Howo 70 Tons Operation Manual

Foreword
Dear customers,
Many thanks for choosing HOWO trucks! Please read this manual carefully before the new vehicles run into operation. And hope you could enjoy your
driving experience.
This manual is about operation and maintenance of HOWO brand ZZ5707, ZZ5507 series off-road dump trucks. It contains the technical information of
HOWO trucks such as operation/performance and structure/maintenance/adjustment and so on. You can find the related assembly information and
attentions according to the specific configuration of your vehicles.
To ensure the normal life of vehicles and obtain the good economic benefit, all the instructions of the operation and maintenance requirements mentioned
in this manual need strictly to be followed.
Pure fuel in accordance with the quality requirement is required to be used during the vehicle’s running. All chosen oil, lubricating oil, hydraulic oil etc.
for vehicles shall be consistent with the grades provided by this manual.
This manual should be used with the “Operation and Maintenance Manual of WD615 Series EuroⅡEngine”, “Operation and Maintenance
Manual of WD615 Series EuroⅢ Engine”, “Operation and Maintenance Manual of D12 Engine”, “Operation and Maintenance Manual of
HW Series Transmission”, “Operator’s Manual of Allison series transmission” and “Operation and Maintenance Manual of Cargo Lifting System” which
are delivered with vehicle together.
When the vehicles break down, please contact the authorized service station by SINOTRUK immediately, and we will supply the timely and effective
services to you.
This manual is the latest edition for vehicle’s operation and maintenance and we reserve the rights of technical alteration and upgrades for better
improvement without prior notice.
Special Attention: Off-road dump truck is not allowed to drive on the road.
China National Heavy Duty Truck Group Co.,

Ltd.
2017.04
Without SINOTRUK’s approval, it is forbidden to make reproduction, copy, translation or extraction. This Operator Manual is under the protection of
the Copyright Law, and all rights are reserved by SINOTRUK.
Vehicle No.
In order to maintain your vehicle conveniently, please fill the Vehicle No. accurately and completely:
Vehicle Model:
VIN:
Engine Code:
Purchasing Date:
ATTENTION:
1. Vehicle model number is printed on the nameplate on front wall of cab (it can be seen while opening the front cover) .
2. VIN code is punched on the ventral shield of right longeron of frame and stands at the centerline of front-axle.
3. Engine No. is punched on the left block of the engine (Check it along the direction of driving) .
ATTENTIONS:
1. When there is welding work in or near the vehicle, it is a must to cut the battery power and unplug all electronic components (electrical connection box, instrument panel, ECU of engine
and ABS etc.) and related connectors.
2. In winter, the water in brake cooling tank must be drained in order to void freezing.
3. The right window of cab can be used as emergency window.

CONTENTS
5.1 Starting...........................................................................................37
Section 1 Operation.......................................................................1
5.2 Gears and Operation of Gearbox....................................................38
1. Operation of Door...................................................................................2
5.3 Operation of Diff-lock....................................................................38
2. Internal device of cab..............................................................................3
5.4 PTO Control...................................................................................40
2.1 Combination Instrument (SAC).......................................................4
6. Operation in Winter...............................................................................41
2.2 Switch panel.....................................................................................5
6.1 Cooling system...............................................................................41
2.3 Sign of signal lamp’s summary sheet(SAC)....................................6
6.2 Brake system..................................................................................41
2.4 Rocker Switch symbol......................................................................9
6.3 Brake Cooling Device....................................................................42
2.5 Power Switch..................................................................................13
6.4 Battery............................................................................................42
2.6 Combination Switch.......................................................................14
7. The Replacement of Spare Tire.............................................................43
2.7 Fog Lamp and Interior Lamp (Pic. 2-12).......................................17
8. New Vehicle Running-in.......................................................................44
2.8 Operation instruction of hand throttle............................................18 Section 2 Operation and Maintenance of Main Components
2.9 Seat.................................................................................................19
................................................................................................... 45
2.10 Shift Handle..................................................................................20
2.11 Retarder control handle................................................................20 1. Engine....................................................................................................46
2.12 Hand Brake Valve (Parking brake of energy-storing with spring) 1.1 Engine low-temperature starting and cab heat supply device
................................................................................................... 21 (optional)........................................................................................47
2.13 Others Internal device of cab........................................................22 1.2 Electric heater of inlet air pipe (Optional)......................................54
3. Exterior of the driver’s cab....................................................................24 1.3 Replacement of the engine oil........................................................55
3.1 Opening of the radiator mask.........................................................24 1.4 Replace the fuel filter.....................................................................56
3.2 Rear mirror.....................................................................................25 2. Inlet air syste.........................................................................................57
3.3 Operation lighting lamp..................................................................26 2.1 Cyclone pre-filter............................................................................57
3.4 Expansion Tank..............................................................................26 2.2 Oil bath air filter.............................................................................58
3.5 Cab suspension...............................................................................27 2.3 Air filter..........................................................................................61
3.6 Tilting and lifting system of cab.....................................................28 3. Clutch....................................................................................................62
4. Preparation before Driving....................................................................30 3.1 Operation Principle of Clutch Operation System...........................63
4.1 Duty Check before Driving............................................................30 3.2 Operation Parameters of Clutch Operation System........................63
4.2 Start the engine...............................................................................34 3.3 Clutch and clutch operation system installation and debugging
4.3 Turn off the Engine.........................................................................36 ................................................................................................... 64
5. Starting and Shift...................................................................................37 3.4 Attentions.........................................................................................65
3.5 Common Errors and Solutions..........................................................65 Quick insert connector 104
4. Transmission.........................................................................................66 9.5 Braking cooling device................................................................104
4.1 Main Performance Parameters of Transmission.............................66 9.6 Operation of ABS (optional)........................................................108
4.2 Installation and Adjustment of Flexible Shaft Control System
9.7 Use of air charging connector.......................................................108
(Onlyfor mechanical transmission).......................................................67 9.8 Braking pipeline maintenance......................................................108
4.3 Control Mechanism(Only mechanical transmission).....................69 10. Electrical instrument and control system (SAC)..............................109
4.4 Pneumatically Controlled System(Only for mechanical transmission)
10.1 System overview........................................................................109
................................................................................................... 70 10.2 Mini controller...........................................................................110
4.5 Power Take-off..............................................................................71 10.3 Combination instrument.............................................................111
4.6 Operation and Maintenance of Transmission................................71 10.3.1 Instrument panel (SAC)..........................................................111
5. Operation and Maintenance for Front Axle..........................................74 10.4 Instructions for Electric Connector Box (SAC).........................123
5.1 HF10 front axle (for ZZ5507)........................................................74 11. Air Conditioner..................................................................................126
5.2 HF12 Front Axle (for ZZ5707)......................................................76 11.1 System Brief Introduction..........................................................126
5.3 Operation and Maintenance for front Axle....................................79 11.2 Instruction...................................................................................128
5.4 Troubleshooting and solutions.......................................................80 11.3 Notice..........................................................................................129
6. Use and Maintenance of Drive Axle.....................................................81 11.4 Repair and Maintenance.............................................................130
6.1 Main specifications of rear driving axle........................................81 11.5 Failure diagnosis and solutions table..........................................131
6.2 Operation and maintenance of drive axle......................................82 Section 3 Maintenance of Vehicle............................................133
6.3 Main bearing pre-tightening force and gear clearance...................84 1. Interval Mileage of Routine Inspection & Maintenance.....................134
6.4 Common Errors and Solutions in rear axle....................................86 2. Specifications and filling volume for lubricating oil and fluid...........135
7. Suspension System................................................................................89 3. Maintenance Items..............................................................................136
7.1 Front suspension system................................................................89 3.1 Regular Maintenance Items..........................................................136
7.2 Rear suspension system.................................................................93 3.2 Maintenance Tasks of Every Grade..............................................136
8. Steering system.....................................................................................96 4. Chassis Lubrication.............................................................................142
8.1 Steering Operation System.............................................................96 5. Electric Welding Maintenance Precautions........................................143
8.2 Hydraulic steering booster system.................................................97 Section 4 Appendix....................................................................144
9. Brake System.......................................................................................100
9.1 Service Brake...............................................................................100 1. Bulb list...............................................................................................145
9.2 Auxiliary Brake............................................................................101 2. Schematic Diagram of Brake System.................................................146
9.3 Emergency and Parking Brake.....................................................103
9.4
Section 1 Operation
Operation 1
1
Section 1 Operation
1. Operation of Door
Warning: Driving without door locked is forbidden!
① Use the Door Lock from Outside
Open the door: When the door is not locked, pull down the handle
to open the door(As shown in picture1-1); if the door is locked, insert the
key and turn 70° anticlockwise(As shown in picture1-2), then pull the Pic.1-1 Pic.1-2
handle to open.
Lock the door: Insert the key and turn 70° clockwise, the door
will be locked.
② Use the Door Lock from Inside
Open the door: Pull the handle (As shown in picture 1-3) and push
the door to open.
Lock the door: Close the door directly
Pic.1-3
2
Section 1 Operation
2. Internal device of cab
Pic.2-1
3
Section 1 Operation
2.1 Combination Instrument (SAC)
1. Engine tachometer 2. Speedometer 3. Engine water temperature gauge 4. Air pressure gauge 5. Button Ⅱ
6. Display screen 7.Button 1 8.Voltage gauge 9.Fuel gauge
4
Section 1 Operation
2.2 Switch panel
1. Handle of hand brake valve 2. Rocker switch 3.Air conditioner control panel and LCD 4. Horn button
5. Steering wheel 6. Transmission shift handle 7. Cigar lighter 8. Hand throttle (Idle Knob) 9.MCS (Turn Page)
Pic.2-3
5
Section 1 Operation
2.3 Sign of signal lamp’s summary sheet(SAC)
Pic.2-4
6
Section 1 Operation
Sign of signal lamp and function description(SAC)
No. Description Signal Colour No. Description Signal Colour
1 Truck left turning indication Green 10 Fault of brake system Red
2 Trailer left turning indication Green 11 Air suspension Red. yellow
3 Trailer right turning indication Green 12 Retarder alarm Red. yellow
4 Truck right turning indication Green 13 Low beam lamp Green
5 Engine oil alarm Red. yellow 14 Low level of coolant Red
6 Alarm symbol Red. yellow 13 Low beam lamp Green
7 Alarm lamp for fault of engine Red. yellow 14 Low level of coolant Red
8 Emergency stopping Red 15 Day running lights Green
9 Parking brake Red 16 Non-locking of cab Red
7
Section 1 Operation
No. Description Signal Colour No. Description Signal Colour
17 PTO 1 Red yellow 28 Small lamp Green
18 PTO 2 Red yellow 29 Exhaust fault Yellow
19 Low level of adblue Yellow 30 Engine speed too high Red
20 ASR working indication Yellow 31 Safety belt fault Red
21 Lifting axle Green 32 Vehicle overspeed Red
22 Front fog lamp Green 33 Low gear Green
23 Cruise indication Green 34 High temp.of coolant Red
24 High beam lamp Blue 35 Air pressure of indicator 1 Green
25 Main truck ABS alarm Yellow 36 Air pressure indicator 2 Green
26 Trailer ABS alarm Yellow 37 Alarm of battery voltage Red
27 Rear fog lamp Yellow 38 Low level of fuel Yellow
8
Section 1 Operation
2.4 Rocker Switch symbol
9
Section 1 Operation
Rocker switches and function description

(Including indicators. It is invalid when the key switch is on 1 gear, unless specified description)
Item Description Status Function Remarks

0 Both Position Lamp and Headlamp Off
Instrument lamp works at Shift 2 and Shift 3,
1 Lamp Switch 1 Position Lamp On/Headlamp Off
headlights will not work
2 Both Position Lamp and Headlamp On headlights will work,the combination switch work
0 Off
2 Front Fog Lamp Switch Precondition: Shift 1 of lighting switch has been
1 On
turned on.
0 Off
3 Rear Fog Lamp Switch Precondition: 1) Shift 1 of lighting switch has been
turned on, front fog lamp has been turned on also; or
1 On
2) Shift 2 of lighting switch has been turned on.
0 Off
4 Serious Alarm Switch
1 On 1, 2, 3, 4 shifts of key switch are available；
0 Electric horn Press horn button on the steering wheel
5 Horn transferring switch
1 Air horn Press horn button on the steering wheel
0 Off
6 Working Lamp Switch
1 On Working Lamp lights
0 Off
7 Front Working Lamp Switch
1 On Front working Lamp lights
10
Section 1 Operation

0 Off
PTO magnetic valve is operated, and the
8 PTO switch
1 On indicator will flash until PTO switch put in right
place, then the indicator lights completely.
0 Off
9 Interwheel Differential Interwheel differential magnetic valve will work, and

the indicator will flash until interwheel differential
1 On
switch put in right place, then the indicator lights
completely.
0 Off
Interaxle differential magnetic valve will work, and
10 Interaxle Differential the indicator will flash until interaxle differential
1 On
switch put in right place, then the indicator lights
completely.
0 Off
11 Brake Cooling Switch Brake cooling solenoid valve operates and water
1 On
sprays.
0 Off
Warming/ Warming/preheating solenoid valve operates. The
12
preheating Switch of Engine 1 On indicator light will be partly on if the switch is not in
place and be completely on if it is in place.
0 Off
13 Heater Switch Heater water pump operates and green indicator light
1 On
is on.
11
Section 1 Operation

0 Off
14 Radiator Switch
1 On Radiator is opened and green indicator light is on.
0 Off
15 Engine Brake Exhaust valve is closed and EVB start working, green
1 On
indicator lights on.
0 Off
16 ECU Diagnostic switch
1 On If there is a malfunction of the instrument lights flashing
0 Off
17 ABS test switch
1 On If there is a malfunction of the instrument lights flashing
0 Off
18 Fuel heating switch
1 On Fuel oil filter to open the fuel heating function
The upper character flashes to
Hydraulic automatic transmission
indicate that the gearbox is faulty
Transmission status
19 The lower character flashesto
indicator
indicate that the transmission oil Hydraulic automatic transmission
temperature is high
0 Off
20 Retarder switch Retarder power, steerable retarder gear handle to open
1 On
retarder function
Notice:
After pushing the interaxle diff-lock switch, the signal lamp will flash, if there is feedback signal from interaxle diff-lock
switch within 5 seconds, the signal lamp for interaxle diff-lock will be completely on; if there is no feedback signal, check
driving output of interaxle diff-lock magnetic valve, and if the output is normal, the lamp will be completely on.
12
Section 1 Operation
2.5 Power Switch
2.5.1 Master Power Switch
The master power switch is at outside of battery box on the longeron of frame (Pic.2-5). Notice:
Switch off if out of using for long time to avoid accident.
The master power switch cannot be closed until the fuel heater switch has been closed for 3 minutes.
Pic.2-5
2.5.2 Key Switch
The key switch is on the steering column. Function of each position is shown as follows.
Position Purpose Remarks
1 (ACC) Switch on the electrical facilities on condition of parking
2 (LOCK) Power cut off Key may be removed
3 (ON) Driving
4 (START) Start engine Return to position 3 automatically

Pic.2-6
13
Section 1 Operation
2.6 Combination Switch

2.6.1 Operation for Steering Indicator: (Pic.2-7)
Pic.2-7 Pic.2-8
1. Turn right
2. Turn left
Notice: When the steering lights on, the indicating lamp on the instrument panel also flashes. If some bulb of indicating lamp
is damaged (lack of all bulb power reaches 21W, the flash of indicating lamp will be more frequent (frequent doubling) ; defect
notice will be shown on information screen at the same time.
2.6.2 Serious Alarm
Power on and press serious alarm switch, then all the steering lights and indicating lamps will be on.
14
Section 1 Operation
2.6.3 Operation of Front Lamp (Pic. 2-9)
High/lowOvertaking beam
dimming
Pic.2-9
Combination switch handle is at middle position. When the key is at position 3 and lamp switch is at shift 2, the low or high beam will be on. Then lift
the handle to 4°upward, the low and high beam will be both on. Continue lifting the handle to 10 degree, the low or high beam will change to the other.
The handle can reposition itself.
When overtaking/passing or meeting vehicles at day time, lift the handle by 4 degrees to turn on high beam, then the handle will reposition after your
action.
2.6.4 Windscreen Wiper and Cleaner (Pic. 2-10)
0 - OFF J - Intermission I
- Low II - High
Press - Windscreen cleaner
Pic.2-10
15
Section 1 Operation
2.6.5 Horn Button
Horn conversion switch
Horn Button
Pic.2-11
There two kinds of horn equipped on truck-electrical horn and electrical controlled air horn. The conversion between them can be realized by horn
conversion switch.
The horn button is installed on the steering wheel (Pic. 2-11). When operating the electrical controlled air horn, first turn on the horn conversion
switch (rocker switch), then press horn button on steering wheel.
16
Section 1 Operation
2.7 Fog Lamp and Interior Lamp (Pic. 2-12)

Front fog lamp switch Rear fog lamp switch
Front fog lamp Rear fog lamp
Pic.2-12
Notice:
The front and rear fog lamps can only be operated when the lamp switch is on.
2.7.1 Front fog lamp

Lamp switch is at position 1;
Press front fog lamp switch, the front fog lamp will be on and also indicator on the instrument panel.
2.7.2 Rear fog lamp

Lamp switch is at position 2, or the front fog lamp is on;
Press rear fog lamp switch, the rear fog lamp will be on and also indicator on the instrument panel.
17
Section 1 Operation
2.7.3 Interior Lamp (Pic.2-13)
Pic.2-13
Press left end of interior lamp switch and the interior lamp will be on, press right end and the interior lamp will be off.
2.8 Operation instruction of hand throttle

The hand throttle is set on the switch panel of cab (Pic.2-14). After starting vehicle, keep the hand throttle at one position and make vehicle drive
smoothly during driving. It is unnecessary for the driver to always keep foot on accelerator pedal, thereby alleviating the driver’s fatigue. In case of
emergency, the hand throttle can be used to cut off fuel supply directly to ensure safety drive.
1. Step the accelerator pedal to a position for appropriate rotating speed of engine, pull out the throttle handle slowly;
2. Rotating speed of engine can be slightly adjusted by turning the end cover of hand throttle handle;
3. When shifting gear, the throttle should be reset at original position.
Notice:
1. At idle speed, the clearance between the retaining nut on throttle cable and the spacing sleeve is
0~1mm;
2. On parking state, the engine rotation controlled by the hand throttle is required to be at 2150～2200r/
min as appropriate ;
3. To avoid the cable break, it is inappropriate to continuously increase the rotation on high rotating speed range.
Warning: In case of emergency, the hand throttle must be reset on initial position immediately. Pic.2-14
18
Section 1 Operation
2.9 Seat
HOWO seat is a new type, with waist support device and double-locking sliding rail, and the backrest is 2-section adjustable unit.
The backrest, designed to be of luxurious high backrest type, consists of the upper and lower parts. The small backrest is used to adjust the bending arc of
the backrest to make driver’s shoulders properly supported and can relieve the driver from fatigue.
2.9.1 Main Technical Parameters

(1) Width: 490mm (2) Height: 935mm (3) Height adjustment: 0～65mm (4) Forward and backward adjustment: 0～±75mm
(5) Adjustment of backrest angle: 0～41.4° (backward relative to vertical line), 0～60° (forward relative to vertical line).
2.9.2 Operation Method

(1) Forward and backward adjustment
Lift the handle and adjust the seat position (Pic. 2-15)
(2) Front height adjustment
Lightly lift the handle and force the front of the seat upward or downward
to adjust the front of the seat . Free the handle when the position is all right.
(3) Rear height adjustment Pic.2-15
Lightly lift the handle and force the rear of the seat upward or downward
to adjust the rear of the seat . Free the handle when the position is all right. (Pic. 2-16)
(4) Backrest adjustable handle
Turn the handle to adjust the backrest to right position. (Pic. 2-16)
(5) Backrest elevation adjustment
List the handle to adjust the elevation of backrest.
Pic.2-16
19
Section 1 Operation
2.10 Shift Handle

The shift handle is mounted on the engine hood (Pic.2-17). Vibration interference of the cab can be eliminated and the transmission is not easy to be out of gear. In addition, tilting
of cab cannot be affected.
Pic.2-17 Pic.2-18
Allison automatic transmission shift handle is installed on the same position. The left picture of pic2-18 is for the fourth generation control handle, and the right is for the fifth
generation control handle. Refer to “Operator’s Manual of Allison series transmission”.
2.11 Retarder control handle

Retarder master switch located on the rocker switch panel (Pic. 2-19),Retarder gear control lever located on the right side of hand brake valve (Pic.2-20). When using retarder, you must open the
master switch first, and operate the retarder control handle then to select the appropriate gear retarder. Refer to “Operator’s Manual of Allison series transmission”.
Parking Brake
Retarder control handle

Pic.2-19 Pic.2-20 Pic.2-21
20
Section 1 Operation
2.12 Hand Brake Valve (Parking brake of energy-storing with spring)

The hand brake valve is at right side of instrument panel. (Pic2-22) . (As
shown in picture is at ‘brake’ position)
Only when the hand brake signal lamp is off and the air pressure is over 0.55 MPa (5.5 bar), the hand brake can be released completely,
then the vehicle can start.
Warning: Do not drive the vehicle before the signal lamp is off!
Hand Brake Valve
Pic.2-22
21
Section 1 Operation
2.13 Others Internal device of cab
2.13.1 Sundry goods box, sunshield,cup seat and radio (Pic. 2-23/24)
There is one sundry goods boxes on either side symmetry.
2.13.2 Safety Belt (Pic. 2-25)

(1) Wearing Safety Belt Pic.2-23 Pic.2-24
Pull the seat belt lock, make belt around the shoulder and insert the latch into the socket until you hear the voice of meshing.
(2) Releasing Safety Belt
Press the red button on the safety belt lock according to the direction of the arrow, pull out the latch, the safety belts will come back to the original
position.
Pic.2-25
Notice: Please wear the safety belt well before driving every time! Check the performance and functions of the safety belt
every day.
22
Section 1 Operation
2.13.3 Sleeper and electric apparatus box and tool box (Pic. 2-26/27)
(1) Combined sleeper, 1 piece of which is the electric cabinet box cover, and 1 piece is the tool box cover.
Sleeper
Electric apparatus cabinet
Pic.2-26 Pic.2-27
(2) Water-cleaning-free detergent for hands with oil dirty is affixed at the side of the tool box. Remove the ball bottle cap to make the detergent
flow out. See the package for detailed instructions.
23
Section 1 Operation
3. Exterior of the driver’s cab
3.1 Opening of the radiator mask
Pull the pull ring as shown in Pic. 3-1, and remove the radiator mask.
Pic.3-1
24
Section 1 Operation
3.2 Rear mirror
Pic.3-2(a) Pic.3-2(b)
Shown in Pic. 3-2 (a) and 3-2 (b):
1-Left close-proximity mirror 2, 3-Rear left mirror 4, 5-Rear right mirror 6-External close-proximity mirror 7-Front lower mirror
25
Section 1 Operation
3.3 Operation lighting lamp 3.4 Expansion Tank

The operation lighting lamp is show in Pic. 3-3, with 2 respectively
The expansion tank is located at the left side of the back of the cab.
at the front and rear sides, and the left and right sides are arranged
(Pic. 3-4)
symmetrically and the angle is adjustable. The operation working
lamp is controlled by the rocker switch in the cab and can be turned
on simultaneously or separately.
1. Water filler 2. Relief valve 3. Scale
Pic.3-3
Pic.3-4
26
Section 1 Operation
3.5 Cab suspension

3.5.1 Front suspension:
Rotator plus rubber shock absorption unit is applied to the front suspension of the driver’s cab. Pic. 3-5.
Pic.3-5 Pic. 3-6 (a) Shock absorber (helix spring) Pic. 3-6 (b) Hydraulic lock assembly
3.5.2 Rear suspension

The left and right structures of the rear suspension are completely the same and are provided with bi-shock absorber plus hydraulic lock
structure, safe and reliable. Pic. 3-6 (a) and 3-6 (b)
The hydraulic lock assembly and the supporting lock shaft are applied with lithium-based grease. Models of the
left and right shock absorbers are different, which cannot be exchangeable or mixed.
3.5.3 Check the Suspension System

Check if the hydraulic lock engages and disengages normally.
27
Section 1 Operation
3.6 Tilting and lifting system of cab
a. Manual hydraulic oil pump

b. Transfer handle
c. Oil plug
Pic.3-8 Pic.3-9
(4) Turn the tilting hand lever of the titling oil pump to“↓” position, tip
down the cab to its original position with hand pump. Turn the titling hand
lever to “↑”position when the oil cylinder gets to the bottom dead point.
Pic.3-7
Shake hand pump 2-3 times to make the pin on the oil cylinder in a free
3.6.1 Tilting operation (Pic.3-7)
state.
(1) Before tilting, remove all the loose articles from the cab.
(2) When tilting, nobody should stand near the front of the cab (Pic.3-8)
Warning: Tilting operation in the ramp is forbidden.
(3) Turn the titling hand lever of the titling oil pump to “↑”position, tip up The cab should be turned to limit position every time, all the
the cab with hand pump. (Pic.3-9) It is not permitted to change the handle operation must be conducted after the cab getting across top
position during tilting. dead point.
Nobody may enter the cab when it is tilting up.
28
Section 1 Operation
3.6.2 Fill oil and discharge air of the tilting system

(1) Remove oil plug c and fill up specific fluid.
(2) Filling oil as tilting up the cab by running the pump manually.
(3) Drop the cab at the same time to make the redundant oil spill out.
(4) Tilt up the cab using the oil pump once more, check the fluid level and fill up after the cab drop back.
(5) Screw the oil plug at last.
Warning: To fill oil and discharge air in tilting system, the cab must be back in origin position.
The hydraulic fluid should be HVN32 anti-freeze fluid, and the amount filling in is about 0.4 liter. Check the hydraulic fluid for cleanness, fill
in if it meets the requirement.
3.6.3 Check Function of the Titling System

(1) Turn the cab to top dead point, and observe dropping of cab after exceeding the TDP,if the cab drop down slowly with damp and without
impact, that means the system operate normally.
(2) The cab should keep it position for 20min without sinkage as tilted for about 30 degree.
29
Section 1 Operation
4. Preparation before Driving
Warning: Make sure no defect before driving!

Preparation includes: duty check before driving, ignition and flameout.
4.1 Duty Check before Driving

4.1.1 Turn on the main electrical power switch to electrify power supply of vehicle. (Pic.4-1)
4.1.2 Check electrical system (system check automatically) Pic.4-1
Master power switch
When the key switch is at the ON position, that is, bus system will self-check after KL15 turning on. After that, all parts will operate as following:
All instruments: Every instrument finger starts from mechanism terminal, and rotate to scale span within 2 seconds. Later on, the odometer
and engine tachometer return to zero position, and air pressure gauge, fuel gauge and water temperature gauge show the real value of current system.
All indicators: All indicators will light up for one second, and then return to real condition.
LCD: Interval of two seconds, it displays SINOTRUK logo firstly and then displays normal driving interface (displays voltage and oil pressure).
After self-checking, if any switch of interaxle differential, interwheel differential lock switch and all-wheel driving switch is on, the differential
lock indicator interface will be displayed;
If above mentioned differential locks are not engaged and error happens, the interface will enter into error information page;
If the two situations above mentioned do not exist, but the working indicator symbol of other indicator interface is working, the system will switch to
indicator interface.
If above mentioned three situations do not appear, the system will stay on normal driving interface.
Notice: It is strictly prohibited to cut off electric circuit connection between battery and body center computer under unclosing
key switch or other input power with wake-up function! Otherwise, all components including the system control units, wire
harness and electronic components of whole vehicle may be damaged, and system data may be lost and down to cause vehicle
unavailable!
30
Section 1 Operation
4.1.3 Check coolant level and Fill coolant. (Pic.4-2)

Check coolant level. Fill the specified coolant to scale if it is insufficient.
Relief valve on expansion can raise boiling point of coolant by keeping inner higher pressure than atmospheric
pressure outside. It is not permitted to change or damage the valve at random. It is especially important in
tableland area.
When the temperature of engine is still low, fill the coolant by two steps: first, release high pressure slowly from
the filling port; second, open the filling port cover, and fill coolant during idle speed.
Note: when the fuel heating for low-temperature starting and heater in the driver’s cab, see the “engine low-
temperature starting and driver’s cab heat supply device” in Part II of the instruction manual (optional).
Warning: Filling coolant in high engine temperature is forbidden!
(1) Check fuel quantity
Pic.4-2
Turn on the key switch to check fuel through the fuel gauge. If it shows incorrectly, please check fuel gauge and sensor.
(2) Check engine oil (Pic.4-3)
Park the truck on horizontal road. After the engine cools down, pull out oil gauge,the level should be between upper and lower scales (around 3L). Fill
specified engine oil if it is insufficient with the stipulated oil.
Pic.4-3
31
Section 1 Operation
4.1.4 Check and remove the water in brake air reservoir
When the vehicle is stopped, pull or push the drain valve 1 to remove water from air reservoir. If liquid mixed by water and oil, the drier is
invalid and it is necessary to change a new one. (Pic. 4-4).
Pic.4-4
4.1.5 Check air pressure of tyres.
4.1.6 Check leakage of lubricant, coolant and air.
32
Section 1 Operation
4.1.7 Check Air Intake System (Pic.4-5)

(1) Check if there is any foreign object at the inlet of the pre-filter to prevent extra large negative pressure in the inlet air system; at the air inlet of
the pre-filter, check the impeller can rotate freely or not with the fine rod; otherwise, repair or replace the pre-filter to extend the maintenance cycle of the
air inlet system.
(2) Check the pipeline from the air filter outlet to the booster inlet is damaged or not. In case of damage, seal and replace with new components;
otherwise, early wear may be caused.
(3) Check the alarm indicator for jamming of air filter alerts or not. If the air filter is jammed, the signal lamp is on. If alerting, check the metal filter
element and the paper filter element are jammed or not, and maintain or replace timely.
(4) The oil can not be added into the oil-bath air filter excessively, the added oil depth no more than 50mm or added oil volume no more than 10L for oil-
bath filter with model of ZZ5707 and added oil depth no more than 50mm or added oil volume no more than 6L for oil-bath filter with model of ZZ5507.
In general, the oil-bath air filter shall be maintained once after 80-150 hours’ use. The metal filter element can be cleaned and used for a long time. It is
replacement-free without damage. Under severe conditions, dust deposit in the metal filter element and oil bottom enclosure shall be checked and
removed every day.
After the metal filter element and the oil bottom enclosure have been cleaned, if the jamming alarm still alerts, clear the paper main filter
element. The main filter element shall be replaced after 5 times of maintenance and the security filter element shall be replaced simultaneously. The
security filter element cannot be used for a second time after clearing.
2
Filter Plug 3
1
1. Dust collection orifice
2. Environmental temperature sensor
3. Filter clogging sensor
Pic.4-5
4.1.8 Make sure that no person or other obstacles near the vehicle before driving.
33
Section 1 Operation
4.2 Start the engine

4.2.1 .Switch on the master power switch and turn the key to “START” position to start the engine.
Notice: When driving, do not turn off the key switch. The key is at “ON” position (drive position) when driving.
Pic.4-6 Pic.4-7
4.2.2 Starting
Launch hand brake. Shift to neutral and turn the key to start. After started, the charging indicator lamp will be off.
Notice: ① If failed to start for first time, turn the key to “LOCK” position and start again.
② Every start should be less than 15 seconds and at least 30 seconds between two times of starting.
34
Section 1 Operation
4.2.3 Check engine oil pressure

After engine is started, watch the engine oil pressure value. The signal lamp on instrument for oil pressure should be off if the oil pressure is normal.
Notice: The engine should never work with high speed while it is cold! Check and repair the vehicle immediately if no oil pressure
value is shown on instrument after starting the engine.
4.2.4 Operation of Turbocharger

Turbocharger is at top-back of the engine, composed with turbo parts and pump wheel parts. The exhaust gas goes into the turbo and makes the pump
rotate with high speed, then press the compressed air into the air inlet pipe of the engine to enlarge air pressure and enhance the engine power.
The rotor of turbocharger has very high speed (7000~10000 rpm). The rotor bearing is lubricated by enforcement and the lubricant is supplied by engine
main oil pipeline. Lubricant is cut with flameout.
Notice:
① The engine should work in idle speed for 3~5 mins after started without hard accelerating before the oil pressure and
temperature is normal (especially in cold weather), or the bearing and sealing ring of turbocharger will be damaged in advance.
② The engine should run in idle speed for 3~5 mins before flameout. Flameout after the speed of turbocharger goes down. No
hard accelerating before flameout because it will cause high speed and lubricant pump will stop immediately after flameout, the
rotor axis, bearing and sealing ring will be damaged in advance.
③ Pre-lubricate the turbocharger before starting the engine which has not been started for a long time. You may remove the oil
inlet pipe of the turbocharger and fill some clean lubricant to avoid the turbocharger from being damaged.
35
Section 1 Operation
4.3 Turn off the Engine

Press exhaust brake switch when the vehicle runs on a long slope (for Euro2, Picture 4-8(a)), or dial the exhaust brake switch to the working position
(for Euro3, Picture 4-8(b)), then the fuel supply will stop and the vehicle will get into the flameout idle state.
Turn the key to ‘LOCK’ position and the engine will stop, then turn off the main electric switch and remove the key for the switch.
Warning: After working with heavy loading, the engine should stop after 3~5 mins working in idle speed.
Pict.4-8 (a) EuroⅡvehicle Pic.4-8 (b) Common rail EuroⅢ vehicle
36
Section 1 Operation
5. Starting and Shift
5.1 Starting
After starting the engine, the vehicle cannot be started if low air pressure warning lamp and alarm is on. After the air pressure reaches
0.55MPa (5.5 bar) and lamp or alarm is off, release the hand brake to start the vehicle.
Pic.5-1 Pic.5-2
1. Clutch pedal 2. Brake pedal 3. Accelerating pedal
37
Section 1 Operation
5.2 Gears and Operation of Gearbox

Refer to the operation details in Transmission Operation System of Section 2.
5.3 Operation of Diff-lock
Wheel differential switch Axle differential switch

Wheel differential Axle differential
Pic.5-3
The driving axles are equipped with diff-locks. When the wheels are sliding or trapped in mud, use the diff-lock to gain more traffic ability.
Diff-locks include inter-wheel diff-lock and inter-axle diff-lock and there is only inter-wheel diff-lock for single axle.
Operation Principle: First engage inter-axles diff-lock, then for inter wheels.
38
Section 1 Operation
5.3.1 Inter-axle diff-lock

Inter-axle diff-lock is for locking the differential between the first and second driving axle.
Engage: When the vehicle is halted state or going straightly under low speed (equivalent to walking speed). Press the switch for inter-wheel
diff-lock and the indicating lamp will be on after engaged.
Warning: When driving, release the clutch before engaging the inter-axle diff-lock!
Release: Stop accelerating and release the clutch, then press top of the switch. The indicating lamp will be off after the lock is released.
5.3.2 Inter-wheel diff-lock

Inter-wheel diff-lock is for locking the inter-wheel lock of the first and second driving axle.
Warning: Inter-wheel diff-lock can only be used when vehicle is going straightly.
(1) Engage: Only when the vehicle is in halted state or driven in straight line under low speed (equivalent to walking speed), can the inter-
wheel differential lock be engaged.
Press the rocker switch for inter-wheel diff-lock and the indicating lamp will be on after inter-wheel diff-lock being engaged.
Warning: During driving, release the clutch before engaging!

(2) Release: stop accelerating and release the clutch, then press top of the rocker switch. The indicating lamp will be off after the lock is
released.
Caution:
① When the indicating lamp of inter-wheel diff-lock is on, the vehicle should not turn or drive in high speed.
② After getting through the rough road, the diff-lock should be released immediately. Stop accelerating, release the clutch and
reposition the tilting switch of diff-lock. The diff-lock will be released after the indicating lamp is off.
39
Section 1 Operation
5.4 PTO Control PTO switch

PTO
Pic.5-4
Caution: PTO can only be used on low gears.
5.4.1 Mechanica gearbox PTO
(1)Engage
Step the clutch pedal and press the rocker switch of PTO to engage PTO, the indicating lamp will be on, then shift the gear and release the clutch. The
rotating direction of PTO does not change during shifting.
(2)Release
Step the clutch pedal and press the switch of PTO, release the PTO rocker switch self-locking device, the rocker switch will be reset, after 3 seconds and
the PTO will be disengaged. At the same time the indicating lamp on instrument will be off.
5.4.2 Automatic gearbox PTO
Press the power take off rocker switch to engage the PTO,release the PTO rocker switch self-locking device, the rocker switch will be reset, the PTO will
be released.
40
Section 1 Operation
6. Operation in Winter
6.1 Cooling system
The anti-freeze and anti-corrosion coolant liquid applied by the coolant system can be prevented from freezing above -35℃. If the truck runs under the
conditions of temperature being lower than -35℃, the coolant concentration may be appropriately increased.
Attention:
It is not allowed to use the coolant combined with different types or brands of products.
The coolant system should be thoroughly cleaned up before replacing coolant of different types or brands.
6.2 Brake system

The water condensed in the air reservoir should be drained in time to
prevent from freezing. Be careful to check the performance of air dryer.
Under normal conditions, the service life of drying agent is two years. If
there is dirty water drained from the air reservoir, it shows that the drying
agent is out of operation and must be replaced immediately.
Pic.6-1
41
Section 1 Operation
6.3 Brake Cooling Device

While the brake cooling device is applied in severe cold area in winter, the water in brake cooling water tank should be drained and fill anti-
freeze to avoid icing up and bursting the tank.
6.4 Battery
The level and specific gravity of battery electrolytic are to be checked every 3 month. The level should be 10-15 mm higher than the
electrode plate, and the specific gravity is above 1.24g/cm³.
If vehicle will be out of service and stored under very low temperature for a long time, it is suggested to take out the battery from vehicle and store it in a
warm room.
Every 500km driving, check if the clamp between battery terminal and conducting wire is loose, and the performance of battery is normal. Replace them
immediately once fault occurs.
Pic.6-2
Special remainder: when the environmental temperature is lower than -30℃, the -40℃ extra-low temperature accumulator shall be
used to assure the low-temperature starting performance of vehicles. Users can select 180Ah extra-low temperature accumulator
when ordering vehicles.
42
Section 1 Operation
7. The Replacement of Spare Tire

(1) When changing a wheel, take care not to damage the stud threads.
(2) The matching surface between the brake drum and rim must be absolutely free from paint,
grease or dirt.
(3) It is essential that the contact face of the wheel nut is clean and free from dirt or grease.
(4) Before installation of wheel, clean the rim matching with wheel locating hole and wheel
reductor housing, and coat it with a little grease.
(5) Coat threads of the wheel studs and nuts with a little grease, oil or antifreeze
(6) All the threads of the wheel nuts are right-hand threads. Put on the wheel and tighten the wheel nuts in
cross sequence while the wheel is still raised, then low the wheel and tighten the nuts with a specified
torque
Pic.7-1
*Specified torque for wheel nuts: 550－600 Nm for ZZ5507 truck and socket number is WG9100850002 which is same as HOWO dump truck. 715—
780Nm for ZZ5707 truck and socket number is WG9770850001.
(7) Every time when the wheel is changed, the nuts must be retightened after driving 50km. And later on, retighten the wheel nuts every
1000km.
(8) Tyre inflation should be in accordance with speed, payload shown in following cross-reference table.
Tyre specification Speed (km/h) Tyre Pressure (kPa) Payload (kg) Tyre specification Speed (km/h) Tyre Pressure (kPa) Payload (kg)
50-65 740 4290 50-65 900 5410
13.00-25 15-50 740 5050 13.00R25 15-50 900 5750
Construction tyre 10-15 930 7610 Construction tyre 10-15 1020 8340
5-10 1000 8750 5-10 1100 9490
65 800 5350 65 900 6300
14.00-25 50 800 6300 14.00R25 50 900 7000
Construction tyre 15 800 7050 Construction tyre 15 1020 10000
10 1075 10920 10 1100 11500
43
Section 1 Operation
8. New Vehicle Running-in

Running-in mileage is specified from 2000 to 4000km.
Before running-in, regular inspection should be carried out to be sure that vehicle keeps in normal working condition.
Running-in notice:
(1) After the engine being started, do not accelerate immediately; increase the engine speed slowly only when reaching normal using
temperature.
(2) During running-in period, drive the vehicle on flat road.
(3) Shift gear timely, make the clutch be smoothly engaged, and avoid to sudden accelerate or brake.
(4) Shift into low-gear before uphill; do not let the engine work at a very low speed.
(5) Do not drive the new vehicle at high speed when full-loaded. Pay attention to every indicating signal and warning light!
(6) Examine and control the normal temperature of cooling fluid and oil pressure. Pay attention to the temperature of gearbox, wheel-hubs and brake
drums of front and rear axle. If serious overheated occurs, find the reason and adjust or repair the fault part immediately.
(7) After the first 50 km running or after changing wheels, tighten the wheel nuts according to set torque.
After running-in, check and maintain the vehicle according to the contents of maintenance requirements ‘First time check’ item.
44
Section 2 Operation and Maintenance of Main Assembly
Operation and Maintenance of Main Assembly 2
45
1. Engine
For the detail instruction of engine, refer to the “Operation and Maintenance Manual of WD615 Series EuroⅡEngine”, “Operation and Maintenance
Manual of WD615 Series EuroⅢ Engine” and “Operation and Maintenance Manual of D12 Engine”.
HOWO dump trucks in this manual use WD615.47, WD615.96C，D12.42-20, D12.42-30or MC11.43-30 engine, the technical parameters of these engines
are shown as follows.
Model WD615.47（EuroⅡ） WD615.96C（EuroⅢ） D12.42-20（EuroⅡ） D12.42-30（EuroⅢ） MC11.43-30（EuroⅢ）
Four-stroke, Four-stroke,
Four-stroke, Four-stroke, Four-stroke,
water-cooled, in-line, water-cooled, in-line,
water-cooled, in-line, water-cooled, in-line, water-cooled, in-line,
Type direct-injection, direct-injection,
direct-injection, direct-injection, direct-injection,
dry cylinder sleeve, dry cylinder sleeve,
dry cylinder sleeve common rail dry cylinder sleeve common rail common rail
Bore × stroke (mm) ×mm) 126mm×130mm 126mm×130mm 126mm×155mm 126mm×155mm 120mm×155mm
Total displacement of engine (L) 9.726L 9.726L 11.596L 11.596L 10.518L
Rated power/rotation speed (kW/

273(371)/2200 279(380)/2000 309(420)/2000 309(420)/2000 316(430)/1900
r/min)
Max. torque/rotation speed (N·m/

1500/1100-1600 1590/1200-1500 1820/1100-1500 1820/1100-1500 2100/1000-1400
r/min)
46
1.1 Engine low-temperature starting and cab heat supply device (optional)
Oil WaterWater
feeding inletoutlet Oil
return
Forward direction
Filtration screen
Pic.1-1 Pic.1-2 Pic.1-3
The device is a heating and heat supply device, which is relatively independent from the engine and ordinary heating air. It consists of fuel heater,
radiator, pipeline etc.
Under low temperature, before starting the engine, turn on the heater, and water pump in the heater enables coolant in the engine circulating among the
engine cylinder block, oil pan, radiator and heater in the cab. Through heat exchange to preheat the cylinder body, oil and working environment in the
cab, it can solve problems like great demand of high heat exchange of the cylinder block, poor engine oil circulation, too low temperature in the cab etc.
It can also effectively shorten the starting time of the engine at low temperature, improve starting performance of the engine at low temperature,
significantly reduce engine wear, fuel consumption and exhaust emissions, extend service life of the engine; and increase temperature in the cab and
improve driver’s working environment.
The heater is arranged on the cab platform (see Pic. 1-1) and there are oil inlet & outlet, water inlet & outlet and hardness interface (see Pic. 1-2) at
the bottom, there is air inlet grid at the right side and the air filter screen is installed at inner side of the air inlet grid, which is easy to remove (see Pic. 1-
3).
47
Pic.1- 4 Pic.1- 5
The radiator is arranged in the base of the tool box behind the driver seat, and air inlet & outlet are at the front end of the base, as shown in Pic.1-4 and
Pic.1-5.
Note: when the vehicle is working under the temperature of lower than -25℃ for a long time, please choose 180Ah extra-low
temperature battery and use it together with the engine low-temperature starting device and heating device in the cab.
1.1.1 Technical parameters

(1) Fuel heater (2) Radiator Type：
Type：YJP-25 SR-5-24-00
Heat flux：25kW Voltage：24V
Oil consumption：2.67kg/h Power：30W
Voltage：24V Power：170W
Heat release：3kW
Usage temperature：-40℃～50℃
Usage altitude：≤3000m
48
1.1.2 Control methods

(1) Operation and usage
● Ensure that the “open” and “close” schematic diagram (Pic. 1-7) for valves in
the heating box is pasted onto the inner wall of the heater box. Set
the valve in Pic. 1-6 at the “Open” status.
● Turn on the heater: press the “heater switch” (Pic.1-8), indicator light on the
switch is on, the heater water pump is operating and the heater is started.
● Turn off the heater: press the “heater switch”, indicator light on the switch is off,
the heater water pump stops operating and the heater stops operating. Pic.1- 6
● Turn on the radiator: press the “radiator switch” (Pic.1-9), indicator light on the
switch is on and the radiator is turned on.
● Turn off the radiator: press the “radiator switch”, indicator light on the switch is
off and the radiator stops operating.
Note: first turn off the heater switch, 3 minutes later, turn off the vehicle
main power; otherwise, the heater will be damaged due to overheating
inside. Pic.1- 7
(2) Working procedure
Turn on the heater power switch (water temperature lower than 68℃) , 18
seconds later, the ignition electrode starts to supply power, 1 second later, the solenoid
valve power starts to supply power, if ignition succeeds, and the host enters the normal
combustion status. When the water temperature increases to 81℃, the heater stops.
After stopping combustion, the main motor stops with 3 minutes’ delay. When water
temperature drops to 68℃, the heater enters the next operation cycle. If the ignition fails,
the heater enters the second ignition 2 minutes later.
Pic.1- 8 Pic.1- 9
49
1.1.3 Commissioning
The heater can work properly only when the water circulation system is full of coolant. Dry operation due to lack of water will
cause damage to the water pump and major faults of heater may occur in severe cases. Fill the coolant in accordance with the 4
procedures below:
(1) Open the pipeline valves (“Open” status as shown in the schematic diagram 1-7) and fill up antifreeze;
(2) Start the engine, open the bleeding valve (see Pic.1-6), apply the accelerator and continue to fill the antifreeze;
(3) When cooling fluid is discharged from the bleeding valve, tighten the bleeding valve, turn on the heater, apply the accelerator, and keep filling the
antifreeze. The coolant is filled at the designed level when the antifreeze does not vary a lot at the scale.
(4) Turn off the heater, wipe off the overflowing anti-freezing fluid and replace the heater cover and expansion tank cover.
Pic.1-10
50
1.1.4 Attentions
(1) For use at the beginning of winter, open the water pipeline valve inside the heater box, and check oil, water and electricity circuit and
turn on if everything is normal.
(2) During operation of the heater, the temperature at the smoke outlet (see Pic. 1-10) is relatively high, and persons cannot work near the
area to avoid injury.
(3) After turning off the heater switch, the water pump will delay to stop working for 3 minutes to lower the temperature, so it is forbidden to
turn off the master power switch within 3 minutes after turning off the heater.
(4) Fuel to be used shall be light diesel which matches the environment temperature to avoid waxing and assure smooth oil pipeline.
(5) The heater water pump is provided with suction head lift without lift, and dry operation and damage to the water pump shall be
prevented due to shortage of water in the pipeline, and the heater cannot work as usual.
(6) Depending on operation environment, clean air filtration screen in the box and ensure sufficient inlet air for normal operation of the
heater.
(7) If the device will be shut down for a long term, close the water pipeline valve in the tank in accordance with the schematic diagram 1-7.
(8) Adjust the air inlet (see Pic. 1-12) as shown in the label (see Pic. 1-11) on the inner wall of the heater.
Pic.1-11 Pic.1-12
51
1.1.5 Repair of the heater

(1) The following items shall be checked in case of fault of the heater:
● The heater is mechanically damaged or not
● Short circuit and open circuit of power fuse and wire joint
● Check if there is any fuel in the fuel tank, fuel pipeline is smooth and fuel is waxing or not
● The combustion air orifice and smoke outlet are jammed or not.
(2) Definitions of fault code
Fault code Fault cause
1 quick flash with 3 seconds’ pause Ignition failure
4 quick flashes with 3 seconds’ pause Damage to sensor
The over-temperature fuse works (temperature in the tank body over 105
7 quick flashes with 3 seconds’ pause
degrees centigrade)
Continuous flashing Sticking of relay contact of general power supply
52
(3) Failure and troubleshooting

Failure Probable causes Troubleshooting
No power or fuse broken Check the power wire and fuse
The indicator light is not on, and the

Wire connected incorrectly or grounding wire
complete machine does not work Check the wire connection and grounding wire grounded or not.
contact non-conformed (note: bonding of
grounding wire of the machine)
Damage of the control switch Replace the control switch
Too low level of the fuel tank, fuel precipitating Add fuel into the fuel tank, make clear of the fuel pipeline and replace the
wax, air leakage or jamming of oil pipeline pipeline
After turning on, the heating Severely low voltage of the accumulator (lower
indicator light is on, ignition fails and than 20V) Charge or replace the accumulator
the program operation is normal
Fault of the ignition coil or inter-electrode Replace the ignition coil Adjust
clearance improper the electrode clearance
Damage of electromagnetic valve Replace the electromagnetic valve
The water pipeline system is not circulated Make clear of the pipeline, add coolant and bleed
Overheating of the heater host
Fault of the water pump motor Replace the water pump
Too low motor voltage Adjust the voltage
Low combustion assistance volume Adjust the combustion assistance air volume
Heater with smoke during
Too low fuel pressure or unsmooth oil pipeline,
combustion Clear obstacles of the fuel pipeline
non-conformed fuel atomization
Local jamming of injection nozzle Replace the injection nozzle
The heater does not combust, and
Injection nozzle or oil pipe joints not tightened Fasten the injection nozzle and oil pipeline joints
oil drip of the smoke pipe
The main motor, electromagnetic
valve and igniter can work as usual, Leakage of oil pipe Check smoothness and sealing of the oil pipeline system and replace the oil
and the oil pump cannot deliver oil Damage of the oil pump pump
After turning on, the heater

The control damaged Replace the control
operation program is abnormal
Dry operation of water seal and severe grinding Replace the water sealing parts or water pump
Water leakage of the water pump
Aging of O seal ring Replace the O seal ring
53
1.2 Electric heater of inlet air pipe (Optional)

1.2.1 Instructions to electric heater of inlet air (With Mini controller)
If the key is turned to gear ON (3 rd gear) , press the electric heating rocker switch, the system starts the inlet air heating function for 30s, if the engine
starts successfully during the period, and stop the inlet air heating function; if the engine fails to start over 30s, press the electric heating rocker switch
again to restart the inlet air heating function (suggested to be started 30s later)
Pic.1-13 Pic.1-14 Electric heating rocker switch
54
1.3 Replacement of the engine oil

Note: replacement of the engine oil shall be carried out under hot status
1. In the process of oil drainage, check the oil color is normal or not and if there is any
foreign objects to find hidden faults 2. After oil is drained thoroughly, clear foreign objects
on the drainage screws and tighten; 3. Replace with the new oil filter cartridge, and fill with
Pic.1-15 10L Vehicle model
new oil to the upper limit of the oil dipstick. To prevent starting the engine without
lubrication, turn the key with the new oil with the high-pressure oil pump at the position
with oil out of supply to the starting position (4 th gear) and operate without load for a while.
After pre-fabrication of the machine has been finished, start the engine and operate under low
speed. Check if there is any leakage of the filter. After stopping for 5 minutes, check and
supplement the oil level to the upper limit of the dipstick.
Pic.1-16 D12 Vehicle model
1-Engine oil filler 2-oil dipstick
Replace the engine oil filter cartridge

In the course of engine oil replacement, the engine oil filters Pic1-17 MC11 Vehicle model
in parallel connection shall be replaced simultaneously.
A thin layer of oil is applied on the sealing pad and the filter
is fastened.
(1) 10L Euro II and common rail III Euro (Pic. 1-18)
(2) D12 common rail Euro III (Pic. 1-19)
Pic1-18 Pic1-19
55
1.4 Replace the fuel filter

As for replacement of the fuel filter, the 2 filter
cartridge shall be replaced simultaneously.
Locations of the coarse fuel filter:
10L filter on the frame and 12L filter on the engine.
(1) 10L Euro II machine fuel filter (Pic.1-20)
(2) 10L common rail Euro III engine fuel filter (Pic.1-21)
(3) D12 common rail Euro III engine fuel filter (Pic.1-22) Pic1-20
(4) D12 Euro II machine fuel filter(Pic1-23)
(5) MC11 Euro III machine fuel filter(Pic1-24)
Pic1-21 Pic1-22
Pic1-23 Pic1-24
56
2. Inlet air syste

As for the industrial and mining environment, the inlet system shall be the
cyclone pre-filter+ oil bath air filter+ paper air filter with 3-level air filtration.
The system assembly is arranged at the rear of the driver’s cab platform (see
Pic. 2-1).
Wherein: 1. Cyclone pre-filter; 2. Oil bath air filter; 3. Paper air filter
Pic 2-1
2.1 Cyclone pre-filter

The pre-filter is provided with maintenance-free fan bearing, and See Pic. 2-2
on air inlet and dust collection orifice.
Pic 2-2
57
2.2 Oil bath air filter

2.2.1 Attentions in use
(1) New vehicles are not added with oil before delivery.
(2) Oil shall be added before being put into operation, and the clarified waste oil shall be adopted.
(3) Adding oil can not be excessive, and oil depth of the oil bath air filter with model of ZZ5707 may not exceed 50mm or the added oil volume may not
be more than 10L; oil depth of the oil bath air filter with model of ZZ5507 may not exceed 50mm or added oil volume may not be more than 6L.
(4) When the machine oil cannot flow when the bottom enclosure is shaken, the metal filter element shall be cleaned and machine oil shall be replaced.
Under the special severe use conditions, the oil must be checked every day. Under general conditions, it can be used for 80- 150 hours. The metal filter
element can be used for a long term, without replacement.
(5) At the end of completing work each day, check the connection bolts or drag hook between the enclosure and the bottom enclosure is
loosened or not, and fasten.
58
2.2.2 Procedure for dismantling, check and clean of oil bath air filter.
(1) Oil bath air filter assembly (2) Open the lock device between upper and lower housing
Pic 2-3 Pic 2-4

(3) Fill oil: Dismantle the oil pan and fill oil till the oil level reaches
(4) Clean the lower filter core
40~50mm.
Use diesel to clean the fan leaves and filter core until there are no mud
visually on the filter core and fan leaves.
Ruler dips in oil 50mm
Pic 2-5
Pic 2-6
59
(5) Clean the upper filter core. The same

(6) Assemble the filter core assembly. First (7) Assemble the lower housing. Use the
way as cleaning the lower filter core.
assemble the upper filter core then the lower hook to fix the lower housing filled with oil.
one. Finally fix them with rubber gasket, flat
gasket and butterfly nut.
Pic 2-7 Pic 2-8 Pic 2-9
60
2.3 Air filter

2.3.1 Maintenance instruction:
2.3.1.1 After 250 hours of service, the external filter elements shall be cleaned per the following methods:
a. Tap the filter element end cover to shake off the dust deposition.
b. Blow off the filter element surface from interior to the exterior via dry compressed air with not greater than 0.5MPa pressure. Warning:
Never use water or oil for cleaning!
2.3.1.2 Replace filter elements under the following conditions:
(1) External filter element is damaged.
(2) External filter element has been cleaned up to 5 times.
(3) The safety filter element cannot be cleaned, and it shall be replaced with external filter element at the same time.
2.3.2 Attentions
(1) In case the filter is jammed and there is an alarm, or the engine with fume or insufficient power, timely check is required: ① Metal filter element
and paper filter element are jammed or not; ② Corrugated pipe connected with the engine booster is deformed or not.
(2) To extend service life of the engine, please use the filter accepted by China Heavy-Duty Truck.
61
3. Clutch
1. Clutch Pedal Assembly. 2. Return Spring. 3. Push Rod of Clutch Master Cylinder. 4. Clutch Oil Reservoir Tank.
5. Clutch Master Cylinder. 6. High Pressure Oil Pipe. 7. Clutch Booster Cylinder.
Fig. 3-1 Assembly Drawing of Pull-type Clutch Operation System
62
3.1 Operation Principle of Clutch Operation System

Clutch operation system adopts hydraulic operation and air force aiding structure. When press down clutch pedal, push rod of driven cylinder will push
piston to forward move, then push brake liquid to enter hydraulic control chamber of clutch aid cylinder along the oil pipe. On the one hand, brake liquid
acts on the piston as working pressure, and on the other hand, it acts as control pressure of air chamber of aid cylinder. When compressed air enters
air chamber of aid cylinder, it will produce aid air force. They push together piston to make push rod of aid cylinder moving, and separating swing
arm rotating. Then, it separates fork to drive separating bearing make forwards movements, and then clutch separates.
The clutch transmission cylinder, clutch oil storage tank, clutch pedal assembly etc. are arranged on the front enclosure of the driver’s cab, the
transmission cylinder is connected with the clutch assistance cylinder arranged on the chassis with the flexible high-pressure pressure and one bracket is
shared by the clutch operating sector and the brake operation sector; the oil storage tank is directly installed on the clutch transmission cylinder,
which is filled with brake fluid out of the driver’s cab after the cover of the radiator is opened.
3.2 Operation Parameters of Clutch Operation System

1. Working medium: compressed air, brake liquid.
2. Max. working pressure: 4MPa for brake liquid, and 0.85MPa for compressed air.
3. Working temperature:-40℃～+80℃.
4. Brake Liquid: meets DOT3, DOT4 or SAEJ1703standards. (Notice: brake liquid has a certain erosion) .
5. Pedal travel: Max. travel≤175mm
6. Pedal force: while air assistant is applied, it is≤190N
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3.3 Clutch and clutch operation system installation and debugging

3.3.1 Clutch installation
Put the clutch plate assembly onto the spline shaft (the tool for location of the clutch plate during installation), and align the assembly with the flywheel
centre bore. Install any two of the bores on the clutch pressure plate onto the two studs of the flywheel. Then install the other 10 hexagon head bolts and
tighten the assembly by diagonal method.
3.3.2 Pull type clutch connection
Subsequent to the above-mentioned steps of the pull type clutch, take down the four jump rings from the pressure assembly. Close the spring clamping
ring on the clutch pressure plate assembly. Install the release bearing and release shifting fork. When the transmission is installed on the engine flywheel
casing, apply a backward drawing force at the installation point of the actuation cylinder onto the release fork (a rope may be attached onto the release
fork and then pulled backward) . When a “Pa—” sound is heard, the clutch cover assembly is installed in place with the release bearing (spring clamping
ring is engaged to the release bearing). Then install the actuation cylinder.
3.3.3 Check and adjust the clearance between the drive cylinder rod and the piston
Pull the pedal gently by hand to feel that the drive cylinder rod reaches the drive cylinder piston during adjustment. Adjust the limit bolt height to ensure
that there is a clearance of 0.5mm- 1mm between the rod and the piston. Then tighten the nut. The clearance between the rod and the piston shouldn’t be
more than 1mm. Or else the effective stroke of drive cylinder is reduced.
3.3.4 Release the Air in Hydraulic System Thoroughly
Air in hydraulic system can reduce the effective travel of booster cylinder pushrod, and the clutch can’t be released thoroughly, thus shifting
becomes difficult.
Loosen the actuation cylinder air-release valve before injecting fresh brake fluid. Inject the brake fluid of a specific brand and grade from the oil
reservoir. Replenish the brake fluid while stepping on the clutch pedal. When the fluid overflows from the air-release valve, stop injection and tighten the
air-release valve. Hit the clutch pedal rapidly for several times and then maintain stepping on the pedal uninterruptedly. Loosen the actuation cylinder air-
release valve until there is no gas flowing out. Then tighten the air-release valve. Repeat the above- mentioned steps for 2-3 times to remove the air in the
hydraulic system.
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3.4 Attentions
(1) During the exhaust process, relax the pedal after the exhaust valve or an associated tube nut is tightened, so as to avoid inhalation of air, lifting the
pedal to the maximum height in order to add the brake fluid inside the tank to the master cylinder fluid anvil cell.
(2) You must adopt DOT3, DOT4 or SAE J1703 brake fluid as actuating medium in hydraulic system.
(3) When changing brake fluid, drain the remaining fluid out of the system thoroughly, and change to the specified brand fluid manufactured
in the same batch.
(4) Brake fluid is corrosive. Avoid brake fluid splashed on the human body and the paint surface of the vehicle during the exhaust process.
3.5 Common Errors and Solutions
Errors Reasons Solutions
Adjust the release bearing

There is no release bearing clearance, and clutch is half-releasing.
clearance as specified.
Clutch Slipping
Clutch plate lining has been worn down to a dangerous level. Replace friction plates
The air went into the clutch hydraulic system, and effective separate Remove all the air in the clutch
Clutch Incomplete Releasing
distance become smaller. hydraulic system.
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4. Transmission
4.1 Main Performance Parameters of Transmission
4.1.1 Ratios for each gear:
Max. Max
amount
Gear torque speed
of fuelL
N·m rpm
Model
1 2 3 4 5 6 7 8 9 10 11 12 R1 R2
HW21709 12.16 8.46 6.26 4.64 3.38 2.5 1.85 1.37 1 2100 2600 14.5
HW21712 15.01 11.67 9.03 7.14 5.57 4.38 3.43 2.67 2.06 1.63 1.27 1.00 13.81 3.16 2100 2600 14
For the other parameters, refer to “Operation Manual of HW series Transmission” and “Operation Manual of SINOTRUK AMT series
Transmission”.
4.1.2 Allison Transmission series：4600 ORS _PR(1-5gear) MY11series.

Transmission gear ratio：1 gear 4.70,2 gear 2.21,3 gear 1.53,4 gear 1.00,5 gear 0.76,Reverse gear:5.55.
Other parameters detailed consultation Allison company contact information, Refer to “Operator’s Manual of Allison series transmission”.
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4.2 Installation and Adjustment of Flexible Shaft Control System(Only for mechanical
transmission)
(1) The flexible shaft shall be arranged on the complete vehicle with a bend radius not less than 300mm. Its operating temperature ranges
between -40℃ and +100℃.
(2) The flexible shaft shall be connected with the gear shift rocker arm and the gear select rocker arm in the following way:
① The flexible shaft shall form a right angle with the rocker arm as possible as it can;
② The spatial positions of the guide sleeve, the protecting pipe joint and the push-and-pull rod of the flexible shaft shall be in a line.
(3) Install the gear select flexible shaft and the gear shift flexible shaft onto the control mechanism separately. Caution:
The spherical hinge threads of the two flexible shafts shall be screwed down.
(4) After the installation, place the gear shift lever in the neutral position and measure if the dimensions of flexible shaft at the transmission end comply
with the requirements. If not, adjust the connection length of the flexible shaft spherical hinge and the push rod tread so as to adjust the installation
dimensions of the flexible shaft.
(5) Then select and shift the gears to check if all the gears can be engaged. If a gear is difficult to be selected and shifted, check and adjust the
installation dimensions of the gear select flexible shaft at the transmission end in accordance with the previous point.
(6) The specific adjustment of the flexible shaft is as shown in Fig. 4-1:
①. After the assembly, if the front row gears cannot be engaged in the test drive, unscrew nut ① (or nut ⑤) and properly rotate spherical hinge ④ (or
spherical hinge Ⓐ) counterclockwise (to extend it). On the contrary, if the rear row gears cannot be engaged, unscrew nut ① (or nut ⑤) and properly
rotate spherical hinge ④ (or spherical hinge Ⓐ) clockwise (to shorten it) . Repeat the above procedures to make adjustment until all the gears can be
engaged.
②.After the assembly, if the low range gears cannot be engaged in the test drive, unscrew nut ② (or nut ⑦) and properly rotate spherical hinge ③ (or
spherical hinge ⑧) counterclockwise (to extend it). On the contrary, if the high range gears cannot be engaged, unscrew nut ② (or nut ⑦) and properly
rotate spherical hinge ③ (or spherical hinge ⑧) clockwise (to shorten it) . Repeat the above procedures to make adjustment until all the gears can be
engaged.
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Pic. 4-1
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4.3 Control Mechanism(Only mechanical transmission)

HW transmissions are all remotely controlled, and there are two operating type-one lever operating and double lever operating. Manual operation is for
main box and air control for rear auxiliary gear boxes. Fig. 4-2 (a) is the schematic diagrams for the gear positions while Fig. 4-2 (c) is the schematic
diagram for the handle. when the preselection valve handle is located on the position L, the handle may engage into the gears 1－2－3－4－5－
R1,when on the position H, may engage into the gears 6－7－8－9－10－R2.
Pic. 4-2 (a)

Pic. 4-2 (b)
Pic. 4-2 (c)
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4.4 Pneumatically Controlled System(Only for mechanical transmission)

The air source is the 0.7~0.8Mpa compressed air from the complete vehicle. Fig. 4-3 (a) and 4-3 (b) are the schematic diagrams for control mechanism.
The rear auxiliary gear boxes is pneumatically controlled,The shift between the high and the low gears of the rear auxiliary gear boxes of the
transmissions is achieved in the dual-H valve control mechanism. When the switch valve is in the H range, air enters the upper port of the split gear
cylinder through Pneumatic lock valve and dual-H valve, range block in high speed area .When the switch valve is in the L range, air enters the lower
port of the split gear cylinder through pneumatic lock valve and dual-H valve, range block in low speed area. Only when transmission is in neutral
position, can the conversion operation of high and low gear on shift handle work.
Fig. 4-3 (a) Schematic Diagram for Transmission Split Air Pipeline Fig. 4-3 (b) 3D Schematic Diagram for Transmission Split Air Pipeline
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4.5 Power Take-off

Main-cylinder & auxiliary-shaft rear power take-off is adopted by the transmission. The output rotation direction is the same with the engine rotation
direction. The power take-off unit is connected to the transmission internal chamber. Forced lubrication is adopted so re-supply of lubricant is not needed.
Automatic Transmission PTO is at 8 o'clock position of the transmission’s left side, the output direction is the same with the engine rotation. The PTO is
interlinked with transmission inner cavity, so there is no need to add oil additionally.
For both ZZ5707 and ZZ5507 model trucks, the HW70 PTO is equipped. Automatic transmission model is equipped with Chelsea or Muncie PTO.
4.6 Operation and Maintenance of Transmission

This is only for mechanical transmission, and the operation and maintenance of automatic transmission is refer to “Operator’s Manual of Allison series
transmission”.
4.6.1 PTO
First shift the handle lever of transmission in neutral gear, then step the clutch pedal and turn the PTO switch. While the PTO is in neutral position,
release the clutch slowly, and then the PTO will be in working condition.
4.6.2 Transmission
Operate the transmission properly, and implement regular servicing and maintenance, which is crucial for vehicle’s reliable driving and the
transmission’s long life expectancy. Please comply with the following requirements for use:
(1) Lubricant Brand
Please fill and inject 85W/90GL-5 vehicle gear oil in the transmission.
(2) Proper Oil Level
Please make sure that the oil level is abreast with the observation opening of oil level. Check the oil level through the observation opening on box flank
until the oil level reached the opening and spillage happens. Refer to the “Main parameters table of HW series transmission” for Oil filing volume.
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(3) Inspection of Oil Level

Regular inspection should be made to the oil level. The truck should be parked on flat road when checking the oil level. Considering the inflation of hot
oil, do not immediately check the vehicle that is just parked, and only when the oil level is stabilized and the oil temperature comes close to the ambient
temperature can we check the oil level, to prevent the inaccurate measurement.
(4) Re-supply of Lubricant
To prevent the chemical reaction of different kinds of lubricants, the re-supplied lubricant should be identical with the former lubricant brand
and specifications
(5) Cycle for Lubricant Replacement
Discharge the used lubricant in the transmission and then rinse the strainer assembly when replacing the lubricant for transmission. The lubricant in the
new transmission must be replaced between 2,000~5,000km.For each 10,000km, the lubricant must be checked for its oil level and leakage. It should be
supplemented and the strainer can also be rinsed at any time if necessary. For each 25,000km, the lubricant must be replaced.
(6) Working Temperature
The maximum temperature for transmission during the continuous working period must not exceed 120℃ and its minimum temperature must not be
below -40℃. The lubricant will decompose and reduce the lifetime of transmission if the working temperature exceeds 120℃.
(7) Working Inclination Angle
The working inclination angle for transmission must not exceed 15°，otherwise, it may not be fully lubricated (the working inclination angle is equal to
transmission’s installation angle on the chassis plus slope angle) .
(8) Dragging and Sliding
When the transmission works, its countershaft rotates and drives the oil pump to run, plus splash lubrication, which can fully lubricate the transmission.
When the vehicle is dragged with rear wheels touching the ground and transmission system connected, the main shaft rotates comparing to main shaft
gear and the planetary mechanism also rotates, although the countershaft gear and main shaft gear for main transmission do not rotate. This will cause
great damage to the transmission’s planetary mechanism and localization elements of main shaft due to insufficient lubrication.
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Pay attention to the following points to prevent this kind of phenomena: Do not step on the clutch pedal to let the vehicle slid on neutral position. When
the vehicle needs to be dragged, draw the half axle out or disconnect the drive shaft, or have the driving wheel dragged liftoff the ground.
(9) Gear shift operation method
When shifting HW19710/HW23710 transmission from lower gears to higher gears (and vice versa), firstly, place the gear shift knob at H
(L) and then change to the neutral position. Wait a moment and then put the gear into 6 position (or 5 position). Trip stop is not allowed. Otherwise the
planetary cylinder synchronizer service life is affected. When the knob is at any gear, the H-L switch is not applicable and only when the knob is at
neutral position the switch is available.
Warning
◆ To avoid personal injury or cause equipment failure and damage, please follow the designated procedures to operate the
transmission;
◆ Before starting, the driver should sit in the seat, shift the lever in neutral position, and use the hand brake;
◆ Before driving or leaving cab while the engine is running, the shift lever should be in neutral position and hand brake should
be engaged to lock the wheels.
◆ When parking, the gear shift lever should be moved into neutral position in low gears area.
◆ Do not shift to relevant gear and start until their brake valves are connected and the air pressure reaches the level required to
release the brake.
◆ Do not drive the vehicle sliding on a slope while the transmission is shifted in neutral position;
◆ When the PTO is operated, clutch pedal should be immediately stepped to bottom end after the PTO switch is pressed. Wait
for a while, release the clutch pedal after the PTO is in normal working condition.
◆ When the vehicle needs to be dragged, draw the half axle out or disconnect the drive shaft, or have the driving wheel dragged
liftoff the ground.
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5. Operation and Maintenance for Front Axle

5.1 HF10 front axle (for ZZ5507)
Fig. 5-1 Overall Figure of HF10 front axle
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Structure sketch of HF75 front axle:
Fig.5-2 Drawing of HF 10 Front axle
1. Front hub 2. Cover 3. Brake drum 4. Steering knuckle assembly 5. Brake plate 6. Dust cap 7. Adjusting shim 8. Thrust bearing 9. Front beam 10.
Steering Tie rod assembly 11. Brake shoe assembly 12. Return spring 13. 24" Diaphragm spring brake chamber 14. Steering Tie rod arm 15. Brake
camshaft 16. Slack Adjuster assembly
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5.2 HF12 Front Axle (for ZZ5707)
Fig. 5-3 Overall Figure of HF12 front axle
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Structure sketch of HF12 front axle:
Fig. 5-4 (a) Overall Pic. of HF12 front axle
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Fig. 5-4 (b) Drawing of HF 12 Front axle
1. Front hub 2. Cover 3. Brake drum 4. Steering knuckle assembly 5. Brake plate 6. Dust cap 7. Adjusting shim 8. knuckle arm 9. Nameplate
10. Front beam 11. Steering Tie rod assembly 12. Brake shoe assembly 13. Return spring 14. 30" /30"Diaphragm spring brake chamber 15. Steering Tie
rod arm 16. Brake camshaft 17. Slack Adjuster assembl
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5.3 Operation and Maintenance for front Axle

5.3.1 Items should be periodically checked and lubricated
(1) Check rotation of wheel bearings, replace grease, and check whether the wheel bearings can continue to use, adjust or replace it if necessary;
(2) Lubricate the king pin, ball pin and brake clearance adjusting arm;
(3) Check the wear, sealing and damage conditions of the moving part;
(4) Check the brake lining wear conditions;
(5) Check whether the camshaft is able to return to its position rapidly;
(6) Check the brake adjusting arm;
(7) Check the brake chamber for air leakage.
Note: When the vehicle is used under harsh conditions (e.g. under chilly or extremely hot weather, or in high dust content
environment), accordingly the regular maintenance interval shall be shorter.
5.3.2 The grease used in wheel hub bearings, brake camshaft and the main pin, tie rod ball pins, brake gap adjustment arm, etc. is for motor
vehicles through the lithium-based grease.
Grease Volume:
(1) Volume of grease for each wheel: at a total of about 1.2kg for wheel hub cavity and two bearings;
(2) Grease volume for each brake camshaft and kingpin is approximately 0.3kg;
(3) Tie rod ball pins, brake slack adjuster arm should be filled with grease.
Attention: different type of lubricating grease must not be used by mixture.
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5.4 Troubleshooting and solutions

Errors Error Source Solutions
Lubricate the kingpin of steering knuckle, check the clearance
Steering knuckle is not flexible
between steering knuckle and front axle.
Heavy Steering Lubricate the kingpin of steering knuckle and track-rod ball pin.
Inadequate lubrication
Improper toe-in adjustment Re-adjust toe-in
Improper pre-tightening of hub bearings Re-adjust the pre-tightening force of hub bearings.
Flexible Steering Ball pin of tie-bar flexible and worn-down Tight or replace the ball pin
Steering knuckle bush worn-out Replace steering knuckle bush
Improper pre-tightening of hub bearings Re-adjust the pre-tightening force of hub bearings
Ball pin of tie-bar flexible and worn-down Tight or replace the ball pin
Wheel Flutter
Steering knuckle bush worn-down Replace steering knuckle bush
Clearance between steering knuckle and front axle is too large Re-adjust the clearance
Brake drum or tire dynamic balance is bad Replace brake drum or tire
Whether the air pressure on both sides of brake chamber of axles are the
Refer to the vehicle manual.
same or not (with barometer measuring the pressure)
Clearance between friction block and retarding disc Initial adjustment and function check
Brake Side-slipping The two sides brake friction plate’s quality are different Replace the brake pads
Remove the brake pads, clean the brake pads, fixed base plate
Whether friction block can move freely within the fixed base plate or not.
and brake calipers
Brake drum lost round Replace hub or brake drum
Whether friction block can move freely within the fixed base plate or not. Readjust the brake pads
Brake clearance is too small Refer to the vehicle manual
Drum overheat Frequent brake or overload Refer to the vehicle manual
Improper pre-tightening of hub bearings Re-adjust the pre-tightening force of hub bearings.
Return spring softening Replace the return spring
Braking Drag
Clearance adjustment arm return not flexible Lubrication camshaft and brake shoe fulcrum pin
Brake drum lost round Replace rim or brake drum
Tyre wear uneven
Improper toe-in adjustment Re-adjust toe-in
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6. Use and Maintenance of Drive Axle

The rear drive axle of vehicles is a double-stage drive axle with one-stage central reduction and hub planetary reduction. Casting axle casing, inter-axle
and inter-wheel differential mechanism and differential locks are adopted. The brake is an involute “S” cam drum brake. Double-chamber diaphragm
spring air chamber is adopted and the adjustment is provided by manual braking clearance adjusting arm. Meanwhile ABS system is optional. AC16
drive axle is applied by ZZ5507 and AC26 by ZZ5707.
6.1 Main specifications of rear driving axle

Item AC16 AC26
Max. input speed 3500 r/min 3500 r/min
Speed ratio 6.73 10.47 8.51
Type of wheel braking Pneumatic chamber cam braking type

Brake chamber 24” diaphragm type 30” diaphragm type
Brake moment 29400 N·m 45000 N·m
For central reduction of 2nd rear

axle: 24L For central reduction of 2nd rear axle:28L For
Oil fill volume for reference (L) For central reduction of 1st rear central reduction of 1st rear axle:33L For
axle: 26.5L each hub reduction: 6L
For each hub reduction: 2L
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6.2 Operation and maintenance of drive axle

Pay Attention to the Following Points in the Use and Maintenance of the Rear Axle:
6.2.1 Proper usage of lubricating oil
Fig. 6-1(b)
Fig. 6-1(a)
(1) The main reducing gear and the hub reductor use the APlGL-5 and SAE85W ／90 viscosity gear
oil. In principle the oil level shall be checked during oil injection. Oil shall be added until it
overflows the lowest point of oil filling port the injection. The oil quantities listed in the technical
parameter list are for reference.
a. The oil change interval for rear axle gear oil is 10000km or one year. Gear oil should be
replaced for the first 2000-3000km compulsory maintenance.
b. The oil filter cartridge on AC26 intermediate axle on the gap axle tank cover shall be
cleaned monthly. Fig. 6-2
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(2) Oil lacking may lead to early wear of running components and even cause burning damage. While, more lubricant does not mean that it
will provide better performance, because excessive lubricant may result in high temperature and even oil leakage.
(3) The main reducing gear oil replacement. There are two screw plugs on the rear axle housing: A drain plug at bottom of the bowl and a fill plug at
approx. half height of the bowl. The normal liquid level should always keep at the height of the fill plug.
(4) Hub reduction gear oil replacement. a. When changing hub reducer lubricant at initial maintenance of a new car, it is required that you should rotate
the wheel until the drain plug is at its lowest position while the fill plug is at upside of the other half and open the drain plug to drain used oil during fresh
oil fill, and then install the drain plug properly, open the fill plug, add lubricant until this high liquid level, and finally screw in the fill plug. b. Rotate the
wheel repeatedly for several turns. Then position the wheel until the drain plug is at its highest position while the fill plug is on the smaller half, and open
the fill plug to allow redundant lubricant to flow out until the liquid level is kept at the position of the fill plug. Finally, install the fill plug properly.
6.2.2 Operation of Differential Lock
The interwheel differential in rear axle is used to automatically realize speed difference between left and right wheel when the vehicle turns corner so as
to avoid tire wear and mechanical damage. Engage the differential lock when the vehicle wheels on one side skids on smooth or muddy road, at this time
the left and right axle shaft become one rigidly coupled shaft, thus the vehicle will drive away from the trouble road.
Notice: After the vehicle driving out of rough road, disengage the differential lock immediately, or it will result in tire worn and
differential damaged.
6.2.3. Avoiding Serious Overloading
Design payload capacity for AC16 rear drive axle is 16 ton, and for AC26 rear drive axle is 26tons. Serious overloading and loading concentration will
result in axle housing deforming and break. Therefore, the loading capacity shall be complied with the specified loading in accordance with certain
driving conditions.
6.2.4 If the connection parts, e.g. differential mechanism and driven gear, are to be re-installed during maintenance, the connection screw shall be
applied with Loctite 262 screw fastening glue. And after tightening, the rear gear clearance shall be ensured to meet the requirements of item 6.3 “Main
bearing pre-tightening force and gear clearance” term list.
If abnormal sound is heard during operation, do not drive the vehicle, check and repair immediately.
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6.3 Main bearing pre-tightening force and gear clearance

If the hub bearing is too tight, the bearing will be overheated during driving. If the bearing is too loosen, impact occurs which damages the bearing as
well. Therefore, special cares shall be taken during hub bearing pre-tightening force calibration. The calibration steps of rear hub bearing pre-tightening
force calibration are:
Twist the hub bearing with a torque of 400Nm and turn the hub bearing to make the bearing in place. Then screw out the hub bearing nut for 1/6-1/4
round and fix the nut with a check washer. At this moment the wheel shall be able to rotate freely and without obvious axial loosening and runout.
Drive the vehicle for approximately 10km (it’s the best that braking is not applied). Touch the wheel edge of temperature-reducing casing to check the
temperature. If there is obvious heating, it is indicated that that the bearing is too tight, and the hub bearing nut shall be loosened. Slight heating is
allowed only when new bearing, new oil sealing or new gears are installed and without run-in.
The rear axle driving rear and driven rears are selected and configured before delivery, so dismantle or adjustment is not needed normally. Dismantle or
adjustment is allowed only when the gears are worn, and the clearance is larger than the specified value or the spare parts are damaged.
Special cares when doing adjustment shall be taken as followings:
(1) Pre-tightening degree of driving bevel gear bearing is adjusted by increasing or cutting the thickness of driving gear bearing adjusting shim. When
adjusting, the driving gear flange should be able to be moved by hand (without oil seal). After adjustment, the driving gear flange nut shall be tightened to
prevent loosening.
(2) The clearance (measured at the larger end of the driven gear) between the driving gear and the driven gear shall be adjusted to the range of 0.3-
0.4mm. The adjusting nuts at the two ends of the differential bearing between the wheels shall be adjusted until the specified clearance is obtained. The
bearing casing shall be pressed tightly when the gear clearance and gear end face run-out are measured.
(3) When the specified gear clearance is obtained, the adjusting nuts at the two ends shall be pressed tightly and then the nuts shall be
made to withdraw for one gap. The locking plate shall be installed properly to prevent loosening.
(4) The engagement area of the driving gear and driven gear shall be greater than 50% of the gear surface. If the engagement area is insufficient, the
driving gear adjusting shim thickness shall be increased or cut to meet the requirement and the contact area shall be located at the middle part of the
gear width and a little in favor of the smaller end.
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(5) After running in of 1500km, the integration clearance of main drive of rear axle should be checked,if abnormal, dismantling and
inspection must be carried out.
Item AC16 AC26

Clearance between differential pinion and half axle gear 0.2～0.3 mm 0.25～0.35 mm
Pre-tightening torque of driven bevel gear bearing 5～7Nm 1.7～3.5 Nm
Pre-tightening torque of driving bevel gear bearing 2～3 Nm 2～3 Nm
Meshing clearance between driving and driven bevel gears 0.3～0.4 mm 0.35～0.45mm
Wheel hub bearing pre-tightening torque 7～9 Nm 7～9 Nm
Fit clearance between camshaft and bush 0.030～0.176 mm 0.030～0.176 mm
wear limit of camshaft and bush 0.35 mm 0.35 mm
Minimum thickness of brake shoe should not be less than 6 mm 6 mm
Tightening torque for shaft head nut 550～600 Nm 715～780Nm
Tightening torque for hollow spline shaft 230Nm 380Nm
Tightening torque for wheel nut 125 Nm 125 Nm
Differential carrier fastening nut 230Nm 380Nm
Nut fastening differential carrier to driven bevel gear 35±10Nm 35±10Nm
Shaft head nut tightening torque:

AC16: internal nut tightening torque 450±50Nm, withdraw 60°. The locking plate locks the internal and external nut simultaneously. The
external nut tightening torque is 450±50Nm.
AC26: internal nut tightening torque 550±50Nm, withdraw 60°. The locking plate locks the internal and external nut simultaneously. The
external nut tightening torque is 550±50Nm.
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6.4 Common Errors and Solutions in rear axle

6.4.1 Oil Leak
There are several leaking places of rear driving axle
(1) There are several leaking places of rear driving axle. Oil leaking place of final gear is always at the input shaft. It is usually because of damage of
worn-out oil seal of the input shaft (driving gear shaft) , or loosen of oil seal spring. When maintaining it should be noticed that if oil leaks from
outside of oil seal, it shows the outside of oil seal and housing are matched loosely. When reassemble the outside of oil seal and oil seal seat hole on
the housing should be cleaned, and apply LOCTITE603 solid glue to the outside of oil seal and punch the seal into the oil seal seat hole. If the oil seal
is intact, but oil still leaks heavily, check the axle housing ventilation devices (which should be checked frequently). If the ventilate port is jammed, the
heat brought from movement of axle may push the lubricant outside by accumulated pressure. This may usually be ignored.
(2) There are three parts should be checked when the hub leaks, the O type ring between the hub and wheel reducer’s shell, the O type ring between the
hub oil seal seat and axis tube of axle housing, the seal of hub. Normally the seal of hub leaks more often. When reassemble the hub seal should notice
that the hub has two seals of the same dimension but materials, normally put the one with yellow mark or engraved mark to the inside, while the other one
to outside. If the outer ring of oil seal and the shell connection loosing, use LOCTITE603 solid glue to the outer ring of oil seal.
(3) If the axle head leaks that shows the end cover and planet carrier contact surface is not airproof, which is connected without mat, we can
disassembly them and clean the end cover and wheel reductor housing flange, then reassemble them. If the axle head leaks, there would be oil stain on
brake lining and brake drum, which can cause failure of brake
(4) Main reducer shell permeability oil account for serious overload, the axle shell has deformation, and transmission of power between the
thing with already change, then you should reduce deadweight, otherwise it will cause a series of major fault appeared.
6.4.2 Overheat of Hub
(1) Overheat of hub commonly arises from excessive pre-tightening force of hub bearing, which commonly occurs after maintenance. If
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haven’t tighten the axle head nuts according to regulation during maintenance, the pre-tightening force is excessive, which will cause over heat of hub.
The hub should be reassembled according to regulation. Certainly, distortion and broke down of hub bearing also can arise over heat of hub.
(2) Overheat of brake drum. There are many factors for overheat of brake drum, some are resulted from mechanical brake parts and some
are resulted from brake control air path system.
Firstly, check out whether the brake chamber back to place quickly after braking. If the brake chamber cannot back to place quickly or back to place
slowly, driver may remove the handspike of brake chamber and the brake adjusting arm to check whether the brake chamber back to place quickly, if not,
it means failure of brake chamber and brake control air path. And if the brake chamber back to place quickly after removing the handspike of brake
chamber and the brake adjusting arm, then should check whether the brake camshaft running neatly. Deformation of the brake camshaft, lacking oil of
axis bush or deformation/dislocation of camshaft bearing, can all make the failure of brake chamber back to place to cause the over heat of brake drum.
Broken or loosing of brake shoe return spring may cause overheat of brake drum or make frictional noise.
During the normal driving, there should have a certain gap between the braking friction plate and the brake drum (normally 0.2 mm) , if the gap is too
large, it may affect the braking effect; and if too small, it will arise overheating.
The heat dissipation of brake drum is not good condition, frequently braking action will make the brake drum overheating very soon, which will seriously
even burn tire valve and cause air leakage of tire. So if vehicles traveling downhill in a long-distance, using engine exhaust braking is highly
recommended instead of using service brake frequently, in order to prevent overheating of brake drum.
6.4.3 Abnormal Noise from Central Powertrain
If there is sudden abnormal noise coming from the rear axle housing while driving, stop the vehicle immediately for inspection. Generally, this abnormal
noise indicates parts have been damaged.
The falling apart of the supporting bearing for the differential, the serious pit corrosion or abrasion of the bearing, the loosening or falling off of the set
bolt of the driven gear, the loosening of the engaging sleeve for the differential lock as well as the tooth breaking of the differential gear may cause
serious abnormal noise.
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If the noise due to gear abrasion is continuous and the level of such noise increases with the increase of vehicle speed, it is generally caused by the pit
corrosion of the bearing, abrasion of driving gear or the scratch pit corrosion of the tooth surface. If the noise is not obvious when driving, but high noise
when slowing the vehicle down by withdrawing fuel, it is generally caused by the drag mark or pit corrosion of the tooth back of the driving gear.
If there is no obvious noise when the vehicle is normally traveling in a straight line, but abnormal noise when the vehicle is turning at the corner, it is
apparently caused by the damage or burning of the differential gear, or by the moving of differential lock’s loosened engaging sleeve.
If there is continuous noise after replacing the driving and driven gears and the level of such noise increases with increase of the vehicle speed, check
whether the backlash of the driving and driven gears and the contact trace of tooth surfaces are qualified, and pay special attention to whether the driving
and driven gears are assembled as a matched set.
The deformation of axle housing can also cause the abnormal noise from the rear axle, which should be attended to during inspection.
In case of abnormal noise from the rear axle, do not drive the vehicle forcibly. Remove and check the rear axle immediately. The falling apart of the
bearing, the loosening of the set bolt and damage of the gear may, if not repaired in time, result in more serious consequences.
6.4.4 The Failure of Differential Lock
When the differential lock is needed to put up, push the switch but the signal light does not on. The first thing you should do is to check out whether the
push rod of differential cylinder moves. When finding the push rod could shoot out, however, not in right position, that means the head of mating gear
tooth mated with the head of gear peak but not in the right position. When move the truck front and back the differential lock will work naturally.
If pushing rod puts the differential lock in right position after pressing the differential lock switch, however, the signal light is not on, obviously the
problem is from the switch of signal light or signal light itself, which is easy to check out by using the test lamp.
6.4.5 Rear Wheel Abrading Tire
There may be several possibilities for rear wheel abrading tire: the distortion of tyre steel ring, loosing of hub bearing and malposition of
rear axle. The reason for malposition of rear axle is commonly the cracking of screw of center armor plate.
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7. Suspension System
7.1 Front suspension system
Front suspension system mainly consists of parallel semi-ellipse leaf spring, telescopic shock absorber and stabilizer bar (φ50mm).
Fig. 7-1 Front Suspension System Structure
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7.1.1 Fastener specifications
ZZ5707 ZZ5507
Number of Fastening
Application
Tightening Tightening Point
Specification Specification
torque(Nm) torque(Nm)
Front spring U-bolt M24×3 800 M22×2 650～700 8
Leaf spring bracket bolt M18×1.5 295 M18×1.5 295 30
Stabilizer bar hanger bolt M16×1.5 210 M16×1.5 210 4
S t a b i l i z e r bar and axle

M14×1.5 185 M14×1.5 185 4
fastening bolt
Absorber upper bracket bolt M16×1.5 210 M16×1.5 210 8
Absorber lower bracket bolt M16×1.5 210 M16×1.5 210 4
Stop block fastening bolt M10 65 M10 65 2
Recommendation value: permissible error range 6%. The tightening torque of the above-mentioned connecting pieces shall be
checked regularly to ensure driving safety.
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7.1.2 Front leaf spring description
ZZ5707: twelve pieces, four main pieces reinforced parallel semi-ellipse front leaf spring;
ZZ5507: ten pieces, three main pieces reinforced parallel semi-ellipse front leaf spring.
The spring configurations of every model have gone through strict complete vehicle performance inspection, so if the configurations are changed
without permission, discordance with other systems may occur, or even the vehicle may be made out of control and cause unnecessary personal injury
and property damage.
7.1.3 Fault diagnosis
Suspension system fault involves multiple systems, including steering mechanism, axle, tyre and wheel, etc. If any abnormal conditions, such as noise,
deviation, vibration and abnormal damage are found during driving, the system shall be checked comprehensively and any relevant problems shall be
corrected, including:
(1) Whether the tyre pressure is normal

(2) Whether there is any uneven wear of the tyre
(3) Whether there is any unbalance or damage
(4) Whether the support connectors are loosened
(5) Whether there is any wear or loosening of the steering parts, e.g.
the tie rod ball joint, etc.
(6) Whether the suspension parts are damaged or loosened, e.g. the wear
pad between the lifting lug and the leaf spring curl ear or bracket, etc.
(Fig. 7-2)
(7) Whether there is any deviation of the front axle or wheel
alignment,
(8) Whether the lubrication system fails; and check for “Three Fig 7-2 Fig 7-3
Leakage”.
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7.1.4 Maintenance
(1) Leaf spring sheets and clamp shall be changed in time: these parts are easy to be damaged if overloaded or when the road condition is rather tough;
once any part is found damaged, replace or repair it, otherwise the damage is accelerated;
(2) Leaf spring connection pins shall be checked and lubricated in time (Fig. 7-3), to ensure the normal operation of the suspension system;
(3) U-shaped bolt and nut and leaf spring central bolt shall be re-tightened in accordance with the torque requirement every 1500km;
(4) If the stop block is damaged or lost, change one in time, or else the jump of the axle under rough road conditions is too significant, which will cause
the fracture of spring plate to be accelerated (Fig. 7-4).
Fig 7-4
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7.2 Rear suspension system

Rear suspension system includes mainly: reinforced integral balance shaft, parallel semi-ellipse leaf spring, single-side 4-M30 U bolt, rear stabilizer bar
(φ50mm).
Fig. 7-5 Rear Suspension System Structure
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7.2.1 Fastener specification
ZZ5707 ZZ5507
Application Tightening torque Number of Fastening Point
Specification Specification Tightening torque *(N.m)
*(N.m)
Rear spring U bolt M30×3 1500～1650 M27×3 1100～1300 16
Stud M18×1.5 440 M16×1.5 300 12
Propelling rod connection bolt M27×3 1100～1300 M24×3 800 18
Slide plate stand and lower
M27×3 1100～1300 M24×3 800 16
propelling rod connection bolt
* Recommendation value: permissible error range 6%. The tightening torque of the above-mentioned connecting pieces shall be
checked regularly to ensure driving safety.
7.2.2 Rear leaf spring introduction
ZZ5707: fifteen pieces, five main pieces, reinforced parallel semi-ellipse rear leaf spring; ZZ5507:
thirteen pieces, four main pieces, reinforced parallel semi-ellipse rear leaf spring;
The spring configurations of models have gone through strict finished vehicle performance check, so if the
configurations are changed without permission, failures or losses may occur.
7.2.3 Fault diagnosis
Since the vehicle load is rather heavy and the road condition is rather complex, the bar system stress is
very large, and shall be closely cared for.
Fig 7-6
(1) During driving, check these locations frequently for: whether upper and lower propelling rods and the connecting bolt is damaged or loosened, stop
block is fallen out, whether there is any fracture or dislocation of the spring, whether there is any fissure of the leaf spring pressure plate, and whether
there is any cross slip of the stabilizer rod connecting (Fig. 7-6).
(2) If there is any debris around the spring, it is indicated that the central bolt is broken and the U-bolt is loosened;
(3) If balance shaft oil leaks, the seal ring may be worn and fail.
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7.2.4 Maintenance
(1) Suspension system is an important part of the vehicle carrying system. If any part is found damaged, change it at a service station, or else damage
of other intact part is to be accelerated, or even seriously accident may be caused;
(2) Apart from being re-tightened during mandatory service, the U-bolt shall be re-tightened in accordance with the torque requirements
every 1500km.
(3) Always remember to inject gear oil into the balance shaft seat to reduce the wear between the shaft and the bushing.
Note: It is strictly prohibited to change the number of leaf springs or to change the leaf springs with other leaf springs of different thickness. It is even
more strictly prohibited to change the suspension structure. It is prohibited to use spare parts, e.g. propelling bars, slide plate seat and guide plate which
are not provided by us. Changed or replaced spare part may be unsuitable for the suspension system of this model, and may cause unnecessary fault and
losses!
(4) Adjust the clearance between the guide plate and the leaf spring. The correct clearance is 0-1mm;
(5) Normally the wear-life the guide plate and slide plate seat is half a year. If the part is seriously worn, it shall be replaced immediately. If the
situation as shown in the figure is found, the vehicle service life has been seriously impaired.
Fig.7-7 Fig.7-8
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8. Steering system
Steering system is comprised of the steering operation system and hydraulic power-assisted steering system. To meet the requirements of tough operation
conditions, the hydraulic steering actuation system includes two systems:internal actuation system and external actuation system.
8.1 Steering Operation System

The steering operation system consists of steering wheel, steering shaft, universal joint and steering column assembly. Diameter of steering
wheel: Φ450 mm.
8.1.1 Steering operation device
Fig. 8-1 Drawing of the Hydraulic Power Steering System and the Steering Control Device
1. Steering wheel 2. Ignition lock assembly 3. Steering column cover 4. Steering column 5. Steering column sleeve 6. Steering column guide sleeve 7.
Universal joint 8. Adjusting handle 9. Stroke limiting screw 10. Steering telescopic shaft
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8.1.2 The adjustment methods of steering control mechanism

The steering control mechanism is continuous and adjustable. The steering wheel may be adjusted in a height range of ±25mm and an angle range of
±5°.
The specific method is: loosen the adjusting handle 8 as shown in the figure, adjust the steering wheel 1 to a suitable application position
and then tighten the adjusting handle 8.
8.2 Hydraulic steering booster system

The system consists of power steering gear, vane pump, oil reservoir, steering booster cylinder and hydraulic pipeline. There are two
booster cylinder sizes (φ50 and φ70) for different models.
8.2.1 Hydraulic steering booster system structure
Fig. 8-2 Hydraulic steering booster system structure
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8.2.2 Maintenance
Note:
1) The input or output shaft shall not be rotated before the steering gear is connected to the steering drag link, to avoid changing the position of internal
left and right stroke unloading valve of steering gear. Therefore the rocker shall be fixed near the middle position to avoid turning when the steering
rocker is to be pre-installed;
2) If it is impossible to fix the rocker during maintenance, screw out the stop screw at the bottom of the housing and retighten the screw after the
system is properly installed;
3) The mark line shall be aligned with the mark line of the output shaft of the steering gear.
(1) Check hydraulic oil level inside the tank. First, clean oil reservoir and its surroundings to keep dirt out. Pay attention to the oil stick mark when
checking, the oil level should be the same as the oil stick when the engine operates; the oil level should be a bit higher when the engine does not work.
(2) The hydraulic oil of new vehicle needs to be replaced, and clean filter in the reservoir after the first 2,500km, and then each subsequent 10,000km (or
a year) the vehicle needs to replace the hydraulic oil.
(3) Check the oil surface height once a week, and check the cleanliness of hydraulic oil.
(4) The procedure for changing oil as following:
① Put up the front axle.
② Open the cover of oil reservoir; screw off the return pipe on the steering gear.
③ Start the engine, idle running about 10 seconds, and turn the steering wheel to its right and left limit position several times, so as to drain oil inside the
oil reservoir, booster pumps, steering gear.
④Re-tighten the return pipe (keep it clean and keep dirt out of the oil circuit), clean oil reservoir, oil filters and filter elements. It is best to renew filter
element every time when changing oil.
⑤After filling up hydraulic oil, run the engine at idle speed, turn left and right the steering wheel repeatedly, at the same time, fill oil continuously
till oil level no longer reduces and no bubble occurs.
Notice: Please replace with the specified hydraulic oil (The brand is ATF-Ⅲ Automatic Transmission Fluid).
(5) Check the clearance between rotating parts during each service. If the steering lateral or longitudinal drag link joint clearance is too
large, the joints shall be replaced. Inject grease into the lubrication ports.
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8.2.3 Steering technology parameters
Parameters
Pressure of safety valve (MPa) Flux (L/min) Transmission ratio
Type
ZF8118 18.5＋1.5 16~20 22.2~26.2
8.2.4 Important connection locations and tightening torque requirement
Designation Specification Torque(Nm) Tightening Point Number
Steering gear bracket fixing bolt M16×1.5 300 5
Steering gear fixing bolt M20×1.5 595 5
Steering wheel fixing nut M22×1.5 50 1
Steering gear telescopic shaft cross universal joint M10×1.5 48+5 2
Steering rocker fastening nut M45×1.5 700 1
Steering lateral and longitudinal tie rod pin nut M25×1.5 250～280 2×2
Steering lateral and longitudinal tie rod clamp nut M14×2 115 2×2
Steering actuation cylinder bracket bolt M16×1.5 280 4
Steering actuation cylinder ball pin nut M24×1.5 740 2
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9. Brake System
Main devices of brake system: WABCO brake system, air dryer, dual circuit brake (Foot brake), Auxiliary brake (Engine exhaust brake), emergency
brake and parking brake (Hand brake) and brake cooling device.
9.1 Service Brake
a. Service brake pedal b. Service brake valve c. Front wall of cab
Pic. 9-1 Pic. 9-2

Pedal controlling, dual circuit compressed air brake, the working pressure is 0.8 MPa and the cutting pressure of pressure regulating valve is 0.85
MPa. The first circuit works on the wheels of rear driving axle or rear tandem driving axle; and the second circuit works on the wheels of front axle.
Once the air pressure of one air reservoir in the two circuits is lower than 0.55MPa, the pressure indicator light on instrument will turn on, please stop the
vehicle immediately and find the reason of pressure leakage.
Do the full application of brake repeatedly and continuously in short time, it may cause air pressure to be lower than 0.55 MPa.
Examination of pressure leakage: Stop the engine and pull up the control lever of hand brake, if the air pressure reduces 0.05MPa at most
in 2 hours, or reduces 0.01MPa in thirty minutes, it shows no leakage occurs in air pipes.
Attention: It is not permitted to adjust the unloading pressure of pressure regulating valve.
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9.2 Auxiliary Brake

9.2.1 Engine exhaust brake
The device shares one control device with the power-off switch. When the device is used, turn the power-off switch on (exhaust braking switch) to shut
down the engine, then the vehicle can use the energy of engine to do the auxiliary brake. Auxiliary braking include exhaust valve brake (EVB) and
exhaust brake. The pic.9-3 is for Euro Ⅱvehicle and pic9-4 is for Euro Ⅲ vehicle.
Pic 9-3 Pic 9-4 Pic 9-5 Pic 9-6
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Two valves are adopted by WD615 Euro II engine. Approximately 176.9kW braking power is
available for EVB braking with a rated speed of 2200r/min.
Two valves are adopted by Euro III engine. Four valves are adopted by D12 engine. Approximately
170kW braking power is available for EVB braking with a rated speed of 2000r/min.
The exhaust brake must be used when driving on the long downhill way; and it also can be used on the
snowy and muddy road to reduce the possibilities of sideslip; when meeting and on the rough road the
exhaust brake also can be used to slow down in advance.
Using the exhaust brake can reduce the times of using service brake, and decrease the abrasion and heat of
the wheel and wheel brake, extend their service life, reduce the fuel consumption and improve drive
security.
Brake performance should be checked after the vehicle has run on the long downhill.
Attention: While the transmission is in neutral or clutch is released or engine speed is
Pic 9-7
lower than 1100rpm, the auxiliary brake will not work. When the gearbox is shifted at lower gear, the
efficiency of exhaust brake will be higher.
9.2.2 Retarder brake
Equipped with hydraulic automatic transmission vehicle can choose hydraulic retarder. This system is controlled by the rocker switch and retarder gear
control handle, please refer to “ retarder control handle " in “Internal device of cab”. This system can provide the maximum 2170Nm braking torque, can
reduce the use of the main braking number, and reduce the wear of tire & brake device, it improves the driving safety.
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2
9.3 Emergency and Parking Brake

Hand brake can be used as emergency and parking brake, it works through energy-stored spring brake cylinder of rear driving axle. And parking brake
operates through controlling the handle of hand brake valve. When there are any errors in brake system, emergency brake operates automatically by
pushing of the energy-stored spring.
Only when the air pressure of brake system is higher than 0.55MPa and the signal light of hand brake is off, can the emergency brake can be removed
completely.
The usage of hand brake: pull down the handle. At the same time, the signal light on the instrument will be on.
Releasing of hand brake: lift the handle and it will return to the releasing position automatically.(Refer to the picture) . The signal light on the
instrument will be off at the same time.
When the air pipeline connected to spring braking cylinder causes automatic braking due to leakage, screw out the bolt at the rear end of the spring
braking cylinder to the release position so that the braking is released.
Parking Brake
Pic 9-8 Pic 9-9
103
Notice：
1. Hand brake must be pulled up when the vehicle stops.
2. Before starting the engine, put the handle of hand brake valve at brake position; if not, the air pressure of brake system will be
raised and all the parking brake will be removed.
3. Do not start the vehicle before the signal lamp of hand brake going out!
4. Under some conditions, the parking brake’s braking power may fail to park the vehicle with full load on slopes, therefore the
wheels shall be blocked for safety considerations when the vehicle is parked on ramp.
9.4 Quick insert connector

Quick insert connectors are adopted by all the pipeline joints of the whole vehicle for better braking system air tightness.
Note: when special tools are not available for dismantling the pipe joints, if the parts are dismantled forcibly, the parts may be
damaged and air tightness may not be guaranteed after re-installation.
9.5 Braking cooling device

9.5.1 Working principle
The device uses the air source of the vehicle to generate pressure in the water tank, and delivers the coolant through the control valve and pipeline to 6
positions, e.g. front, middle and rear axles, to balance the heat generated by braking and ensure braking performance (see Fig. 9-10). See Fig. 9-11for
detailed device condition.
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4
Fig. 9-10 Braking Cooling Schematic
105
Water spray pipe for front axle
Ports on water tank

Water spray pipe for middle and rear axle
1. 5—Water filler；2. 4—Water outlet；3—Air inlet；6—Spray pipe Fig.

9-11 Braking cooling device
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6
9.5.2 Operation instruction
(1) Check the braking cooling device pipeline for water leakage carefully before normal application
to avoid failure of braking drum cooling due to water loss.
(2) The driver presses down the braking cooling switch in the cab (Fig. 9-12). Then the solenoid valve
controls the pneumatic shut-off valve to be connected. The water flows through the water pipe to the
braking drums of the front and rear wheels to cool the brake drum down during braking.
(3) When the water pipe is blocked, plug the outlet and turn the cab braking cooling switch on to let
the water pressure in the radiator rise. Approximately 15 to 20 minutes later, loosen the outlet and
clean the pipeline with the high pressure water flow. Fig 9-12
(4) The two water filler valves shall be open simultaneously during the water filling. One of the valves is for water filling and the other is
open to the air.
9.5.3 Precautions
(1) A small amount of water will flows back to and out of the pneumatic shut-off valve O port, when the braking cooling switch is turned off.
(2) When the air temperature is lower than 0℃, the water in the braking cooling radiator shall be drained to prevent freezing.
107
9.6 Operation of ABS (optional)

ABS system, a part of the braking system, is to prevent the wheels from locking during braking and to allow the wheels to turn. As long as the vehicle
speed is higher than walking speed, the system works regardless of whatever road conditions.
When dangerous conditions occur, depress the braking pedal to the end to ensure best deceleration effect.
If the ABS system is installed, it doesn’t mean the driver can drive without care of the traffic and road conditions. If enough distance for
safety is not kept, or the vehicle is changing direction or the speed is too high, ABS may fail to protect the driver and the vehicle.
When ABS inspection indicator is on, fault occurs to the ABS system. Refer to the ABS manufacturer’s technical data delivered with the vehicle for
ABS inspection, repair and maintenance.
9.7 Use of air charging connector
Combined air drier shall be installed. The pressure regulating valve and air drier
are combined. Air charging connector 1 shall be installed on the air reservoir (Fig.
9-13) .
Screw the air charging hose onto the air charging connector to charge the tyre.
External air source may be used for charging the air circuit of the vehicle.
9.8 Braking pipeline maintenance

Fig 9-13
During operation, e.g. welding, cutting or drill near the braking plastic pipe, the following regulations shall be complied with:
(1) Discharge the air in the pipeline;
(2) Cover the pipelines to prevent them from being damaged by sparks, flame as well as hot cuttings;
(3) The highest permissible temperature of pressure-free pipes is 130℃, for a period of 1 hour.
Warning: Do disconnect the battery power in advance and unplug the electrical appliance connector clips connected to the
electronic components (CBCU, junction box, instrument, engine ECU as well as ABS ECU, etc.)
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8
10. Electrical instrument and control system (SAC)
10.1 System overview

The vehicle electrical system installed SAC instrument mainly
includes Mini controller, Combination instrument,
Electric Connector Box, Switch and other electrical components.
Pic 10-1
109
10.2 Mini controller

10.1.1 Overview
The Mini controller has flash, wiper, fog, preheating, exhaust brake and flameout control functions.
10.1.2 Appearance
Pic. 10-2 For Common Rail Engine Pic. 10-3 For Euro Ⅱ Engine
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0
10.3 Combination instrument

10.3.1 Instrument panel (SAC)
1. Engine tachometer 2. Speedometer 3. Coolant thermometer 4. Barometer 5. Button 2

6. Driver’s display screen 7. Button 1 8. Voltmeter 9. Fuel gauge
Pic 10-4
111
10.3.2 Pin definition of instrument connector
Pic 10-5
Connector X1 White
NO. Description NO. Description

1 Low beam 11 Rear shaft lock
2 Daytime running light 12 Off road gear
3 Lifting bridge 13 Neutral gear
4 Low coolant 14 Air filter
5 First front wheel lock 15 Exhausted brake
6 Second front wheel lock 16 Air intake preheat
7 First rear wheel lock 17 Water in fuel
8 Second rear wheel lock 18 Battery charging
9 Front shaft lock 19 Main ABS
10 Middle shaft lock 20 ASR
11
2
Connector X2 Black
1 5V sensor power output 11 12V sensor power output
2 5V sensor power output 12 Empty
5 Rear fog output 15 Empty
6 Front fog output 16 Sensor GND
7 Lamp(WPM) output 17 Sensor GND
8 Hazard output 18 Sensor GND
9 Empty 19 Sensor GND
10 Vehicle speed output 20 Sensor GND
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Connector X3 Blue
1 IIIumination PWM input 11 Air pressure2 input
2 Empty 12 Oil pressure input
3 KL15 13 LNG level input
4 Empty 14 Air filter input
5 Empty 15 Empty
6 GND 16 CAN_High
7 Coolant temperature input 17 CAN_LOW
8 Fuel level input 18 Vehicle speed input
9 CNG level input 19 Engine speed input
10 Air pressure1 input 20 KL 30
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4
Connector X4 Gray
1 Main turn right 11 Air pressure3
2 Main turn left 12 Air pressure4
3 Trailer left 13 Low gear
4 Trailer right 14 Safe belt
5 Engine amber warning 15 Cabin lock
6 Front fog 16 PTO1
7 Rear fog 17 PTO2
8 High beam 18 OBD
9 Little lamp 19 Trailer ABS
10 Parking brake 20 ECAS
115
10.3.3 Driver’s display
① Driver’s display and fuel level display
Pic. 10-6 Driver’s display Pic. 10-7 Oil pressure display

② Total mileage and Subtotal mileage
Total mileage, indicating range is 0-999999km. If the mileage is stored incorrectly, the meter will display fault “----------------”.
Pic.10-8 Total mileage Pic.10-9 Subtotal mileage

Subtotal mileage, indicating range is 0-999.9km. Instrument only save the integer portion of the subtotal mileage, KL30 power-down, the fractional part
will be lost.
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6
③ Operation of button 1 and button 2
Information display Controlled by button 1 and button 2 (As shown in Pic.10-10), this area is controlled by button 1 and button 2.Short press button for
less than 3s, long press button is greater or equal to 3s, If KL15 is power on and engine isn’t running, press button 1and 2 same time, then it will come
into diagnostic mode.
Pic.10-10 Information display Controlled by button 1 and button 2
④ Button 1 functional description:(The right side)

• Driving mode
• Short press to switchover air pressure 1 and pressure 2;
• Long press button can clear subtotal mileage.
Pic.10-11 Air pressure display
117
• Diagnosis mode
Changing nodal point: short press button, changing nodal point circularly; long press button, exit diagnosis mode; Changing DM1 information (same
nodal point contains many DM1 information); short press, changing information forward; long press, exit to the previous screen.
Pic.10-12 Node selection Pic.10-13 Node selection sample

⑤ Button 2 functional description:(The left side)
• Driving mode
Short press: Cyclic switch-over air pressure, Average fuel consumption of 100Km, Average fuel consumption of short distance, Total fuel
consumption, Subtotal fuel consumption, Engine working time.
Pic.10-14 Total fuel consumption Pic.10-15 Average fuel consumption Pic.10-16 Engine working time
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8
• Diagnosis mode
① Confirm DM1 information selected: short press, enter;
② Changing DM1 information (same nodal point contains much DM1 information), short press, changing information backward.
Pic.10-17 DM1display
When displaying DM1 information, if there is only one piece of information, it will as shown in pic.10-18
pic.10-18 DM1display
If there is much more DM1 information, it will display the first one, it will as shown in pic.10-19
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If the display is not the first nor the last information, it will as shown in pic.10-20
If the display is the last one, it will as shown in pic.10-21.
10.3.4 Differential lock display
The instrument according to the signal input (low control) to indicate the differential lock, transfer case off-road gear and neutral gear work status. When
working, the corresponding differential lock segment code blinks to indicate. Differential lock structure can be configured to display a different number
of front axle, rear axle.
Pic.10-22 Differential lock display
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0
10.3.5 Fuel economic mode display
When receiving multi-torque CAN information, instrument will display correspondingly, When it working, (X contains：H,M,L or
blank),Mode0 = H,Mode1 = M,Mode2 = L,Mode3 = Blank;Normal torque 0 correspond H, Mode 1 correspond M,Mode 2 correspond L,Mode 3
correspond no load(Blank).
Pic.10-23 Fuel economic mode display
10.3.6 Actual time display
If MTCO is online,instrument indicate time controlled by CAN information ;

If MTCO is not online,this area is blank.
Pic.10-24 Actual time display
121
10.3.7 Alarm signal screen displaying
No. Signal Description No. Signal Description
1 Air filter block 4 Water run into fuel
2 Exhaust brake 5 Maintenance alarm
3 Intake preheating 6 Retarder working
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2
10.4 Instructions for Electric Connector Box (SAC)
Pic.10-25 Instructions for Electric Connector Box (SAC)
123
10.4.1 Electrical junction boxes(common rail engine and NG engine)
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4
10.4.2 Electrical junction boxes(Euro Ⅱ engine)
125
11. Air Conditioner

11.1 System Brief Introduction
The system is composed by radiator, compressor, condenser, expansion valve, receiver drier, evaporator and fan and they are connected with pipes and
form one closed system. The radiator takes engine circulating water as heat source, the compressor is driven by engine belt, the fan and compressor
electromagnetic clutch is powered by vehicle and condenser is cooled by radiator fan. The refrigerant type is R134a which is green environmental
protection and freon-free.
11.1.1Controller
(1) Panel:
① Screen
② Wind power adjuster
③ Defrost wind directions
④ Air inlet mode select: circulatory selecting
⑤ Power off
Ⓐ Auto mode
⑦ Wind mode select: Blowing head, foot, etc.
⑧ Cooling
⑨ Temperature settings: press “▲” (“▼”) one time to increasing (decrease) indoor temperature 1℃.
(2) Information Shown on Screen
(1) Wind power
(6) Defrost
(2) Air inlet mode
(7) Blowing mode
(3) Air-out mode
(8) Cooling mode
(4) Set temperature and real temperature
(5) AUTO Function
Pic. 11-2 Display Information

126
11.1.2 Main Technical Parameter
Model KQZN-4.9
Refrigerating output 423Kcal/h(4.9KW)
Refrigerant R134a
Model SE5H14
Compressor Working voltage D.C 24V
Engine displacement 138cc/r
Electromagnetic clutch power 50W
Clutch Belt slot Poly V-belt (PV6)
Pitch diameter of belt 120
Core Parallel flow: 630×490×20mm

Condenser
Front face area 0.31m2
Core Stake-up type:390×205×70mm

Radiator
Front face area 0.08m2
Expansion Valve “H” type, 1.5T
127
11.2 Instruction
11.2.1 Set Needed Inside Temperature
Adjust the button to your needed indoor temperature with scope “LO, 18℃--29℃, HI”. Set at “LO” to make cooler and “HI” to make warmer.
11.2.2 Wind Power Setting
Wind power can be adjusted manually or automatically according to temperature being set.
11.2.3 Night Vision Function
Turn on small lamp switch, the buttons’ symbol can be shown with other symbols on instrument.
11.2.4 Wind Mode Selecting
Four (4) modes can be selected by wind mode button and defrost button-blowing head, blowing feet, blowing feet and defrost, defrost.
11.2.5 Air inlet mode selecting
Inside and outside air inlet circulation mode can be selected by selecting button.
Inside circulation can be adopted within short time in following cases:
● In hot weather, quickly reduces temperature inside.
● In cold weather, quickly rises temperature inside.
● Bad air outside, for instance dusty or smelly.
128
11.3 Notice
(1) Regularly maintain A/C.
(2) Clean the panel with soft and dry cloth when it is dirty. Wet cloth and hard thing may cause damages to panel, buttons and screen.
(3) Do not touch the screen with finger, hard or grease things, because they can cause the screen to display unclearly.
(4) Refrigerant filling port is on compressor and pipe. Please contact technician of designated service station if the refrigerant is insufficient. When
refrigerant is insufficient, white foam can be seen through the window on fluid reservoir; when refrigerant is sufficient, colorless liquid can be seen.
(5) If defect occurs to the system, please contact with technician of designated service station.
(6) The air inlet paper filter element of air conditioner should be regularly cleaned or changed according to service condition.
Pic. 11-3 Pic. 11-4 Pic. 11-5

(7) In the seasons when there is no need to use air conditioner, start A/C refrigeration system for 2-3 times monthly for about 10 minutes. This can avoid
the poor sealing of seal rings, compressor shaft seals etc. in the system pipeline caused by insufficient lubricant, and avoid sticky glue or rust of
compressor, expansion valve and refrigeration system other moving parts.
(8) It is suggeted that dust-proof net in front of radiator should be removed for cleaning for 1 time monthly.
If the working condition is too harsh, the cleaning intervals can be shortened correspondingly.
129
11.4 Repair and Maintenance

Maintenance period
Maintenance contents
Maintenance item
Weekly Monthly Bimonthly Quarterly Annually
Refrigerant amount Check the amount of refrigerant from observation window ＋

Refrigerant leakage Detect the leakage with halogen leak detector ＋
Check for cracks and damage of the hose ＋
Check for leakage of each connector and looseness of
A/C unit Hose & pipe
retaining clip
－
Replace dryer and filter －
Refrigeration oil Replace with the corresponding brand of refrigeration oil. ＋
Shaft seal Check oil leakage marks with the white paper ＋－
Compressor Belt Strain with tension pulley and check for wear ＋
Bolt overhaul Check for looseness. Overhaul and reinstall if necessary ＋
Evaporator core Check for dirt and clean it if necessary ＋
Fan motor Check if operation is normal or not ＋
Evaporator & con- Check if action is normal or not. Remove and clean filter
Expansion valve
screen ＋
denser
Condenser core Check for dirt and clean it if necessary ＋
Fan motor Check if operation is normal or not ＋
Connector Check for looseness of clamp plug ＋＋
Thermistor switch Check if action is normal or not ＋
Electrical components Electromagnetic clutch Check if the specified requirements are met or not ＋
Electromagnetic clutch Replace when it can not be rotated stably
bearing ＋
Check for dirt. Clean and replace it if necessary
Paper filter element Clean and replace according to the actual situation.
Air inlet filtering
Note: symbol “+” indicates adjustment and repair if necessary; and the symbol “-” indicates replacement.
130
11.5 Failure diagnosis and solutions table

NO. Errors Possible Reasons Solutions
Leak Leak checking and repair
Expansion valve error Replacement
Return-air valve closed Turn on
1 High pressure is low Lack of freezing medium Liquid charging

Drier blocked Replacement
Compressor return-air valve leak Replacing the valve
Compressor reed valve damaged Replacement
Air in the system Re-inject freezing medium
Condenser blocked Clear the condenser
2 High pressure is high
Out valve was closed Open the out valve
Freezing medium overcapacity Discharge redundant freezing medium
Lack of freezing medium Add the freezing medium
Compressor piston worn-out Repair
Compressor head gasket leak Replace head gasket
3 Back pressure is low Tube jammed or squeezed Replace tubes

Compressor return-air valve leak Replace the valve plate
Moisture in the system Replace drier
Expansion valve trap valve blocked Clean and replace the drier
Expansion valve sensing bulb flexible Tightening the sensing bulb retaining clip
Freezing medium overcapacity Out redundant freezing medium
4 Back pressure is high Expansion valve cannot be closed Replace expansion valve
Compressor reed valve damaged Replace reed valve
Compressor head gasket leak Replace air cylinder gasket
131
NO. Errors Possible Reasons Solutions

Driving belt damaged Replace belt
Clutch wire damaged Replace wire
5 Compressor doesn’t work Compressor piston damaged Replace compressor
Thermostat switch failure Replace thermostat switch
Clutch coil damaged Replace coil
Coil freezing, the temperature adjusted overvaluation Tighten down the thermostat switch, and defrosting
Hot air infiltrates into cab Turn off heat source valve
Drier clogged Replace the drier
Lack of freezing medium Add the freezing medium
High pressure is a little high Refer to 2
6 Poor cooling effect Return pressure is a little low Refer to 3
Return pressure is a little high Refer to 4
Drier blocked Clear and replace the drier
Expansion valve error Replace expansion valve
Thermostat switch failure Replace thermostat switch
Thermostat switch improper adjustment Adjust to the working condition
7 Evaporator coil freeze
Insufficient air capacity going through evaporator Examine evaporator fan
Misalignment belt pulley Adjust the belt pulley axial location
Too tight or too loose Right adjustment
8 Trouble in Belts
Improper specification Replacement
Damaged idler bearings Replace the bearing
Fuse is burned down Replacement
Pilot switch failure Replacement
9 The fan doesn’t work Injured motor of fans Replacement
Motor voltage is low Check the wires
Contact unreliable Examination
Wires become flexible or short circuit Troubleshooting
Crooked rotor spindle Replacement
10 The fan runs too slow Controller resistance is burned down Replace the resistance
Low voltage Examine the engine
Screws used to fix the blades Tightening the screws
Connectors leaking Repair or Replacement
11 Leak of hose or connectors
Hose leaking Replace the hose
132
Section 3 Maintenance of Vehicle
Maintenance of Vehicle 3
133
Routine inspection
1. Interval Mileage of Routine Inspection & Maintenance
1. Interval Mileage of Routine Inspection &

0
5
1st class maintenance
0
1 Routine inspection
5
1
2nd class maintenance

200
Routine inspection
300
250
Routine inspection
3
3rd class maintenance

4
Routine inspection
4

5
Routine inspection
5
2nd class maintenance

6
Section 3 Maintenance of
Routine inspection
6

7
Routine inspection
7
4th class maintenance

8
1
2. Specifications and filling volume for lubricating oil and fluid
Power Component Filling Condition Oil Type and Model Filling Volume (ZZ5707) (L) Filling Volume (ZZ5507) (L)
Steering System Hydraulic liquid ATF-Ⅲ automatic transmission fluid 7.4 6.9
For central reduction of 2nd rear
axle: 28 For central reduction of 2nd rear axle: 24 For
Central reduction and hub
Heavy duty gear oil APIGL-5 SAE85W/90 For central reduction of 1st rear central reduction of 1st rear axle: 26.5 For
reduction of rear axle
axle: 33 each hub reduction: 2
For each hub reduction: 6
Heavy duty long-lasting antifreeze

Long-lasting antifreeze anti-corrosion
Engine Cooling system anti-corrosion coolant used in four Fill to scale Fill to scale
coolant
seasons
Use CH-4 grade oil according to

Lubricating system Engine oil 25 25
service condition
Transmission Heavy duty gear oil 85W/90 GL-5 About 12(Additional 1L oil should be filled while equipped with PTO )
Corresponding to JG3,JG4 stan-
Clutch Operating System Brake fluid About 1 About 1
dard,or DOT3,DOT4 standard
Fill until oil flows from filling open- Fill until oil flows from filling opening (about
Balance shaft Heavy duty gear oil 85W/90 GL-5
ing (about 1.5 for each side) 1.2 for each side)
Cab tilting system Hydraulic liquid No.10 aviation hydraulic fluid 0.4 0.4
Less than ear oilltion and hub re-

Oil bath air filter Engine oil or gear oil Clean used oil ductiong feet and defrost, defrost Less Less than 6
than 10
Note:
(1) Oil bath mainly uses engine oil to absorb dust particles etc., so the clean used engine oil or gear oil can be used.
(2) Volume of fuel tank is 500L, so 400L volume can be selected.
(3) Select lubricant that meets the standard according to different ambient temperature.
135
3. Maintenance Items
3.1 Regular Maintenance Items
(1) Check hand brake and service brake;
(2) Check illuminating lamps, signal lamps and indication lamps (oil pressure, air pressure, air filter indicator and battery charge indicator, etc.);
(3) Check the working mode of starter, alternator and battery;
(4) Check tyre pressure and condition;
(5) Check the level of engine oil, coolant and steering hydraulic oil;
(6) Drain water from air reservoir.
3.2 Maintenance Tasks of Every Grade

Table 3-1 ● Maintenance items include changing oil, examining and adjustment
Engine First-time Check Routine Check 1st-grade Service 2nd-grade Service 3rd-grade Service 4th-grade Service
Replace oil (at least once a year ) ● ● ● ● ● ●
Replace oil filter or filter element ● When changing oil
Check and adjust valve clearance ● ● ● ● ●
Replace fuel filter element ● ● ● ●
Clean primary fuel filter or replace filter element ● ● ● ●
Check coolant volume and add it to full ● ● ● ● ● ●
Replace coolant Replace it every six months
Fasten cooling pipe clamp ●
Fasten inlet air pipe, soft tube, and flange connection parts ● ● ● ● ●
Check air filter maintenance indicating light or indicator ● ● ● ●
Clean dust cup of air filter ● ● ● ● ●
Clean main filter element of air filter Clean it every 250 hours
Replace safety filter core of air filter When changing main filter
Check bearing clearance of turbocharger ●
136
Table 4-
137
Engine First-time Check Routine Check 1st-grade Service 2nd-grade Service 3rd-grade Service 4th-grade Service
Electric components and electronically

Check it every 250 hours
controlled system wiring harness
Transmission
Check oil level ●
Change oil(One time every year at least) ● One time every 25000km
Change the vent device ● ● ●
Front Axle
Check and adjust the clearance of tapered roller

While first 2nd-grade maintenance
bearing of hub
Change lubricant of hub ● ●
Rear Axle
Check oil level of final drive and hub reduction ●
Change oil of final drive and hub reduction(One

● ● ● ●
time every year at least)
Clean the vent device ● ● ● ●
Check and adjust the clearance of tapered roller

While first 2nd-grade maintenance
bearing of hub
137
Table 4-
138
Propeller Shaft First-time Check Routine Check 1st-grade Service 2nd-grade Service 3rd-grade Service 4th-grade Service
Retighten the propeller shaft bolt ●
Visual examination of connection and wearing of propeller shaft ● ● ●
Cab
Check the wiper ● ● ● ● ● ●
Re-tighten locking handle on driver’s cab ● ● ● ●
Re-tighten engine radiator’s cover ●
Check oil level of cab tipping hand pump ● ● ●
Check lifting cylinder ● ● ● ● ●
Chassis
Check fixation and action of towing hook ● ● ● ● ●
Re-tighten the bolts on cross member of the frame ●
Tighten front and rear leaf spring bolts and brackets ● ● ● ●
Check and adjust slide rail clearance of leaf spring ● ● ●
Check the fixation of wheel nuts ● ● ● ● ●
138
Table 4-
139
Chassis First-time Check Routine Check 1st-grade Service 2nd-grade Service 3rd-grade Service 4th-grade Service
Check the fixation of battery ● ● ●
Check the fixation of fuel tank ● ● ●
Brake System
Drain water from air reservoir ● ● ● ● ● ●
Check leakproofness of air pressure system (With barometer)

● ● ● ● ●
Check brake lining thickness and adjust brake clearance ● ● ●

Clean wheel brake ● ●
Check vulnerability of brake pipeline and hoses ● ● ● ●
Check brake chamber ● ● ● ●
Check footbrake, handbrake and out brake action ● ● ● ● ●
Electrical System
Check the working condition of electrical system

● ● ● ● ● ●
(Instrument, lamps, wiper, and air conditioner).
Check electrolyte level and cell voltage ● ● ● ● ●
Check the fixation of battery terminal, coat electrode with

● ● ● ● ●
grease
Check electric tachometer and speed accuracy ● ● ● ● ● ●
139
Table 4-5
Steering System First-time Check Routine Check 1st-grade Service 2nd-grade Service 3rd-grade Service 4th-grade Service
Change oil of steering system(20000－

25000km) ●
Check and adjust wheel alignment ●
Check the oil level in oil tank ● ● ● ● ●
Change oil filter of oil tank ● ●
Check the performance of steering system

● ●
Check the clearance of tie rod ● ● ●
Check the bolt, connector and retaining

●
parts of steering rods
Vehicle
Short distance trial running (Including

● ● ● ● ●
braking test)
Visual check for leakage ● ● ● ● ● ●
Check and tighten cargo body ● ● ● ● ● ●
140
Table 4-6
Lubrication First-time Check Routine Check 1st-grade Service 2nd-grade Service 3rd-grade Service 4th-grade Service
Water pump ● ● ● ● ● ●
Clutch pedal shaft ● ● ● ● ● ●
Clutch release bearing ● ● ● ● ● ●
Clutch cable and rocker ● ● ● ● ● ●

Universal joint and intermediate support of
● ● ● ● ● ●
transmission shaft
Steering knuckle and front axle ● ● ● ● ●
Leaf spring pin ● At least once every four weeks
Check leaf spring slide rail clearance of

● ● ● ● ● ●
suspension
Shock absorber mounting ● ● ● ● ● ●
Gearshift lever bracket ● ● ● ● ●
Brake camshaft and brake arm ● ● ● ● ● ●
Towing hook ● ● ● ● ● ●
Cab door hinge ● ● ● ● ● ●
Perform rust-proofing treatment of driver’s cab

One time at intervals of 12 months
again according to schedule
141
4. Chassis Lubrication
Pic. 4-1 Scatter diagram of chassis lubricating points
142
5. Electric Welding Maintenance Precautions

When performing electric welding during vehicle maintenance and modification, the vehicle electrical control system must be removed! And the specific
steps are as follows:
(1) Change battery switch from ON to OFF, as shown in Pic. 5-1 & Pic. 5-2;
Pic. 5-1 Pic. 5-2

(2) Remove and tilt instrument in cab. When performing electric welding, disconnect the instrument plugs as shown in Pic. 5-3 & Pic. 5-4;
Pic. 5-3 Pic. 5-4
(3) After electric welding, recover each connection plug.
143
Section 4 Appendix
Appendix 4
144
Section 4 Appendix
1. Bulb list
Light Name Bulb Type Bulb Power Quantity for every vehicle
Headlamp (High beam/low beam) H1 P14.5s 70W 4
Front fog lamp H3 PK22S 70W 2
Front turn signal lamp P21W BA15SR5W 21W 2
Height lamp BA15S 5W 3
Work lamp 70W 4

Turn signal lamp P21W BA15SR5W 21W 2
Parking light R5W BA15S 5W 4
Brake light P21W BA15S 21W 2
Reverse light P21W BA15S 21W 2

Rear combined lamp
Rear fog lamp P21W BA15S 21W 2
Side position light R10W BA15S 10W 2
License plate lamp R5W BA15S 5W 1
Indoor illumination light R10W BA15S 10W 1
145
Section 4 Appendix
2. Schematic Diagram of Brake System
Pic. 2-1
146
Section 4 Appendix
Instruction
1. Service brake valve 2. Hand brake valve 3. Spiral protection pipe 4. Air compressor inlet pipe 5. Front axle brake chamber 6. Brake hose assembly
7. Air compressor 8. Pipe 15 (Air compressor/hose) 9. Stainless steel bellows assembly (300mm) 10. Recoiling air reservior 11. Dryer assembly 12.
Four Circuit Protection Valve 13. Front axle air reservior assembly (ZZ5707:40L, ZZ5507:30L) 14. Wire harness sheath 15. Rear axleair reservior
assembly (ZZ5707: 40L, ZZ5507: 30L) 16. Parking brake air reservoir assembly 17. Electromagnetic valve 18. Auxiliary air module 19. Differential lock
20. Diaphragm spring brake chamber 21. Diaphragm spring brake chamber 22. Relay Valve 23. Overflow valve 24. Auxiliary air reservoir 25.
Pressure maintaining air reservoir 26. Exhaust braking
27. Clutch booster cylinder 28. Drain valve
Instruction for connector marks:
1/11/12－Air inlet 2/21/22/23/24－Air outlet 3－Air vent (open to atmosphere) 4/41/42/43－Control port
147

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Foreword

China National Heavy Duty Truck Group Co.,

3. The right window of cab can be used as emergency window.

Warning: Driving without door locked is forbidden!

① Use the Door Lock from Outside

② Use the Door Lock from Inside

the door to open.

Lock the door: Close the door directly

2. Internal device of cab

2.1 Combination Instrument (SAC)

2.2 Switch panel

2.3 Sign of signal lamp’s summary sheet(SAC)

Sign of signal lamp and function description(SAC)

No. Description Signal Colour No. Description Signal Colour

1 Truck left turning indication Green 10 Fault of brake system Red

2 Trailer left turning indication Green 11 Air suspension Red. yellow

3 Trailer right turning indication Green 12 Retarder alarm Red. yellow

4 Truck right turning indication Green 13 Low beam lamp Green

5 Engine oil alarm Red. yellow 14 Low level of coolant Red

6 Alarm symbol Red. yellow 13 Low beam lamp Green

8 Emergency stopping Red 15 Day running lights Green

9 Parking brake Red 16 Non-locking of cab Red

No. Description Signal Colour No. Description Signal Colour

17 PTO 1 Red yellow 28 Small lamp Green

18 PTO 2 Red yellow 29 Exhaust fault Yellow

19 Low level of adblue Yellow 30 Engine speed too high Red

20 ASR working indication Yellow 31 Safety belt fault Red

21 Lifting axle Green 32 Vehicle overspeed Red

22 Front fog lamp Green 33 Low gear Green

23 Cruise indication Green 34 High temp.of coolant Red

24 High beam lamp Blue 35 Air pressure of indicator 1 Green

25 Main truck ABS alarm Yellow 36 Air pressure indicator 2 Green

26 Trailer ABS alarm Yellow 37 Alarm of battery voltage Red

27 Rear fog lamp Yellow 38 Low level of fuel Yellow

2.4 Rocker Switch symbol

Rocker switches and function description

Item Description Status Function Remarks

Item Description Status Function Remarks

9 Interwheel Differential Interwheel differential magnetic valve will work, and

Item Description Status Function Remarks

2.5 Power Switch

2.5.1 Master Power Switch

Switch off if out of using for long time to avoid accident.

Position Purpose Remarks

1 (ACC) Switch on the electrical facilities on condition of parking

2 (LOCK) Power cut off Key may be removed

4 (START) Start engine Return to position 3 automatically

2.6 Combination Switch

2.6.2 Serious Alarm

2.6.3 Operation of Front Lamp (Pic. 2-9)

2.6.4 Windscreen Wiper and Cleaner (Pic. 2-10)

2.6.5 Horn Button

Horn conversion switch

2.7 Fog Lamp and Interior Lamp (Pic. 2-12)

Front fog lamp Rear fog lamp

2.7.1 Front fog lamp

2.7.2 Rear fog lamp

2.7.3 Interior Lamp (Pic.2-13)

2.8 Operation instruction of hand throttle