness of transmission shaft universal joint flange bolt, steering mechanism
connection bolts
● Check the free space of clutch pedal.
● Check and adjust the clutch release bearing clearance of 2-3mm.
● Adjust front wiring harness.
● Check and tighten all connection parts of front shaft.
● Check parking braking equipment.
● Lubricate all section according to the items in 4000km column in lubrication
table.
Maintenance manual
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58
Normal operation：
In order to prolong vehicle life, and get high economic benefit, guarantee safety,
operation must be as follows:
★ Turn on power switch.
★ Make sure the position of the transmission .
★ For engine starting operation, please refer to the engine staring specification
section.
★ When the engine temperature is comparatively low, don’t raise engine
rotational speed very fast, which will intensify the abrasion of engine motion
parts.
★ The vehicle may start to run until the braking system pressure reaches or
exceeds 650kPa.
★ The vehicle must start to run with gear 1 when it loads.
★ Avoid throttle full-gear starting and emergency braking. The throttle full-gear
starting shall lead to clutch damage or uneven tire abrasion. Emergency
braking shall accelerate the abrasion of tires and braking friction plate.
★ Avoid sudden turning while vehicle is adjusting.
★ Don’t allow vehicle over-load operation, over-load shall shorten vehicle
duration.
★ When loading goods with mechanical equipment, the goods are tipped into
wagon from low position as far as possible, to avoid forming force-impact,
causing part damages.
★ Don’t stream water into fuel reserve tank while cleaning vehicle.
★ Strictly prohibit turning off power switch in engine operation process; be sure
to turn off power switch after vehicle parking.
★ Before tilting cab, be sure to check whether there are dumped things, if there is,
must clean up.

Maintenance manual
Regular maintenance
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59
Regular maintenance
Daily maintenance
Check before driving
● Check engine lubricating oil level height: Park at flat road surface, after the
whole vehicle is warm, stop 10 minutes, check oil level, take out oil gauge, wipe
it clean with clean cloth, insert to limit position, then pull out again, observe oil
level position, the oil level must be between two marks of oil gauge.
● If the oil level is near or lower than the lower scale mark , must to fill engine oil
immediately, to make the oil level reach the upper scale mark as far as possible.
● If the oil level exceeds the upper scale mark, discharge excessive engine oil from
the outlet bolt of engine oil disk.
● During new vehicle running-in period, engine consumption is comparatively
more, so check the oil level twice each day, after the running-in period, check it
once each day.
● Check fuel tank storage content.
● Check the connection of fuel feeding control mechanism and oil cutting-off
mechanism.
● Check cab locking.
● Check whether all lights are
normal.
● Check coolant storage, and
fill in time.
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Regular maintenance
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60
Check tire pressure
● Measuring tire pressure should
be carried out when tire is in
room temperature state.
● Pressure specifications:
Equip 10.00-20 tire Front wheel 560kPa
Rear wheel and spare tire 670kPa
● Tire pressure should keep in the range of specified value. If the tire pressure is
over high, which will accelerate abrasion, shorten tire life; if the pressure is over
low, crack will generate, and influence driving speed, increase fuel consumption.

Maintenance manual
Regular maintenance
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61
Check in driving:
● In safe place, while driving at about 20km/h, check braking effect and steering
mechanism work.
● Check shock absorber.
○ In driving, if you find the vehicle has abnormal continuous dithering, stop
running to check whether shock absorber has leakage.
○ After driving on bad road for a while (not less than 10 km), stop running to touch
shock absorber to feel whether it is hot; If not hot, it shows that the shock
absorber doesn’t play a role of vibration damping, must replace it with a new one
in time.
● In driving, observe all instrument working condition, especially is engine oil
pressure meter, water thermometer, barometer.
● Often listen to whether there is abnormal sound from engine, once there is
abnormal sound, stop running to check immediately, to find out the cause and
remove it.
Filling and discharging of coolant:
Preparation for coolant
● The preparation and inspect for water-cooling engine coolant is a very important
step, because corrosion, cave erosion and icing leads to engine destruction.
● Coolant consists of water, high-effective anti-freeze of anti-corrosion, anti-cave
erosion and anti-freeze. Anti-freeze concentration of coolant should not be lower
than the following limit:
Anti-freeze in cooling system Distilled water
Max. volume 50% 50%
Max. volume 35% 65%
Note: recommend using FAW F35 long-acting anti-freeze.
Maintenance manual
Regular maintenance
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62
Coolant filling
● Open expansion tank pressure cap, fill coolant on inlet, until it be filled to upper
reticle( heating valve must be opened).
● After covering the pressure cap, start engine, operate about 5minutes, be sure
water thermometer hand is beyond the center, touch the water chamber on
radiator, and stop until you feel warm. After a while, open the pressure cap, if the
coolant level in the expansion tank drops, need to fill coolant more, until the
coolant level of expansion tank has not obvious change before and after
operation.
● When it is used normally, if the engine is over hot or coolant warning light comes
on, must check coolant level height, if necessary, refill it in time.
Caution
★ Don’t open the pressure cap in hot state immediately, to avoid the hot-pressured
gas in cooling system spilling to cause scald. Open the pressure cap of hot engine
until the engine stops 10 minutes. Put wiping rag on the cap, first turn the cap to
first stop, and turn on the pressure cap after pressure releases!
Coolant discharging:
● When using anti-freeze in winter, but the temperature is below -35℃, after
returning the vehicle to the garage, must discharge coolant.
● There are two discharging water switches, one is at cylinder body left side, and
the other is under radiator outlet pipe.
● While discharging water, must open the pressure cover on the expansion cap.
● If there is still partial remain coolant in pipe, unscrew the relative low pipe clamp,
discharge remain coolant from the connection.
● After coolant is discharged completely, start engine at idle about 1 minute, to
discharge coolant thoroughly.
Discharging water
Switch handle
Discharging water valve

Maintenance manual
Regular maintenance
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63
Daily check after stopping driving:
● Discharge the storage water in wet gas
holder (wet gas holder is at left of the
vehicle)
● Check whether there is scratch, crack or
abnormal abrasion.
● If such things as metal plate and stones
embed tire surface, must remove in time.
● If there are such things as, stones between
double tires of rear wheel, must remove in time.
4000km maintenance takes tightening and lubricating as the main.
(Implement routine maintenance items and add the following times)
● Whenever vehicle runs 4000km, check and tighten the connection bolts and nuts
of engine suspension, intake and exhaust manifold, noise silencer, and check
whether all bushes are good.
● Check main bearing cap, connection rod, and cylinder cap bolt tightening torque.
● Check regulation valve clearance, and check oil feed advance angle.
● Check and tighten the connection bolts of transmission shaft universal joint pin
and middle support, steering mechanism (especially steering crossbar pull-rod,
upper/lower steering knuckle arms, steering propeller shaft, etc.), steel plate
spring, half shaft and wheel.
● Clean and maintain engine oil filter and diesel filter, remove the dust on air filter
element.
● Wash engine oil disc, replace lubricating oil, wash engine oil receiver filter
screen.
● Discharge the oil dirt and water in gas holder.
● Check fan belt tension degree.
● Check tire pressure, and inflate according to specification.
● Check and tighten the connection bolt nuts of cab and carriage.
● Check whether the expansion tank liquid level is between high and low scales.
● Observe the connecting of supercharger and inlet and outlet pipes, don’t leak gas.
● Check whether supercharger bearing has oil leakage, if there is remove in time.
● Carry out lubrication according to lubrication table.
Check valve
Discharge
Valve
Relief valve
Water drain valve
Maintenance manual
Regular maintenance
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64
8000km maintenance takes check and adjusting as the main (to implement
4000km maintenance items and add the following items)
● Replace engine lubricating oil, wash engine oil disk.
● Check and fill the lubricating oil of transmission, rear axle and dredge vent-plug.
● Adjust and lubricate front and rear wheel hub and wheel brake.
● Adjust the clearance between brake shoe friction sheet and brake drum
● Check parking brake working condition,
● Check steering wheel free turning.
● Replace power steering oil.
● Check tire, and change position according specified sequence.
● Check and adjust front wheel toe-in.
● Clean fuel tank, fuel delivery pump filter screen and pipeline.
● Clean engine oil fine filter retro, clean sediment in rotor case interior wall,
dredge jet nozzle.
● Clean the main filter element of secondary air filter.
● For the maintenance of bath air filter, please refer to the above operation
description.
● Adjust valve clearance.
● Clean diesel coarse filter element; Replace diesel fine filter and engine oil filter
element.
● Lay emphasis on check safety parts (e.g. all pull-rods and pipelines in braking
system, crossbar pull-rod, knuckle arm, drop arm and all connection sections in
steering system).
● Check shock absorber; If finding it is out of work, replace it in time.
● Check the bushes in steel plate spring support and sling, if necessary, replace.
● Lubricate according to lubrication table.

Maintenance manual
Regular maintenance
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65
24000km maintenance (to implement 8000km maintenance items and add the
following items)
● Whenever vehicle runs 24000km, check and replace brake friction sheet.
● Dismount rear axle transmission shaft, tighten drive bevel gear flange nuts and
middle transmission shaft flange nuts according to specified torque.
● Dismount the rear caps of jackshaft and rear axle housing, clean decelerator
interior cavity, tighten differential bearing cap nuts and differential housing nuts
according to specified torque, replace the lubricating oil of jackshaft and rear
axle.
● Replace lubricating oil of transmission.
● Check steel plate spring support and sling bush abrasion, if necessary, replace.
● Replace the main filter element and safe filter element of secondary air filter.
● For the maintenance of oil bath air filter, please refer to the above operation
description.
48000km maintenance takes assembly disassembly and eliminating hidden
danger as the main (to implement 24000km maintenance items and add the
following items)
● Whenever the vehicle runs 48000km, clean up crankshaft box ventilation unit.
● Clean cooling system and fuel tank.
● Clean engine oil cooler.
● Check injection pressure of oil injector and injection condition on test table by
professional, carry out necessary adjustment.
● Check fuel feed advance angle, and carry out necessary adjustment.
● Adjust engine oil pump if necessary.
● Replace the braking liquid of clutch hydraulic operation.
● If necessary, dismount cylinder head, clean and check all parts and grinding
valve.
● Besides the first 48000km treatment according to the condition, since then, every
48000km, carry out necessary the check, regulation and maintain of engine, to
eliminate hidden danger.
Maintenance manual
Regular maintenance
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66
● Engine disassembly should be determined according to its working condition,
any engine that has good working performance, should not be disassembled, or
prolong disassembly cycle, to keep its original technical performance.
● Oil injection pump generally does not require adjustment, if the engine does not
work normally, must check and adjust on oil injection pump test table by
professional.
● Remove the carbon deposit on supercharger compressor, turbine cap and rotor
vanes.
● Dismount and check parking and running brake controls and pipeline. Clean
gasholder single-way valve, check brake valve, and adjust if necessary.
● Dismount and check air compressor according to its condition.
● Dismount and check clutch, transmission, propeller shaft, rear axle, front shaft
and steering system if necessary.
● Replace power steering system oil and the cylinder element in steering oil tank.
● Dismount and check spare tire regulator, replace seriously abraded parts, clean
and lubricate.
● Wheel rim is scaled, and painted.
● Check chassis frame conditions (the presence and absence of deformation, crack,
rivet looseness and drop-out), if necessary repair.
● Check, repair and maintain vehicle body and accessories, replace damaged parts.
● Maintain starter and generator, and check bearing.
● Check and adjust battery electrolyte density.

Maintenance manual
Maintenance and adjustment of main assemblies
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67
Air filter
● Maintain air filter carefully and in time, which is very important to prolong
diesel durability.
● Air filter core must keep clean, if not, the filter core block will make engine
power reduce, oil consumption increase, and accelerate engine abrasion.
● The vehicle runs in general areas, every 8000 km, clean the main filter core
once; If often runs in windy and dust areas, shorten maintenance mileage
appropriately.
● Whenever the main filter core is used 24000km or one year, replace with new
filter core, at the same time replace safe filter core.
● The safe filter core is not allowed to clean, only replaced.
1-main filter core 2-safe filter core 3-tightening nut 4-end housing
Notice
★ The user should buy the filter core that is produced by the original manufacturer,
and also buy the filter core that is qualified and provided test report by FAW
Technical Center.
★ Don’t buy non-qualified filter core, since non-qualified filter core will cause
the engine non-normal abrasion.
Maintenance manual
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68
Maintenance of air filter:
● when maintaining, first unscrew
tightening nut, open filter cap, take
out main core, clean the dust
inside of housing.
● Knock slightly two end of filter
core with hand or wood stick, and
as knocking, turn the filter core, to
make dust drop. Also blow clean compressed air not larger than 600kPa
outward from filter core interior outward, to remove dust.
Notice for air filter maintenance:
★ Filter core cannot be cleaned in gasoline, kerosene, can only be blown with
compressed air or knocked with hand.
★ If finding main filter core is blocked or damaged, must replace in time.
★ In the process of maintaining air filter, note not to destroy filter paper, to
influence filter effect.
★ When mounting, must first check the rubber seal ring between filter core end
surface and housing to see whether it is intact, then, mount it into the housing,
if it is damaged, must replace it in time, to guarantee good seal. Check nut seal
ring, then tighten nut.
★ Check the seal of filter core seal ring and housing, to see whether it is intact,
and whether the connection pipeline is tight, if the sealing is not good, dust will
enter directly into cylinder, to accelerate engine abrasion.
☆ For the maintenance and adjustment of the modified vehicle type that can select
Oil bath air filter (that is primary filter), please refer to the operation and
maintenance description of filter body.
☆ The air filter mentioned above is secondary air filter.

Maintenance manual
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69
Notice for secondary air filter maintenance:
★ Main filter core cannot be cleaned in gasoline, kerosene, can only be blown
with compressed air or knocked with hand. Safe filter core can only be replaced,
not allow to clean.
★ If finding main filter core is blocked or damaged, must replace in time, and at
the same time replace safe filter core.
★ In the process of maintaining air filter, note not to destroy filter paper, to
influence filter effect.
★ When mounting, must first check the rubber seal ring between filter core end
surface and housing to see whether it is intact, then, mount it into the housing
body, if it is damaged, must replace it in time, to guarantee good seal. Check
nut seal ring, then tighten nut.
★ Check the seal of filter core seal ring and housing, to see whether it is intact.,
and whether the connection pipeline from filter outlet to engine supercharger
inlet is loose or broken, if necessary, replace, otherwise, dust will enter directly
into cylinder, to accelerate engine abrasion.
Crankshaft housing ventilation
◆ Whenever a vehicle runs 2000km, check whether connection pipeline is loose
or broken, if necessary, replace.
◆ Whenever a vehicle runs 8000km, check and clean crankshaft housing oil-gas
separator. When cleaning it,
first soak oil-gas separator in
gasoline for several minutes,
then scrub and blow off it
with compressed air.
★ When oil-gas separator is
blocked, must replace in
time.
Oil-gas separator
Maintenance manual
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70
Rotation engine oil filter
● Generally, every 6 months or every 8000km, must replace engine oil filter.
● In dust areas, every 3 months or every 4000km, must replace engine oil filter.
● Replace engine oil filter assembly.
○ Use special tool kit to turn anticlockwise, to dismount engine oil filter.
○ When installing, coat engine oil on new filter rubber seal gasket
○ Filter installation surface must be even and smooth, doesn’t have dirty things or
rubber remainder.
○ Tighten engine oil filter clockwise, and after rubber gasket touches seating
plane, re-tighten it one circle.
1
5
1-gasket 2-combined bolt 3-seat 4-rotation engine oil filter
5-engine cylinder block
Notice
★ The user must purchase the rotation engine oil filter assembly that is produced
by the original manufacturer, also can purchase the engine oil filter assembly
that is qualified and provided report by FAW Technical Center.
★ Don’t purchase non-qualified product, otherwise, it will bring about engine
non-normal abrasion and parts damage.

Maintenance manual
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71
Engine oil fine filter
● When a new vehicle runs 2000km, clean rotor.
● Generally, every 8000km, clean rotor and sediment in rotor cover interior wall,
dredge nozzle 6.
● Rotor dismounting method:
First take down cap nut 1, take down housing 4, take down tightening rotor nut
2, take down thrust shim, to take out rotor assembly 5. Then as unscrew
pressing nut, rotor cap rises, to take out rotor.
● Note in dismounting and check:
Because rotor assembly is through dynamic balance, must put and take slightly,
don’t collide to avoid destroying it dynamic balance.
● Remove foreign matter with bamboo sheet, wood batten, not with metal things,
to avoid scratch parts.
● Note to mount according original mark, don’t miss seal parts. Check seal ring
intactness. After mounting rotor should rotate easily. Pull up the rotor, check
whether its spill quantity is 0.4-0.8mm. If there is no axial spill quantity, find
out the cause.
Generally, don’t dismount intake
pressure limit valve 7.
1-cap nut 2-nut 3-block 4-housing
5-rotor assembly 6-nozzle
7-intke pressure limit valve
Maintenance manual
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72
Diesel coarse filter
● Every 8000-12000km, clean filter core.
● When cleaning or replace filter core, unscrew sedimentation cup fixing ring
with special spanner, take down sedimentation cup and filter core, and clean
them with kerosene.
● When mounting, don’t miss gasket, then screw sedimentation cup fixing ring
slightly with hand.
● If it is necessary to dismount inlet and out joints, check whether spacer is intact,
if it is damaged, replace in time. Joint tightening torque is 20-25N·m.
Diesel fine filter
● Diesel fine filter plays an important part in guaranteeing normal work of oil
injection pump and oil injector. If finding oil cannot pass through fine filter,
must dismount and check, replace
with new filter.
● Generally running 8000-12000km,
replace with new filter.
● When replacing with new filter, first
coat lubricating oil on gasket, then
turn it on seat, and screw it with
hand.
Caution
★ When mounting, check sealing ring
intactness, if it is damaged, replace
in time. Don’t miss sealing ring.
Inlet connection outlet connection
Tightening bolt
Sedimentation cup
Filter element

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73
Oil injection pump
● Oil injection ump has been debugged strictly before leaving the factory, lead
sealing section cannot be changed. If adjustment is needed in operation, must
carry out on test table by professional.
● Coupler cannot be replaced randomly, to avoid influencing diesel performance.
● If diesel cannot work normally, or injection time and injection amount are
abnormal, the maintenance and adjustment must be done on test table by
professional.
Notice for oil injection pump
dismounting and mounting:
● In operation process, if it is necessary to
dismount injection pump, don’t dismount
injection pump stand, if not, which will
cause injection pump and air compressor
with different core, resulting in
connection disk plate damage.
● When dismounting, in order to oil feeding
advance angle not change after
remounting, must make a mark on
advance unit.
● If only dismounting injection pump,
unscrew two bolts 3 for fixing connection
disk, in this way, when mounting, the
advance angle does not change.
● Don’t dismount bolt 1 connecting
coupling on steel plate as far as possible,
because the coupling is damaged easily in
remounting.
● When remounting injection pump on
engine, pay a particular attention to
timing adjustment: That is, guarantee the
alignment of mark on advance unit
exterior circle (it is the first cylinder
feeding start point of injection pump).
If there is any error, must unscrew two bolts 2 connecting flange to adjust
advance angle, that is, let the reticule on steel plate align 0 line on flange,
finally screw down bolts.
Oil delivery pump Advance unit
1-bolt connecting coupling 2-bolt
3-bolt fixing connection disk
Maintenance manual
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74
● If only dismounting injection pump, when mounting, first make “1-6” mark on
flywheel advance 10±1°align the hand
on the flywheel, or make the scale on
shock absorber align the hand on the
body, and be sure that engine first
cylinder piston is in compression
process(that is, inlet and outlet valves
close simultaneously), then let the scale
on advance unit align the mark on the
pump body, then can mount coupling.
● When mounting coupling, don’t change
the mark position.
● If while dismounting injection pump, dismount air compressor, besides aligning
the timing mark on the flywheel, and be sure that engine first cylinder piston is
on the stop point in compression process, at the same time, unscrew screw-plug,
to make the timing hand in flywheel housing align the mark on injection pump
propeller gear, then mount air compressor, at last, mount injection pump
according to former request..
● To assure the same core both injection pump and air compressor, the error is
not larger than 0.3mm.
Check method of oil feeding advance angle:
★ Dismount the high-pressure oil pipe of the first cylinder injection pump.
★ Turn crankshaft anticlockwise, at the same time observe carefully the presence
or absence of oil level fluctuation of injection pump outlet valve connection
(that is, the oil level just begin to rise), stop turning crankshaft immediately.
★ Examine whether the angle pointed out by the hand on pulley end or flywheel
shell observation hole is the advance angle data specified in above two items. If
necessary, re-examine once more, if it is correct, adjust.
Flywheel
housing
Flywheel
Screw-plug

Maintenance manual
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75
Adjusting method of oil feed advance angle:
★ Turn anticlockwise crankshaft up to the advance angle value specified for this
engine type in front of the first cylinder upper dead-point, and conform it is the
first cylinder compression upper dead-point.
★ Unscrew the plate coupling bolt of advance unit end, rotate advance angle, at
the same time, observe carefully the first outlet valve connection oil level, if
there is fluctuation, stop rotating, and screw down coupling bolt.
★ Rotate crankshaft, recheck oil feed advance angle, the method is the same as
the above-mentioned.
Oil injector
● When maintaining every 48000km, it is necessary to check the unlock pressure
and injection condition of oil injector, if necessary, clean and adjust.
● Professional must do repairing and replacing nozzle. When pumping oil at 30
times per minute, the pressure is 22-23Mpa, spray must be uniform,
interruption must be thorough, and can hear particular ringing sound. (see
following figure)
● When oil injector cannot inject oil well, dismount needle valve coupler to wash
(wash in clean diesel oil), and adjust pressure up to specified value.
Maintenance manual
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76
★ Needle valve and needle valve
body are pairing coupler, cannot
be exchanged in repairing.
★ When oil injector is reinstalled on
cylinder head, don’t miss the head
copper grommet and rear dust ring,
the copper grommet must be good,
if not, injector will bring about air
leakage or is blocked, new oil
injector require to use copper
grommet to adjust protective
height.
★ When checking oil injector, don’t
exchange cylinder nozzles, to
guarantee oil injector tip to protect
cylinder head bottom plane within
allowed range.
Oil delivery pump
● Whenever a vehicle runs 8000km,
oil delivery pump inlet connection,
filter screen and pipeline should
be cleaned.
● In operation, if finding the oil
delivery pump feeds impeded, or
doesn’t feed, check whether oil pipe connection has leakage, and inlet
connection filter screen is blocked.
● If there is air in oil delivery pump, which may handicap the normal operation of
oil delivery pump, therefore, the oil injection pump works again after it stops
operating for a long time, or replace oil pipe and connection, air will enter into
it, must discharge air. Discharge method is: unscrew discharge bolt, press the
hand pump pull button of oil delivery pump continuously, after discharging air,
tighten screw.
★ The piston spring, check valve, dust cover, sealing ring and gasket of oil
delivery pump are all consumable, cannot be used repeatedly, whenever they
are dismounted, must be replaced.
Bad spray Good spray
Discharge bolt
oil delivery pump oil injection pump advance unit

Maintenance manual
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77
Adjustment of valve clearance
● The clearance between valve rod and rocker is called valve clearance. Valve
clearance should keep within specified range, to guarantee engine work
normally. If finding valve sound, adjust in time.
● Generally every 8000km adjust once.
● Valve clearance (cool state)
Inlet valve: 0.30mm;
Outlet valve: 0.35mm;
Adjustment sequence:
● Toggle flywheel ring gear from the sight hole at left side of flywheel, to make
“1-6” mark on the flywheel align the hand fixed on flywheel housing, and to
make the first cylinder valve unlock simultaneously, then adjust valves
4,5,8,9,11,12 clearances in turn.
● Then crank crankshaft one circle, to make the mark on flywheel align the hand
(at that time to make the sixth valve unlock simultaneously), adjust valves
1,2,3,6,7 and 10 clearances in turn.
Adjustment method:
● Unscrew locking nut with special spanner and screw drive, insert feeler gauge
between valve stem end and rocker arm,
tighten adjusting bolt, to make the feeler gauge
be pressed slightly, when drawing out it, you
feel slight pressure, see the figure in next page.
● Screw down locking nut again, then recheck
once with feeler gauge.
Maintenance manual
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78
Supercharging system
● The connection of supercharger and inlet and exhaust pipes must be tight, if
there is air leakage between exhaust pie and waste gas turbine, supercharger
efficiency will drop greatly, diesel exhaust temperature will rise sharply, to
damage valve and supercharger.
● Before a new diesel starts, must fill clean engine oil into supercharger and the
engine oil filter of the supercharger, to guarantee the supercharger bearing to
get lubricating as soon as the diesel starts. After a vehicle runs 8000-10000km,
must replace supercharger engine oil filter element.
● Before the diesel stops, let it idle about 3-5 minutes to make supercharger
rotation speed decrease and temperature drop, and listen to supercharger
rotation sound. If finding any abnormal, must stop to check immediately. If
supercharger rotor doesn’t rotate easily, with detent or abrasion sound, they
should be sent to qualified service station to repair.
● Every 500h or 30000km, must check supercharger rotor spindle clearance, and
remove the dirt and soot on compressor turbine shell and rotor vane. At that
time, dismount turbine supercharger from diesel, replace the metal spacer
between supercharger exhaust pipes. Don’t allow removing the scaling on rotor
component with mechanical method, the scaling must be cleaned with gasoline
or other detergent to wash aluminium parts.
Caution
★ Don’t make any rotation parts dismounted from turbine supercharger be
damaged or deformed, otherwise, turbine balance will be influenced. And any
rubber sealing elements cannot be damaged either.

Maintenance manual
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79
1-tunbine casing 2-thermal baffle
3-turbine component 4-turnbine end
sealing ring 5-bearing shield ring
6-floating bearing 7-middle shell
8-distance thrust sleeve 9-thrust bearing
10-oil scraper board 11-compressor end
dog component 12-compressor casing
13-shaft seal 14-compressor end sealing
ring 15-compressor impeller 16-diffuser
17-O-rubber sealing ring
Axial clearance check:
● Nestle the contact of dial centesimal meter against the end of turbine drive shaft,
press down the shaft to centesimal meter to record indicated numerical value,
then push the shaft reverse to record numerical value. The difference between
both values is axial clearance, which cannot exceed 0.20mm.
Radial clearance check:
● Nestle the contact of dial centesimal meter against impeller body top, press
down impeller to record indicated numerical value, then raise impeller to record
numerical value. The difference between both values is radial clearance, which
cannot exceed 0.65mm.
Maintenance manual
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80
Check and adjustment of fan belt and water pump belt
● Check whether the belt has tortuous shell crack, chip, stripping, and strong
layer broken and damage, if it has, replace.
● Tension of fan and water belts should be often checked, over-tightness will
make water pump bearing and generator bearing damaged early;
over-looseness will cause belt creep to make engine over-hot.
● New belt should be rechecked and adjusted once after running 15 minutes after
a new belt is adjusted; check once after running 1000km, later, the belt
deformation gets stable, and is checked every about 2000km.
● Press 78N load on single belt, belt deflection should be 10-15mm, if it is not,
adjust the belt with moving generator and adjusting arm relative position.
★ When installing belts, the centerlines of several pulleys must be on the same
plane, if not, the belt durability will be shortened.
★ When check, tense and replace belts, must stop.
★ The pulleys must be tightened reliably on water pump flange, don’t allow any
looseness.
★ When replacing belts, two belts must be replaced simultaneously, a new one is
not collocated with an old one
Fan and fan clutch
1. Fan: If fan has the following
conditions, must replace immediately.
● Whether fan vane butt gets white, or
has crack.
● Serious deformation and torsion of
fan vanes.
● Fan vane is broken.

Maintenance manual
● ● ● ● ● ● ● ● ● ●
81
2. Fan clutch: Fan clutch must be check and adjusted 100% before it leaves the
factory, don’t dismount randomly in operation. If finding that the fan vanes has
silicone oil, which shows silicon leakage. If there are the following conditions
when checking, replace fan clutch.
● Fan clutch bearing has silicone oil bleeding.
● Double metal temperature sensor is damaged, such as broken, loose, seized,
lost.
● When turning it with hand, there is abnormal sound or it is not turned.
● When turning it with hand, fan clutch is abnormally easy.
● Fan vane tip swings over large
● In fan hub interior and fan clutch edge there is silicon exudation.
● At fan clutch pin shaft, and housing and front cap junction surface there is
silicon oil exudation or when engaging, fan rotation speed drops over 10%.
Emergency measures:
● When the vehicle is running, under the conditions that fan belt is not loose,
temperature regulator, water pump, and fan work normally, radiator is not
blocked, if coolant is over hot, check and replace fan clutch.
● Under the condition that fan clutch has leakage, pry double-metal temperature
sensor, turn clockwise (about 25) pin shaft valve plate to make fan clutch in
engage state.
● Replace in time until
return the vehicle to the
garage.
1-fan clutch assembly
2-fan assembly
3-locking block
Maintenance manual
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82
Water pump
If there are the following conditions, replace water pump
● Water pump impeller and shaft is loose. When grasping connection flange, turn
impeller with hand, the impeller and shaft turn.
● Water pump flange and shaft is loose. When grasping impeller, rotate
connection flange with hand, the connection flange and shaft turn.
● Water sealing leak.
● Bearing makes abnormal sound or is seized. (Since the water pump adopts
shaft-connected bearing, it is unnecessary to maintain and fill lubricating oil
routinely.
● Water pump impeller and water pump casing eroded seriously. The impeller
doesn’t work, make water in hull or the link surface between hull and cover
board make water.
Caution
★ Since water pump assembly adopts integral pressing process, if there appear the
above-mentioned conditions, must replace water pump assembly, not parts.
Temperature regulator
● Check the unlocking temperature of temperature regulator.
○ Put temperature regulator into water trough and heat water up to specified
temperature.
○ Check the unlocking temperature of temperature regulator.
The unlocking temperature of temperature regulator should be 76±2℃, if the
unlocking temperature of temperature regulator is not within the
above-mentioned temperature, temperature regulator should be replaced.
● Check temperature regulator lift:
○ When temperature continues to rise, and keeps 86℃, check temperature
regulator lift. The temperature regulator lift should be ≥8mm, if the lift does
not reach the specified value, replace temperature regulator.
● Check spring force when the temperature regulator is closed completely, if
necessary, replace temperature regulator.
● Check hose and diaphragm to see whether they have wax leakage, if necessary,
replace temperature regulator.

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