Operation and
Maintenance Manual
Preface
Welcome you to buy and use Shaanxi Automobile Brand
X5000 Heady-Duty Truck. Use, operation, and maintenance
of the X5000 Heady-Duty Truck are introduced in this
Manual. How for your truck to gain optimal benefit is our
and your common pursuance target, but it depends on
whether or not you have a careful and general familiarity
with and maintenance of the truck. We sincerely hope that
you will read through this Manual, and have the operating
procedures introduced herein under your perfect control,
prior to use of the truck.
What is to be reminded and notified is that Shaanxi HeavyDuty Automobile Co., Ltd will persist in improvement of the
truck products to be made, to adapt to user demands, and
our Company reserves the right for modification of product
designs and technical characteristics at any moment. On this
account, the graphic figures and descriptions in this Manual
are correct at publication, and they are subject to
consequent alterations in design and technical
characteristics, without prior notice, for which your kind
understanding is expected.
This Manual is one part of the truck, and shall be kept and
used together with the truck.
Please contact the Sales Company’s Customer Service
Center of Shaanxi Heavy Duty Automobile Co., Ltd
concerning quality warranty, purchase of accessories, and
other issues related to the products of our
Company.（Tel:+86 29 86956908）
Contents
I. Cab overview
005
1. Steering wheel switch
006
1. Air-conditioning system
037
2. Instrument
006
1.1 Control panel layout
037
2.1 Instrument interface display
006
1.2 Air supply mode
038
2.2 LCD screen display area interface control
020
1.3 Air conditioner operation
039
2.3 Menu browsing interface
021
1.3.1 Switch on the air conditioner
039
II. Use of electrical appliances in the cab
037
2.3.1 Primary menu for travel information
021
1.3.2 Heating
040
2.3.2 Primary menu for vehicle status
022
1.3.3 A/C button
040
2.3.3 Primary menu for personal setting
022
1.3.4 Automatic mode button
040
2.3.4 Primary menu for diagnosis information
023
1.3.5 Economic mode
040
2.3.5 Primary menu for system information
023
1.3.6 Internal and external circulation switch button
041
3. Multimedia
023
1.3.7 Parking air conditioner button function (optional)
041
4. Rocker switch Ⅰ/Ⅱ
024
1.3.8 PM2.5 button function (optional)
041
5. Left door control switch
026
1.3.9 Negative ion generator on/off button (optional)
041
5.1 Window lift
027
2. Water-heated type independent air heater (optional)
042
5.2 Rear view mirror adjustment and heating
027
2.1 Introduction to control panel
042
5.3 Door lock control
027
2.2 Control the heater power-on/off operation
042
5.4 Right door control switch
028
2.3 Controller setup
043
6. Axle differential lock switch
028
2.3.1 Set system time
043
7. Transfer case switch
029
2.3.2 Set timing starting time
043
8. Key switch
029
2.4 Timing starting operation process
044
9. Cigarette lighter
030
3. Air-heated type independent air heater (optional)
045
10. 24V power port
030
3.1 Introduction to control panel
045
11. USB power interface
030
3.2 Fuel supply
045
12. Overhead box
031
3.3 Safety inspection shall be conducted before startup
045
13. Left control lever
031
3.4 Power-on and power-off
046
13.1 Use of windshield washing
031
3.5 Heater gear adjustment
046
13.2 Use of high/low beam light
032
4. All-oil circuit heating system
047
13.3 Use of turn light
032
4.1 Main technical parameters
047
14. Right control lever
033
4.2 Operation method
047
14.1 Auxiliary brake handle of an engine with retarder
033
14.2 Auxiliary brake handle of an engine
without retarder
033
14.3 Right control lever of the vehicle model with AMT
transmission
034
14.4 Right control lever of the vehicle model with
4.3 Function
047
5. Refrigerator (optional)
048
6. Water dispenser (optional)
048
6.1 Water dispenser functions
049
6.2 Key functions
049
6.3 Water taking method
049
automatic control
034
6.4 Boiled drinking water
050
15. Lighting knob switch
035
6.5 Normal temperature drinking water
050
16. Other devices
035
6.6 Usage of water tank
050
16.1 OBD diagnostic interface
035
7. Multimedia
050
16.2 Step-on pneumatic button
035
7.1 10-inch display screen
050
16.3 Sleeper 220V power supply
036
7.2 Main interface of the system
051
7.3 Basic operation and button description
051
Contents
7.4 Entertainment
052
7. Use of air suspension system (optional)
082
7.4.1 Radio
052
7.1 Introduction to air suspension system
082
7.4.2 Video
053
7.2 Height valve adjustment
082
7.4.3 Music
053
7.3 Precautions for use
083
7.4.4 Image
054
8. Use of ECAS system (optional)
083
7.4.5 USB device support
054
8.1 Introduction to ECAS system
083
7.5 Bluetooth
055
8.2 Operation and function of ECAS system remote
7.6 Assistive touch
056
controller
084
7.6.1 Car doctor
057
8.3 Operation and function of ECAS rocker switch
085
058
9. Use of lighting system
086
1. Vehicle appearance and vehicle No.
058
9.1 Interior light
086
1.1 Vehicle appearance
058
9.2 Front combination headlight
087
1.2 Model
059
9.3 Combination tail light
090
1.3 Engine nameplate and cylinder No.
060
9.4 Exterior signal light
091
1.4 Location of microwave window
062
10. Use of environmental monitoring system (optional) 092
1.5 Vehicle identification number
062
10.1 Function introduction
092
2. Door opening and locking
III. Vehicle use
062
10.2 Driving image
092
2.1 Operation outside the vehicle
062
10.3 Reversing image
092
2.2 In-vehicle operation
063
10.4 Left and right turn image
093
3. Use of seat and seat belt
063
10.5 Playback
093
3.1 Seat style
063
11. Use of ADAS system (optional)
093
3.2 Seat adjustment function
064
11.1 Application method
093
3.3 Safety warning
066
12. Use of tyre pressure monitoring system (optional)
097
3.4 Seat maintenance
066
12.1 Electronic control unit
097
3.5 Use of seat belt
066
12.2 Vehicle wheel module
098
4. Preparation before driving
067
12.3 Display module
098
4.1 Routine inspection before each drive
067
13. Other vehicle operations
098
4.2 Engine self-inspection before startup
070
13.1 Steering wheel adjustment
098
5. Start and gear shift
071
13.2 Use of sleeping berth
099
5.1 Use of ignition key switch
071
13.3 Front cover opening and closing
100
5.2 Gear shift of Fast 12-gear mechanical transmission
071
13.4 Cab tilt
100
5.3 Gear shift of Fast 16-gear AMT transmission
072
13.4.1 Preparation before tilting
100
6. Use of braking system
074
13.4.2 Operational process
101
6.1 Service braking
074
13.4.3 Precautions for tilt
101
6.2 Assistant brake
075
13.4.4 Hydraulic oil filling
101
6.2.1 Handle operation
076
13.4.5 Tilt system function checkout
101
6.2.2 Foot pedal operation
077
13.5 Side tool kit opening and closing
102
6.2.3 Display of indicator light
077
13.6 Trailer connection and removal
102
6.3 Emergency and parking brake
078
13.6.1 Before connecting the trailer, it is required to
102
6.4 Precautions for Use of Brake System
078
13.6.2 Connect the trailer as below
102
6.5 ABS electronic control system
079
13.6.3 Pipeline and circuit connection
103
6.6 EBS system (optional)
080
13.6.4 Before removing the trailer, it is required to
103
080
13.6.5 Saddle lifting lock
104
6.7 AEBS system (optional)
Contents
13.7 Use of parallel fuel supply system
105
3.5 Introduction to HPDI Supply System
139
13.8 Removal of overhaul cover plate
106
3.5.1 Working Principle of HPDI System
139
IV. Use and Maintenance of Special Parts for
3.5.2 Componnents of HPDI System
139
107
Natural Gas Vehicles
1 Overview of Natural Gas Engine System
107
1.1 Difference between LNG and CNG
107
1.2 Overview of gas engine
107
1.3 General technical characteristics of the gas engine
108
1.4 Safety precautions
108
1.5 Control system installation and precautions
109
1.6 Precautions for the use of gas engines
110
1.7 Precautions for the daily use of gas engine
110
1.8 Instrument of gas engine
112
1.9 Maintenance of gas engine
113
1.9.1 Routine maintenance instructions
114
1.10 Brand and quantity of lubricating oil filled in
3.5.3 Operating Specifications for LNG Vehicle
Gas Supply Systems:
141
3.5.4 HPDI Systems Safety Precautions:
142
3.5.5 Maintenance of HPDI System:
142
3.5.6 Fault Diagnosis of Gas Cylinder
143
4. LNG Vehicle Transportation and Storage
Requirements
143
4.1 Transportation of LNG Vehicles
143
4.2 Storage of LNG Vehicles
143
5.Instructions for Use of Natural Gas
144
China VI Aftertreatment System
144
5.1 Introduction of Aftertreatment System:
144
5.2 Key Components Precautions
144
5.3 Emission Control Precautions
144
the assembly
115
1.11 Precautions for gas system maintenance
116
2. CNG gas supply
116
2.1 Overview of CNG Vehicle Safety
116
V. Maintenance of vehicle
146
supply system
117
1 Inspection and replacement of working fluid
146
2.3 Composition of natural gas supply system
117
1.1 Engine oil change cycle and filling amount
146
5.4 Instructions for Use of Natural Gas China VI
Aftertreatment System
145
2.2 Schematic diagram of the CNG vehicle
1.2 Oil replacement cycle and filling amount of
2.4 Operational guidelines for gas supply
system of CNG vehicles
120
transmission gear oil
2.5 Repair and maintenance
122
1.3 Transfer case gear oil change interval and filling
quantity
2.6 CNG Supply System Failure and
149
151
Troubleshooting Methods
126
1.4 Oil replacement cycle and filling amount of axle
3. LNG Gas Supply Section
126
gear oil
152
3.1 Characteristics of LNG
126
1.5 Engine oil change
155
3.2 Safety Summary and Protective Measures
127
1.6 Fuel service condition
155
3.3 Introduction to LNG Vehicle Gas Supply System
129
1.7 Engine oil service condition
155
3.3.1 LNG Vehicle Gas Cylinder
129
1.8 Inspection and replacement of transmission oil
156
1.9 Oil change period of retarder
156
3.3.2 Introduction to LNG Vehicle Supply
System Process
130
1.10 Inspection and filling of urea solution
157
3.3.3 Sign Description:
131
1.11 Coolant replacement
158
1.12 Inspection and replacement of steering
3.3.4 Operating Specifications for LNG Vehicle Gas
Supply Systems:
132
hydraulic oil
159
3.4 Repair and Maintenance of LNG
136
1.13 Drive axle lubricating oil
159
3.4.1 Routine Maintenance Requirements
136
1.14 Filling windshield washer fluid
160
2. Cleaning
161
2.1 Vehicle cleaning
161
3.4.2 Basic Faults and Troubleshooting Methods
of LNG Vehicle Gas Part:
138
Contents
2.2 Polishing and waxing
161
12. Wheels and tyres
174
2.3 Cleaning interior trims
161
12.1 Regular inspection of tyres
174
3. Air filter
162
12.2 Tyre wear inspection
174
3.1 Air filter maintenance
162
12.3 Tyre service life
174
3.2 Maintenance of ordinary air filter
162
12.4 Tyre type and load capacity
174
3.3 Maintenance of oil bath type air filter
164
12.5 Tyre pattern selection
175
3.4 Maintenance of desert air filter
164
13. Cab tilt device
175
4. Urea system
165
13.1 Replacing the tilt cylinder
175
4.1 Urea system maintenance
165
13.2 Hydraulic oil filling
175
5. Exterior light
165
14. Protective measures for electric welding
175
5.1 Routine maintenance of light
165
14.1 Procedure
176
5.2 Replacing bulb
165
15. Long-term parking of vehicles
176
6. Battery
166
VI. Appendix
177
6.1 Battery box layout
166
1. Brake line diagram
177
6.2 Battery maintenance requirements
166
2. Common tyre load and air pressure
178
6.3 Battery charging
167
3. Allowable total mass and axle load mass
178
7. Braking system
168
4. Tightening torque of main bolts and nuts
179
7.1 Inspection of travel of brake pedal
168
5. Main parameters of engine
180
7.2 Replacing air handling unit
168
6. Main assemblies and configurations of the vehicle
181
7.3 Clearance adjustment of wheel brake
168
7. Front wheel alignment parameters
181
7.4 Check for stagnant water
168
8. Clutch
169
8.1 Clutch fluid inspection
169
8.2 Clutch wear indication
169
8.3 Clutch exhaust
170
9. Fuel supply system
170
9.1 Replacing the coarse fuel filter
170
9.2 Drainage of coarse fuel filter
171
9.3 Fuel tank blowdown
171
9.4 Tightening of fuel tank fastening tape
171
10. Axle and suspension system
171
10.1 Inspection of disc brake friction plate
171
10.2 Routine maintenance of air suspension
171
10.3 Inspection method of air suspension
172
10.4 Regular inspection
172
10.5 Height valve adjustment
172
10.6 Tightening of fastening bolt for key parts of
suspension
173
11. Steering system
173
11.1 Inspection and adjustment of front wheel toe-in
173
11.2 Measurement of front wheel toe-in
173
11.3 Adjustment of front wheel toe-in
174
5
Cab overview
1. Cab overview
6
5
14
3
2
15
4
17
16
13
13
1
10
8
11
9
7
12
Item
Description
Page
Item
Description
Page
1
Steering wheel switch
P6
9
All-wheel drive switch
P29
2
Instrument
P6
10
Key switch
P29
3
Multimedia
P23
11
Cigarette lighter
P30
4
Rocker switch Ⅰ
P24
12
24V power port
P30
5
Rocker switch Ⅱ
P24
13
USB power interface
P30
6
Left door control switch
P26
14
Overhead box
P31
7
Right door control switch
P28
15
Left control lever
P31
8
Differential lock switch
P28
16
Right control lever
P33
17
Lighting knob switch
P35
6
Cab overview
⑧ Constant speed cruise on/Exit key:
1. Steering wheel switch
Pressed, used to enter, pause, resume or exit constant
speed cruise
1
2
⑨ Speed ＋:
4
Press once to increase cruise speed by 2km/h
⑩ Speed－
Press once to decrease cruise speed by 2km/h
6
Cruise resumption switch
7
After temporarily exiting cruise, press the cruise resumption
switch to resume the last cruise state
3
5
2. Instrument
2.1 Instrument interface display
① Control key:
Pressed, used for function change-over switching of 10"
screen (radio, Bluetooth etc.);
Long pressed 3s, the instrument will display the control key
1
3
2
description interface. After 5s, it will exit this interface.
② Volume+/Page up:
Volume control is effective under non-instrument setting;
Roll upward in instrument setting.
③ Volume-/Page down:
Volume control is effective under non-instrument setting;
4
Roll downward in instrument setting.
6
5
④ Phone call/OK key:
Put through or enter into instrument setting.
①
Warning light display area
②
Speedometer
Exit setting option or current setting interface.
③
Tachometer
⑥ Menu left key:
④
Fuel gauge
⑤
Water temperature gauge
⑥
Vehicle-mounted computer display screen
⑤ Voice input/Esc key:
Speech interaction with vehicle-mounted computer;
Turn page to the left
⑦ Menu right key:
Turn page to the right:
① Warning light display area
8
9
Alarm symbol:
The alarm symbol area consists of four parts, which are the
area around speedometer, the area around tachometer,
upper section of travel computer display area and the lower
section of the travel computer display area. After the
instrument is powered on, the indicator lights for intake air
preheating, engine oil pressure too low, transmission fault,
transmission oil temperature too high, OBD alarm, EDC
11
10
maintenance, EDC diagnosis, EDC shutdown, fuel level (air
volume, liquid volume) indication and braking system fault
run self-inspection. If no fault is detected, the indicator
lights are off 3s after they are lit.
Cab overview
Instrument cluster indicator light (all symbols, including the optional devices)
Symbol
Vehicle turn
indicator light
Green
Trailer turn
indicator light
Green
High beam light
Blue
Conditions for lighting
When the left and right turn lights are
If the left and right turn indicator lights flicker at a
turned on, the left and right turn
frequency higher than the normal frequency or flicker
indicator lights will flicker with a certain
only once, it means the left and right turn lights have
frequency. Press the emergency alarm
failed. Please check and replace the bulbs.
light switch, and the left and right turn
indicator lights will be lit simultaneously.
Note: the normal flickering frequency of the left and
When the turn lights are turned off, the
right turn lights is (60-90) times/minute. If the
turn indicator lights are turned off
frequency is more than 90 times/minute, the driver
automatically.
needs to solve the problem.
When the left and right turn lights are
If the left and right trailer turn indicator lights flicker at
turned on, the left and right trailer turn
a frequency higher than the normal frequency or
indicator lights will flicker with a certain
flicker only once, it means the left and right trailer turn
frequency. Press the emergency alarm
lights have failed. Please check and replace the bulbs.
light, and the left and right trailer turn
indicator lights will be lit simultaneously.
The normal flickering frequency of the left and right
When the turn lights are turned off, the
turn lights is (60-90) times/minute. If the frequency is
turn indicator lights are turned off
more than 90 times/minute, the driver needs to solve
automatically.
the problem.
When the high beam lights or
If the indicator lights are on, it means the high beam
overtaking lights are turned on, the high
lights are on. It is recommended to not keep the high
beam indicator lights will be lit instantly.
beam lights on for a long time when the engine is
down, to avoid battery level being too low.
When the small light switch is turned on,
Small light
Green
Consequences
It means the small light and position light are working.
this light is lit.
When the small light is on, turn on the
This means the front fog lights are on .
front fog light switch, and this indicator
Front fog light
light will be lit.
Green
When the lighting knob switch is on,
This means the rear fog lights are on .
turn on the front fog lights and then the
Rear fog light
Green
STOP
Emergency stop light
Red
rear fog lights, and this indicator light
will be lit.
The emergency stop light is on if the
This means the travel conditions are unavailable, and
ve h i c l e o p e r a t i n g c o n d i t i o n s a re
the other fault indicator lights are also lit. Please make
unavailable.
sure to drive the vehicle after this light is off .
7
8
Cab overview
Instrument cluster indicator light (all symbols, including the optional devices)
Symbol
Conditions for lighting
Consequences
When the hand brake valve is manually
This means the parking brake is enabled now.
pulled up to brake the vehicle or the air
Parking braking
indicator light
pressure of the vehicle is insufficient, the
parking braking signal light is lit .
Red
After the instrument is powered on, the
EDC diagnosis
indicator light
If this light stays lit after self-inspection of EDC
EDC diagnosis indicator light runs self-
diagnosis light, it means the electronic control system
inspection. It will be off in 3s if no fault
of engine has a fault. Please contact the service station
is detected.
personnel for troubleshooting.
Red
OBD indicator light
Yellow
After the instrument is powered on, the
If the OBD indicator light stays lit after the vehicle is
OBD alarm light runs self-inspection. It
started, it means the exhaust gas treatment system has
will be off in 3s if no fault is detected. In
a fault. After 50 hours of travel with fault, the vehicle
the Sixth Stage National Vehicle
will limit the engine torque. Please contact the service
Pollutant Emission Standard, the OBD
station personnel for testing and troubleshooting.
indicator light stays lit after selfinspection. After the vehicle is started,
this indicator light is off.
Vehicle ABS
indicator light
After the instrument is powered on, the
If the vehicle speed is greater than 7km/h and the light
ABS indicator light runs self-inspection
is off, it indicates that the ABS system is normal. If the
and will be off in 3-4s, which means the
vehicle speed is greater than 7km/h and the indicator
system is normal. If the light is unlit or
remains lit, it indicates that the ABS system is faulty.
stays lit, it means the system has a fault.
Note: if the ABS light is lit when the vehicle is
traveling, it means the ABS system is faulty, but the
conventional brake still works and it is still safe to drive
Yellow
the vehicle. However, such a vehicle must be sent to
the designated maintenance shop for diagnosis and
maintenance as soon as possible to restore the
function of ABS system.
Trailer ABS
indicator light
Yellow
Battery charging
indicator light
Red
If the trailer ABS system has a fault, the
Please contact the service station personnel for testing
trailer ABS indicator light will be lit as an
and troubleshooting.
alarm.
If the key switch is at the ON position
When the engine is on and is recharging the battery,
and the engine is not started, this
this light is off. Whenever this indicator light is lit, it
indicator light is lit.
means the generator has not recharged the battery.
Note: the vehicle shall not travel for a long time when
this indicator light is lit.
Cab overview
Instrument cluster indicator light (all symbols, including the optional devices)
Symbol
Conditions for lighting
If the cruise function is activated, this
Consequences
It means cruise has started.
indicator light is lit.
Cruise state
indicator light
Green
If the seat belt is not fastened, the
Please fasten the seat belt.
indicator light will be lit for a few
Seat belt unfastened
indicator light
Red
Engine oil pressure
low indicator light
seconds or until the seat belt is fastened.
While the light is lit, the alarm buzzer
also sounds.
After the instrument is powered on, the
If this indicator light stays lit after the vehicle is
engine oil pressure low indicator light
started, please check the lubricating system or contact
runs self-inspection. This light stays lit
the ser vice station personnel for testing and
after self-inspection. After the vehicle is
maintenance. Note: if the engine oil pressure low
started, this light is off.
indicator light is lit, stop driving the vehicle.
Red
Braking air pressure
low indicator light
Red
If the air pressure of any braking line is
If this indicator light is lit during travel, drive the
≤5.5 bar, the braking air pressure low
vehicle with slow speed, and hit the brake by pressing
indicator light will be lit, and at the same
hard on the pedal.
time the emergency shutdown alarm
light will be lit and the alarm buzzer will
sound.
It is used for start-up in low temperature
If the intake air preheating indicator light stays lit after
in winter. If this light is lit when the key
self-inspection, it means the intake air preheating
switch is turned on, it means the engine
system has a fault. Please contact the service station
star ts preheating. If the engine
personnel for testing and troubleshooting.
preheating indicator light is off, it means
preheating is completed.
Note: if the ABS light is lit when the vehicle is
traveling, it means the ABS system is faulty, but the
Intake air preheating
indicator light
conventional brake still works and it is still safe to drive
Yellow
the vehicle. However, such a vehicle must be sent to
the designated maintenance shop for diagnosis and
maintenance as soon as possible to restore the
function of ABS system.
9
10
Cab overview
Instrument cluster indicator light (all symbols, including the optional devices)
Symbol
Conditions for lighting
Consequences
If the coolant temperature is too high or
The vehicle should not continue traveling if this light is
CAN bus communication is abnormal,
lit. If you continue driving it, the engine temperature
this indicator light is lit. If the water
will keep rising, which will damage the engine.
temperature is above 103°C, the
Coolant temperature
high indicator light
Red
Exhaust brake
indicator light
Yellow
Fuel level low
indicator light
instrument water temperature too high
If the coolant alarm is triggered by too high
indicator light stays lit, and at the same
temperature of engine when the vehicle is traveling,
time the "STOP" emergency shutdown
the best option is to pull over and stop the vehicle. Do
alarm light is also lit and the buzzer
not shut down engine. Instead, keep the engine in idle
keeps sounding.
state until the water temperature warning light is off.
Turn on the exhaust brake switch to
When the vehicle travels down slope, effectively using
activate the exhaust brake function.
the engine exhaust brake will allow the vehicle to
When the exhaust brake butterfly valve
maintain a safe speed.
is open, the exhaust brake indicator light
Note: the vehicle shall not travel for a long time when
is displayed on the instrument.
this indicator light is lit.
If the fuel level low indicator light is lit, it
Please refuel in time.
means the fuel is about to be depleted.
Yellow
If the vehicle has reached the
Repair indicator light
Please repair the vehicle in time.
maintenance mileage, this light is lit.
Yellow
Also known as gear switch, it is used for
It means the transmission is in the low-gear area.
the low-gear area of a transmission with
Transmission low gear
indicator light
auxiliary transmission.
Green
ASR indicator light
Yellow
If the drive anti-sideslip system has a
Please contact the service station personnel for testing
fault, this light is constantly lit.
and troubleshooting.
Cab overview
Instrument cluster indicator light (all symbols, including the optional devices)
Symbol
Conditions for lighting
When the daytime running light is
Consequences
It means the daytime running light is on.
working, this light is lit.
Daytime running light
Green
If remote key power is insufficient, this
Please pay attention to the battery power of remote
indicator light is lit.
key.
Remote key low
power indicator light
Yellow
When the ESP is in operating state, this
If it is constantly lit, that means the electronic
light is lit.
stabilization system has a fault. Please contact the
service station personnel for testing and maintenance.
ESP working light
Yellow
The engine antitheft locking is activated.
It means the electronic lock of the vehicle is engaged.
If the cab is not locked in position, the
The cab is connected by the locking device at the rear
Engine antitheft
indicator light
Red
cab locking alarm light is lit.
suspension system to the rear suspension system to
form a whole. If the cab is locked, the vehicle may
Cab tilt indicator light
overturn forward when being braked, thus causing an
Red
accident. In this case, travel is forbidden, and the fault
of the locking device must be solved.
The carriage is lifted or is not fixed
Make sure this indicator light is off before travel.
securely.
Carriage lifted
indicator light
Red
After the instrument is powered on, this
Coolant level low
indicator light
Red
If the observed coolant level is too low, replenish the
indicator light is lit for 3s and then off. If
coolant. If the coolant is normal, please contact the
the coolant level in the auxiliary water
ser vice station personnel for testing and
tank of engine is lower than the
troubleshooting.
specified limit level, this indicator light is
Note: if the vehicle with insufficient coolant continues
lit. The level too low buzzer also sound.
traveling, the engine will be overheated and damaged.
11
12
Cab overview
Instrument cluster indicator light (all symbols, including the optional devices)
Symbol
EDC repair
indicator light
Conditions for lighting
Consequences
After the instrument is powered on, the
If this light stays lit after self-inspection of EDC
EDC repair indicator light runs self-
diagnosis light, it means the electronic control system
inspection. It will be off in 3s if no fault
of engine has a common fault. Please contact the
is detected.
ser vice station personnel for testing and
troubleshooting.
Yellow
Urea level low
indicator light
If the urea level is ≤13%, the urea level
Traveling without sufficient urea for a long time will
low indicator light is lit and the alarm
limit the torque of engine, so please replenish urea in
buzzer sounds for 5s.
time.
Yellow
If any tyre triggers the alarm, the tyre
If any tyre shows "limit overpressure" or "limit
pressure alarm light is lit on the screen
underpressure", the tyre pressure alarm is triggered
Tyre pressure alarm
indicator light
Yellow
and the buzzer sounds for 5s.
and the emergency shutdown alarm light is lit.
If the brake shoe is excessively abraded,
This reminds the vehicle owner to replace the faulty or
Disc brake abrasion
alarm light
this indicator light is lit.
overly abraded brake pad.
If the retarder system has a major fault,
If this system fails, please contact the service station
this light is lit.
personnel for testing and troubleshooting.
Yellow
Retarder fault
indicator light
Red
Transmission fault
indicator light
If the automatic transmission system has
Please contact the service station personnel for testing
a major fault, this light is lit.
and troubleshooting.
If the inter-axle differential lock switch is
The differential lock can be engaged or disengaged
Red
Inter-axle differential
working indicator light
Yellow
turned on and the lock works, this
only when the vehicle is static. If the vehicle is to travel
indicator light is lit and the multi-
on a road with poor road holding or slippery
functional buzzer sounds.
pavement, the differential lock is engaged.
Cab overview
Instrument cluster indicator light (all symbols, including the optional devices)
Symbol
Conditions for lighting
If the suspension is in lifted state, this
ECAS working
indicator light
Yellow
Consequences
It means the ECAS system is working.
light is lit.
When the ignition switch is turned on,
Contact the manufacturer personnel for troubleshooting.
the ECAS fault indicator light will be lit
ECAS fault
indicator light
Red
for approx. 2s. After self-inspection, this
indicator light is off. Otherwise, the
ECAS system is abnormal.
When the retarder switch is turned on or
It means the retarder system is working.
the retarder is working, this light is lit.
Retarder working
indicator light
Green
Wheel differential lock
working indicator light
Yellow
When the inter-wheel differential lock
The differential lock can be engaged or disengaged
switch is turned on and the hub
only when the vehicle is static. Or the vehicle travels on
reduction is effective, this indicator light
a road with poor road holding or slippery pavement.
is lit and the multi-functional buzzer
sounds.
If the ECAS system lifting shaft is
It means the lifting shaft is working.
moving, this light is lit.
Floating axle
indicator light
Green
If the transmission oil temperature is too
Please contact the service station personnel for testing
high, this light is lit.
and troubleshooting.
If the power take-off signal switch is
It means the stop power take-off has started working.
Transmission oil
temperature high
indicator light
Red
connected after the power take-off
starts working, the power take-off
Stop power
take-off indicator light
Yellow
working indicator light is lit or flickers.
13
14
Cab overview
Instrument cluster indicator light (all symbols, including the optional devices)
Symbol
Conditions for lighting
It means the air intake resistance has
Consequences
Please replace or repair the filter element.
increased.
Air filter blocked
indicator light
Yellow
Travel power take-off
indicator light
After the travel power take-off starts
It means the travel stop power take-off has started
working, the power take-off working
working.
indicator light is lit or flickers.
Yellow
When the transfer case switch is flipped
It means the transfer case is in the high-gear area.
to the high gear and the transfer case
Transfer case high gear
indicator light
Green
high gear signal switch is connected, the
transfer case high gear working
indicator light is lit.
When the transfer case switch is flipped
It means the transfer case is in the low-gear area.
to the low gear and the transfer case low
Transfer case low gear
indicator light
Red
Cab main door open/
closed status signal
gear signal switch is connected, the
transfer case low gear working indicator
light is lit.
If the cab main door is opened or is not
This light is lit to remind the vehicle owner that cab
fully closed, this light is lit.
main door is not properly closed.
Yellow
Cab auxiliary door
open/closed
status signal
If the cab auxiliary door is opened or is
This light is lit to remind the vehicle owner that cab
not fully closed, this light is lit.
auxiliary door is not properly closed.
If the adaptive headlight is on, this light
It means the adaptive headlight function is activated.
Yellow
is lit.
Adaptive front
working light
Green
Cab overview
Instrument cluster indicator light (all symbols, including the optional devices)
Symbol
Conditions for lighting
The adaptive headlight system is faulty.
Please contact the service station personnel for
testing and troubleshooting.
Adaptive front
alarm light
Red
When the vehicle is subject to hill-start
Hill-start reminder
indicator light
Consequences
It means the hill-start assist function is working.
and the hill-start assist function is on,
this light is lit.
Yellow
After the adaptive cruise function is
ACC cruise
indicator light
It means adaptive cruise has been enabled.
activated, this indicator light is lit.
Green
The adaptive cruise system is faulty.
You need to check the adaptive cruise system.
If the all-wheel drive switch is turned on
It means the all-wheel drive function has been enabled.
ACC cruise fault
indicator light
Red
All-wheel drive
indicator light
and the all-wheel drive signal switch is
connected, the all-wheel drive working
indicator light is lit.
Yellow
Vehicle information
indicator light
If the vehicle control system is faulty,
You need to examine the fault and solve it accordingly.
this light is lit.
Yellow
Collision alarm
indicator light
If collision is about to happen, the
If this indicator light is constantly lit, it means the
collision alarm system will send the
collision alarm system is faulty. Please contact the
alarm signal to the driver and the
service personnel.
indicator light will flicker.
Yellow
15
16
Cab overview
Instrument cluster indicator light (all symbols, including the optional devices)
Symbol
Conditions for lighting
During travel, if the driver fatigue
Consequences
It means the driver is fatigued and needs a rest.
camera detects fatigued facial
Driver fatigue reminder
indicator light
expression of the driver, this light is lit.
Yellow
If the gas leakage sensor detects
Please contact the service station personnel for testing
leakage, this light is constantly lit and
and troubleshooting.
the alarm buzzer keeps sounding. If the
Gas leak alarm light
Red
gas leakage sensor signal is abnormal,
this indicator light flickers 10s and then
stays lit and the alarm buzzer does not
sound.
ADR abnormal
indicator light
Red
Front inter-wheel
differential lock
indicator light
Green
EBS
EBS yellow light
Yellow
EBS
When the vehicle key is at the ON
If the emergency power supply system is abnormal,
position, the ADR indicator light will be
this indicator light is lit.
lit for 2s and then off. Its purpose is to
tell the user that the indicator light is
working normally indicator light is lit.
When the front inter-wheel differential
The differential lock can be engaged or disengaged
lock switch is turned on and the hub
only when the vehicle is static. If the vehicle is to travel
reduction is effective, this indicator light
on a road with poor road holding or slippery
is lit and the multi-functional buzzer
pavement, the differential lock is engaged.
sounds.
If this indicator light is constantly lit, it
means the EBS system has a common
sensor signal, this indicator light is off. If it is not off,
fault, which is usually a problem in the
please contact the service station personnel for testing
wheel speed sensor
and troubleshooting.
If this indicator light is constantly lit, it
If this light is constantly lit, check whether the vehicle
means the electronic brake control
can be braked. If the brake works, drive the vehicle
system has a major fault.
EBS red light
and troubleshooting.
If spray cleaning fluid is insufficient, this
Yellow
slowly to the service station for repair. If the brake fails,
please contact the service station personnel for testing
Red
Spray pot fluid
level low
If the vehicle travel system detects the wheel speed
light is lit.
Replenish spray fluid.
Cab overview
Instrument cluster indicator light (all symbols, including the optional devices)
Symbol
Power-assisted
steering alarm
Conditions for lighting
Consequences
If this light is lit, it means the power-
Now power-assisted steering may be impaired or
assisted steering system is faulty.
disabled.
Red
Press the AUTOHOLD switch, and the vehicle will
automatically hold when shut down. When starting up
the vehicle, step on the accelerator pedal and engage
AUTO
HOLD
a gear to disengage auto hold. When waiting at a
Press the AUTOHOLD switch, and the
auto hold status indicator light will be lit.
traffic light, the vehicle will automatically hold. When
starting up again, step on the accelerator pedal, and
the system will automatically disengage the brake,
Auto hold status
indicator light
which makes the driver more comfortable. If the
Yellow
AUTOHOLD switch is not pressed, you need to
manually hold the vehicle or disengage brake.
When independent parking brake is
Independent parking
brake status
indicator light
It means this function is enabled.
working, this indicator light is lit.
Yellow
If the load on the saddle is transferred to both the
second and third axles, the drive axle which works as
the second axle only bears half the load. If the vehicle
If the load transfer switch is turned on,
this indicator light is lit.
Load transfer
indicator light
travels on a muddy road, the drive axle will have
insufficient friction and the driving wheels will slip. In
this condition, the load transfer function will decrease
the air pressure of the airbag at the third axle and
increase that of the airbag at the second axle. A part of
Yellow
the load at the third axle will be transferred to the
second axle, to ensure the second axle has sufficient
friction to prevent the driving wheel from slipping.
It indicates the exhaust temperature of
Exhaust temperature
aftertreatment system is too high.
too high indicator light
Please contact the service station personnel for testing
and troubleshooting.
Red
If the vehicle speed exceeds the
Overspeed alarm
indicator light
Yellow
maximum speed, the instrument will
light up the speed limit signal mark.
Please control the vehicle speed.
17
18
Cab overview
Instrument cluster indicator light (all symbols, including the optional devices)
Symbol
Conditions for lighting
Consequences
If the NCD indicator light on the
Traveling for a long time in this condition will limit the
instrument is lit, it indicates the driver
torque of engine.
alert system is activated and the
exhaust monitoring system is faulty.
NCD indicator light
Yellow
Please travel to the service station for
troubleshooting.
If the lane departure warning (LDW)
It means you need to repair the LDW system. Please
system camera is faulty, this light is lit.
contact the service station personnel for testing and
troubleshooting.
Front camera faulty
Yellow
After the LDW assistance function is
After the LDP function is activated, the system will
activated, this light is lit.
apply a torque on the steering wheel to actively
maneuver the vehicle back to the lane.
LDP on/LCC on
Yellow
When the LDW assistance function
It means the system is actively correcting the direction.
applies a torque on the steering wheel,
LDP intervention
this light is lit.
Green
If the autonomous emergency braking
system is disabled, this light is lit
OFF
AEB system shutdown
Yellow
Note: AEB means the vehicle travels normally in the
non-adaptive cruise state. If the vehicle runs into a
dangerous situation or its distance from the vehicle or
pedestrian ahead is less than the safe distance, the
system actively brakes the vehicle (but a vehicle with
this function may not necessarily be able to fully
brake), in order to minimize the probability of rear-end
collision and improve travel safety.
Cab overview
1
3
2
⑤ Water temperature gauge
It indicates the temperature of engine
coolant. C on the dial indicates the engine
coolant temperature is low, and H indicates
engine coolant temperature is high.
When the ignition key is turned to IGN ON,
the water temperature gauge works.
4
6
5
The display range is 40 ~ 120°C.
If the water temperature is higher than the
engine alarm point, the water temperature
too high indicator light is lit, and at the same
①
Warning light display area
②
Speedometer
light is also lit and the buzzer keeps
③
Tachometer
sounding.
④
Fuel gauge
⑤
Water temperature gauge
Note: in normal condition, the engine water
Vehicle-mounted computer display screen
temperature is usually no more than 110°C and it can
⑥
time the "STOP" emergency shutdown alarm
work normally. In a special situation (e.g. travel up
slope with heavy load or travel down slope with
② Speedometer
retarder), the engine water temperature may exceed
The speedometer works when the
110°C and trigger the alarm. The user can cool the
vehicle is running. The display range
engine by lowering the transmission gear and
is 0 ~ 140km/h.
increasing the engine speed (over 1400rpm) (if the
designed permissible maximum water temperature of
engine is above 110°C and the actual water
temperature is above this value, the automatic
protection will be engaged to prevent any fault of the
③ Tachometer
When the engine is started, the
tachometer starts working.
The display range is 0 ~ 30×100rpm.
Economic zone of tachometer: green
zone is the most economically
efficient zone, red zone is the zone
with high fuel consumption; The
instrument will light the LED lamp of
the corresponding color when the
engine reaches a certain economic
zone.
④ Fuel gauge
It indicates fuel level in fuel tank. 0 on the
dial means the fuel tank is empty and 1
means the fuel tank is full.
When the ignition key is turned to the IGN
ON position, the fuel gauge star ts
working.
The display range is 0 ~ 100%.
If the fuel level of the vehicle is less than
13%, the fuel level low alarm light is lit
and the buzzer sounds for 5s. Refuel the
vehicle as soon as possible.
engine).
19
Cab overview
20
⑥ Vehicle-mounted computer display screen
The vehicle-mounted computer display screen shows the
following information
The LCD screen display area interface works in two modes:
b
a
2.2 LCD screen display area interface
control
instrument operating mode and multimedia operating
c
mode. The driver can use the instrument and multimedia
d
f
operation keys shown in the figure below to control the
g
e
instrument and multimedia. Press the control key in the
middle to switch between the operating modes, and long
h
press this key to pop up the key description.
I
I
When the instrument is working, the default mode is
instrument operating mode. The multimedia steering wheel
j
k
l
is controlled by four keys, i.e. "Up", "Down", "Left" and
"Right" keys, and there are also the "OK" key in the upper
right corner and the "Return" key in the lower right corner.
a
Cab interior temperature
b
Alarm light display
c
Remain fuel level
d
Battery voltage
e
Instantaneous fuel consumption
f
Real-time vehicle speed
g
Engine oil pressure
h
General fuel consumption
I
Air reservoir pressure
j
Short mileage
k
Gear display
l
Total mileage
The driver uses the multi-functional steering wheel key to
control the instrument. The instrument will display the
prompt message and operation instruction in the LCD screen
display area.
The "Up" and "Down" keys are used to switch the travel
interface/page up interface on the main interface and to flip
up or down the secondary menu on the menu interface.
The "Left" and "Right" keys are used to flip left or right the
primary menu on the menu interface.
When in the multimedia operating mode, the steering
wheel keys control the multimedia settings. In this mode,
the "Up" and "Down" keys control the switching of Radio
channels, and the "Left" and "Right" keys control the
volume of multimedia.
Description of keys in instrument operating mode
Cab overview
2.3 Menu browsing interface
Fuel consumption since the last refueling
In the instrument operating mode, the driver can press the
"OK" key to enter the menu browsing interface.
The menu interface contains five primary menus: travel
information, vehicle status, personal setting, diagnosis
information and system information. Each primary menu
contains a number of secondary menus.
Browse, operate, and set the secondary menu as prompted
by arrows and text on the screen.
2.3.1 Primary menu for travel
information
TPMS system (optional)
Including the following secondary menus
General fuel consumption
Driver assistance
Fuel consumption subtotal
Mileage subtotal zero clearing
Fuel consumption of this travel
21
22
Cab overview
2.3.2 Primary menu for vehicle status
Rainfall sensitivity setting
Including the following secondary menus
Maintenance setting
Backlight setting
Cargo weighing (optional)
2.3.3 Primary menu for personal
setting
Including the following secondary menus
Language setting
23
Cab overview
2.3.4 Primary menu for diagnosis
information
3. Multimedia
View the fault information
1
2.3.5 Primary menu for system
information
Including the following secondary menus
Vehicle information
2
3
4
5
6
①
OFF/AUTO automatic mode and switch
②
A/C cooling switch
③
7
Internal and external circulation: in-vehicle
circulation change-over of air conditioner
④
SIM card/USB port/earphone jack (flip)
⑤
Return to Home
⑥
Return to the previous level
⑦
PWR/MUTE shutdown and mute
OFF/AUTO automatic mode and switch
Press: automatic mode;
Long press: air conditioner on/off;
Knob: air volume adjustment
On/Off:
Turn the key to ACC or ON position, and the audio system
will start automatically. Turn the key to LOCK position, and
the system will shut down automatically.
Press the [PWR/MUTE] button on the panel. When the
system is on, long press this button to shut down the
Version information
system.
The system has the poweroff memory recovery function. If
the radio experiences poweroff when working and is
powered on again, the radio will return to the operating
state before the poweroff.
Screen sleep/mute
Knob: volume adjustment: increase media volume by
turning it clockwise or decrease by counterclockwise. If
volume is adjusted when in mute mode, the mute mode is
cancelled automatically.
Cab overview
24
Volume adjustment:
Turn the [PWR/MUTE] button on the panel leftward or
1
All oil circuits heating switch
rightward to decrease or increase volume in the range of
2
Main and auxiliary fuel tanks selector switch
3
Working light switch behind the cab
Mute:
Press the [PWR/MUTE] button on the panel to enter the
4
Cab tilt switch
mute mode. Press it again to restore volume.
5
Strobe warning light switch
The mute key is effective when hit once. When the radio is in
6
Multimodal fuel saving switch
7
Electric and pneumatic horn change-over switch
8
Cab ceiling light switch
9
Emergency alarm light switch
10
All-wheel drive switch
11
Front axle inter wheel differential
0~40.
operating state, the user can press the physical or virtual
mute key before poweroff. If the radio is powered off and
powered on again, it resumes working and cancels mute
mode, to make sure the user remembers that mute was
done before poweroff and will not be confused when the
radio is in operating state without any sound after being
powered on again.
If the user needs to mute the radio and keep it silent after
being powered on again, change the volume to 0. If the
① All oil circuits heating switch
radio is powered on again after poweroff, its volume is still 0
For a vehicle equipped with all oil circuits heating system,
and it stays silent.
when you turn the key switch to the ON position and press
the heating control switch, the system will automatically
start working if it meets the preset temperature value.
4. Rocker switch Ⅰ/Ⅱ
1
2
3
4
5
6
② Main and auxiliary fuel tanks selector switch
For a vehicle equipped with parallel fuel supply system, you
can use this switch to select the supply fuel tank. The main
fuel tank and auxiliary fuel tank are mutually independent.
The default state of the switch is fuel tank I, and the main
fuel tank of the parallel fuel tanks works at this time. The
fuel level displayed by the fuel gauge is the current fuel
level in the main fuel tank. When this switch is closed, the
fuel change-over valve works to switch the oil circuit from
the main fuel tank to the auxiliary fuel tank. Do not deplete
the fuel in the fuel tank, otherwise the air in the supply line
needs to be emptied.
7
8
10
11
9
25
Cab overview
③ Working light switch behind the cab
Press this switch to turn on the working light behind the cab.
⑨⑨
Strobe warning light
⑥ Multimodal fuel saving switch
Depending on the load of the vehicle, select a proper gear
and adjust the engine torque to minimize fuel consumption.
0 gear is suitable for empty load or light load
1 gear is suitable for medium load or heavy load
④ Cab tilt switch
When the key switch is at the ON position, press this switch
to disengage cab lock, so you can operate cab tilt
⑦ Electric and pneumatic horn change-over switch
It is used to switch between electric horn and pneumatic
horn. The initial state is electric horn. Press the switch, and
the indicator light on the switch is lit. Now the electric horn
⑤ Strobe warning light switch
When the key switch is at the ON position, press this switch
to turn on the strobe warning light at the top of the cab.
This is meant to draw attention from the driver and
pedestrians and give them an obvious warning.
is turned off and the pneumatic horn is connected.
26
Cab overview
⑧ Cab ceiling light switch
⑩ Al.whee drive switch
It is used to turn on the cab ceiling light. Press the switch to
turn on the ceiling light.
When the vehicle crosses an obstacle. tum on the Al-wheel
drive switch and the front axle inter wheel differential lock
switch iradvance, connect the front axle, shift the transfer
case into low gear and slowly approach the obstacle. When
the front wheelcontacts the obstacle. refuel to make the
front axle cross the obstacle. and then use the sae method
to make the middle and rearwheels cross the obstacle.
5. Left door control switch
⑨ Emergency alarm light switch
It is used as a warning in the event of emergency. Press the
5
switch, and all the turn lights of the vehicle will flicker.
⑩ Al.whee drive switch
3
4
1
2
①
Driver side glass lift control
②
Passenger side glass lift control
③
Central lock closing control
④
Central lock opening control
⑤
Electric rear view mirror adjustment and heating
control
Note: only when the ignition key is at the ON position, can
all the door control switches be effective.
Cab overview
5.1 Window lift
27
5.3 Door lock control
The glass lift switches ① and ② have 5 modes. The initial
position is 0 mode. Pull-up can be done by two modes:
Lock and unlock manually
Press the locking key ③, and the door will be locked and the
mode 1 is lift step by step, and mode 2 is lift by one hit of
locking indicator light will be lit; Press the locking key ④,
the button. Pull-down can be done by two modes: mode 1 is
and the door will be unlocked and the unlocking indicator
lift step by step, and mode 2 is lift by one hit of the button.
light will be lit.
Manual lift: pull up to mode 1 and the window glass will
Automatic locking
If the door is locked or vehicle speed is over 20km/h, the
rise. Release the button, and the window glass will stop
rising. Press down to mode 1, and the window glass will
lower. Release the button, and the window glass will stop
lowering.
door is locked automatically. After the door is automatically
locked, if you open the door from inside and close it again
and now the vehicle speed is still over 20km/h, the door will
be automatically locked again.
Lift by one hit of the button: pull up to mode 2 and the
window glass will rise. Release the button, and the window
Remote controller
locking key
glass will continue rising until it is fully closed. Press down to
mode 2, and the window glass will lower. Release the button,
and the window glass will continue lowering until it is fully
opened.
Note: glass lift by one hit of the button can be interrupted
by resetting the glass lift button.
Locked rotor protection: when the window glass moves to
the limit position (motor rotor locked), the controller will
Remote controller
unlocking key
automatically disconnect the power supply of motor.
5.2 Rear view mirror adjustment
and heating
Move the knob to position a to select left rear view mirror
adjustment. Move the rocker to adjust the angle of the left
rear view mirror.
Move the knob to position b to select right rear view mirror
adjustment. Move the rocker to adjust the angle of the right
rear view mirror.
Move the knob to position c to select the rear view mirror
heating function. After 15min of heating, it automatically
Remote controlled lock/window
When the ignition key is at the OFF position and the doors
on both sides are closed, the remote control is enabled.
Remote locking: press the remote locking key, and the door
central lock will be locked; If the door is locked, the turn
light will flicker 1 time.
Remote unlocking: press the remote unlocking key, and the
door central lock will be unlocked and the turn light will
flicker 2 times.
Remote locking failed: if the door is not closed and you use
remote locking, the door will fail to lock.
stops. If the knob is moved to position O or the rear view
Window glass rise by one hit of the button: long press the
mirror adjustment position during heating, heating
remote locking key for over 3s, and the window glass will
automatically rise until it is fully closed. In this process, press
automatically stops.
any remote control key, and the glass will stop rising.
Position indication
Window glass lower by one hit of the button: long press
the remote locking key for over 3s, and the window glass will
automatically lower. In this process, press any remote control
key, and the glass will stop lowering.
a
b
c
Remote controller coding: one door control unit can be
coded to at most two remote controllers.
Cab overview
28
5.4 Right door control switch
6. Axle differential lock switch
The buttons on the control panel at the passenger side can
The drive axle is fitted with differential lock. If the wheels are
only control the right window glass.
slipping or the vehicle is caught in a muddy puddle, you can
Manual lift: pull up to mode 1 and the window glass will rise.
Differential locks include inter-wheel differential lock and
Release the button, and the window glass will stop rising.
inter-axle differential lock.
use the differential lock help the vehicle move forward.
Press down to mode 1, and the window glass will lower.
Release the button, and the window glass will stop lowering.
Wheel differential gear
Lift by one hit of the button: pull up to mode 2 and the
window glass will rise. Release the button, and the window
glass will continue rising until it is fully closed. Press down to
mode 2, and the window glass will lower. Release the button,
and the window glass will continue lowering until it is fully
opened.
Axle differential gear
How to use the inter-wheel differential lock of
4×2/6×2/6×2 rear-lifting
Only when the vehicle is static, can the differential lock be
engaged. Turn the knob switch to the differential lock
position to engage the differential lock. The clutch must be
disengaged before the differential lock is engaged. When
the inter-wheel differential lock is engaged, the indicator
Passenger side glass
lift control
light
on the instrument is lit.
Disengage differential lock: release the accelerator pedal,
！ Warning
step on the clutch pedal, and flip the rocker switch back to
the original position. When the indicator light on the switch
is off, the differential lock is disengaged.
The window glass does not have the anti-pinch feature,
so please be careful with your safety. When the window
How to use the differential lock of 6×4/8×4 vehicle
glass is rising, do not reach your hand, arm or head out
model
of the window, so as to prevent injury.
Inter-axle differential lock: the axle differential position is
used to lock the inter-axle differential between the first and
second rear axles. When the vehicle is static, turn the knob
switch to the axle differential position to engage the interaxle differential lock, but the clutch must be disengaged
before the inter-axle differential lock is engaged. When the
inter-axle differential lock is engaged, the indicator light
on the instrument is lit.
Inter-wheel differential lock: the axle differential position is
used to lock the inter-wheel differential between the first
and second rear axles. The inter-wheel differential lock can
be used only when the vehicle travels on a straight line.
When the vehicle is static, turn the knob switch to the wheel
differential position to engage the inter-wheel differential
lock, but the clutch must be disengaged before that.
29
Cab overview
7. Transfer case switch
8. Key switch
From left to right, the following picture shows the front axle
1
inter-wheel differential and all wheel drive switch in
R
sequence, through which the front axle inter-wheel
differential and front axle differential can be controlled ,
2
0
Improve the passing of vehicles.
3
Press the transfer case control switch, the corresponding
gear indicator will light up. The indicator light marked “
rabbit ” on the combined instrument panel is on, indicating
that the transfer case is in the high-end. If the indicator light
marked " tortoise" is on, it means that the transfer case is in
the low gear position. When climbing a hill or passing offroad roads, the transfer case needs to be hung in the low
It is shown in the following figure:
gear position. When the rocker switch is in the horizontal
0 position is the LOCK position (shutoff position): the
position, the transfer case is in neutral.
position to insert or pull the key
R position is the ACC position (stop position): some of the
electric equipment can still work (radio and tape player,
cigarette lighter, charging socket)
① position is the ON position (travel position): the electric
equipment of the vehicle can still work
② There is no 2 position
③ position is the START position (start-up position):
precautions upon start-up of engine: do not turn off the key
switch when the vehicle is traveling
Front axle inter-wheel
differential
All wheel drive switch
Transfer case
control switch
Note: The transfer gear can only be shifted when the vehicle
is at a stop or at a speed equivalent to walking speed, and
the clutch pedal must be pressed when shifting.
High/low range switching operation
When switching between high and low ranges, you only
need to gently push the shift lever handle to the right/pull
to the left to realize the conversion.
Please pay attention to the conversion operation:
a. The engine speed cannot be too high, generally not
exceeding 1500 rpm.
b. After pushing the shift lever to the right/pulling the shift
lever to the left, release your right hand to make the shift
lever freely rebound into place, and the shift lever shall not
have rebound resistance.
c. After pushing the shift lever to the right/pulling the shift
lever to the left, there should be a noticeable intermittent
pause, and the gear should be put into gear after the engine
speed drops significantly.
Cab overview
30
9. Cigarette lighter
The cigarette lighter is used to ignite cigarettes. To use it,
directly press it, then release the hand and wait for 10s. After
the resistance wire at the front of cigarette lighter is heated
24V power port
to red, the lighter will automatically pop up and return to
the original position. Then the user can pull out the
cigarette. After use, put it back.
Note: if it is unused for a long time, close the dust cover, to
keep the power port safe from dust or foreign matter which
may impair its functionality.
11. USB power interface
USB power interfaces include sleeper USB power module
and instrument console USB power module.
Sleeper USB power module is integrated into the sleeper
！ Warning
assembled lamp. The instrument console USB power
module is installed on the instrument console, with one on
The cigarette lighter shall not be connected for a long
each of the driver and passenger instrument consoles. It is
time. If it can not pop out automatically, it must be
used to connect the USB port of externally interfaced
pulled out manually.
equipment, so that the driver can recharge the mobile
Snuff out cigarette butt and put it in the ashtray. Do
electronic devices such as mobile phone and tablet
not put it away haphazardly.
computer when resting at the sleeper or at the driver or
Do not touch the heated resistance wire at the front of
passenger seat.
cigarette lighter, for it may scald you.
Never use the cigarette lighter as a power socket,
USB port can supply 5V and maximally 2.1A DC power.
otherwise its fuse may be damaged.
Note:
This port can be used for recharging only and not for
data communication.
10. 24V power port
It can be used to supply ≤24V/5A (12V power interface with
maximum power 120W) power to the electric equipment
that have on-board power supply plug. Make sure to
distinguish the voltage marking on the dust cover and use
the power supply as per corresponding voltage and power
requirements. Please avoid overload use, so as to protect the
on-board power supply and electrical apparatus from
damage.
It is forbidden to charge multiple devices at the same
time by using a USB cable with one line and multiple ports.
Cab overview
31
To use the windshield wiper, turn the switch knob in the
12. Overhead box
indicated direction to set the arrow 1 of switch handle to the
position “0”, “①”, “②”, “③” or “④.
At the position "O", the windshield wiper is turned off.
At the position “①”, two modes, i.e. intermittent wipe or
automatic wipe are available, and the initial time for
intermittent wipe is about 11s. The automatic wiper can
automatically adjust the wipe frequency according to the
actual rainfall.
At the position "②", the wiper motor works with low speed.
At the position "③", the wiper motor works with high speed.
When the switch is turned to the position “④”, the wiper
wipes water once and the switch resets to the position 0. The
intermittent wipe time can be set, and is generally stepless
adjustable intermittent time of 2.5s ~ 60s.
The intermittent time adjusting steps for intermittent
wipe:
The overhead box has ample storage space. The internal
a.Turn the intermittent wipe to the position "①"
lighting lamp is turned on when the box is opened and
b.Turn the intermittent wipe to the position "0"
turned off when the box is closed.
c.After the intermittent wipe time to be set expires, turn the
To keep yourself and your belongs safe, you need to heed
d.The intermittent time is set successfully.
switch back to the position ①.
the following safety precautions.
a.Do not put any overweight or hazardous article in the
Note: The intermittent time shall not exceed 1 min. If the
overhead box.
operating time of steps 2 and 3 exceeds 1 min, the
b.Make sure the articles are securely placed in the box.
intermittent time will automatically reset to 11s (default
c.To close the lid, make sure the locking mechanism is
value).
locked, to prevent the articles from falling when the lid is
opened.
d.Before cab tilt, check whether any article needs to be
13.1 Use of windshield washing
taken out from the overhead box, to prevent it from falling
during cab tilt, for this may damage the article itself or the
Press the button ⑤ in the direction indicated by the arrow to
activate the water spray function. Meanwhile, the wiper runs
box.
twice at a low speed. Continue pressing the button ⑤, and
13. Left control lever
the sprayer/wiper will work cyclically and continuously.
Before using the left control handle, turn the key switch to
the ON position
⑤
Wiper spray switch
③
②
①
0
④
Wiper position selector switch
Cab overview
32
13.2 Use of high/low beam light
When the low beam switch is turned on, the low beam light
stays lit if the switchgroup handle is at the position 0.
13.3 Use of turn light
①
Push the switch handle up to the position ①. At this time,
the high beam indicator light of the instrument is lit and the
high beam light is on. After releasing the handle, the switch
automatically resets to the position 0, the indicator is off and
the high beam is off.
Push the switch handle down to the position ②. At this time,
②
the high beam indicator light is on and the high beam light
When the turn light switch is turned on, the green indicator
is on.
light indicated as tractor turn indicator light starts flickering.
①
If the tractor is equipped with trailer, the green indicator
light indicated as trailer turn indicator light also starts
flickering. The steering switch is capable of automatic reset.
Push the switch handle forwards until the switch handle
passes through the pressure point and reaches the position
①, and the right turn light flickers continuously. When the
vehicle travels on a straight line, the handle automatically
resets to the position 0 and the right turn light is turned off.
Pull the switch handle back until the switch handle passes
②
through the pressure and reaches the position ②, and the
left turn light flickers continuously. When the vehicle travels
on a straight line, the handle automatically resets to the
position 0 and the left turn light is turned off.
Push forwards or backwards, pull the switch handle to the
pressure point and stay it at the position (have not arrived
at the position ① or ②). After releasing the switch handle,
the switch handle automatically resets to position 0. The
right or left turn light flickers at least 5 times.
33
Cab overview
14. Right control lever
14.1 Auxiliary brake handle of an engine
with retarder
The right control lever of the vehicle is used to control the
auxiliary brake and retarder. For a vehicle model with
automatic control, the right control lever is also used to
change positions and select positions, so the right control
lever comes in different forms depending on the vehicle
Enable exhaust brake or in-cylinder brake:
model.
If the vehicle has a retarder, push the switch handle in the
direction indicated in the figure to enable the exhaust brake
or in-cylinder brake. The exhaust brake has two positions, i.e.
0 and 1, and the in-cylinder brake has three positions, i.e. 0,
1 and 2. Position 0 means the brake function is disabled.
14.2 Auxiliary brake handle of an
engine without retarder
Position 1 means the exhaust brake function is activated or
the in-cylinder level 1 brake function is 50% activated.
Position 2 means the in-cylinder level 2 is 100% activated.
0
1
2
If the vehicle has no retarder, push the switch handle in the
direction indicated in the figure to enable the exhaust brake
or in-cylinder brake. The exhaust brake has two positions,
How to control hydraulic retarder:
The driver can flip the manual switch handle step by step to
control the retarder. The schematic diagram for retarder
switch handle is shown in Fig. 1. The manual switch has five
positions (1 constant speed position and 4 braking
positions). The retarding function of each position is as
follows:
Position 0—retarder off;
Position 1—constant speed position of retarder;
Position 2—1/4 of the maximum retarding torque;
Position 3—1/2 of the maximum retarding torque;
Position 4—3/4 of the maximum retarding torque;
Position 5—maximum retarding torque.
i.e. 0 and 1, and the in-cylinder brake has three positions, i.e.
0, 1 and 2. Position 0 means the brake function is disabled.
Position 1 means the exhaust brake function is activated or
the in-cylinder level 1 brake function is 50% activated.
Position 2 means the in-cylinder level 2 is 100% activated.
Cab overview
34
14.3 Right control lever of the vehicle
model with AMT transmission
14.4 Right control lever of the vehicle
model with automatic control
⑤Push the right switch group forward to enable the
3
retarder or increase the retarder position by 1 (the retarder
has 5 positions in total).
1
⑥Pull the right switch group backward to decrease the
4
retarder position by 1 or disable the retarder.
⑦In the travel gear (D position) manual mode, push the
right switch group up 1 time to increase the position by 1.
⑧In the travel gear (D position) manual mode, press the
right switch group down to decrease the position by 1.
2
⑤
①
Position selector switch
②
Power mode selector switch
③
Auxiliary brake position selector switch
④
Power mode selector switch
⑥
① Position selector switch:
Change the switch position to engage the corresponding
gear of the transmission. N-neutral gear, D-travel gear, R-
⑦
reverse gear.
② Power mode selector switch:
In the initial state, the system is in economic mode by
default. Turn the switch rightward to enable the power
mode, and turn the switch leftward to revert to economic
mode.
③ Auxiliary brake position selector switch:
Change the switch position to directly use the vehicle
auxiliary brake (engine brake or exhaust brake); OFF-auxiliary
brake disabled, I-auxiliary brake position 1, with 50% braking
force, II-auxiliary brake position 2, with 100% braking force.
④ Automatic/manual selector switch:
Press the switch inward to change between manual and
automatic gear shift modes
⑧
Cab overview
15. Lighting knob switch
35
16. Other devices
16.1 OBD diagnostic interface
Lighting knob switch
①
②
Low beam light height adjustment knob
The diagnostic interface is a dedicated interface that uses
engine dedicated calibration or diagnosis tools (e.g.
③
diagnosis instrument) for data input and fault information
③
output. The diagnostic interface is installed in the diagnostic
interface board at the passenger side in the cab.
① Lighting knob switch: used to select a light
A position-automatic lighting: the position light or low beam
16.2 Step-on pneumatic button
light is automatically turned on or off according to the light
intensity.
0 position-light off
-position light position
-high/low beam light position.
② Low beam light height adjustment knob:
It is used to adjust the illumination height of low beam light.
Position 0-maximum illumination height of low beam light.
Position 3-minimum illumination height of low beam light.
③ Use of fog light:
When the light switch is at
The step-on pneumatic button is installed at the lower left
position,
part of the driver side panel in the cab. When the air
pull the light switch outward to turn on the front fog lights
reservoir has sufficient pressure, step on it to adjust the
position or
(automatically locked), pull the switch outward again to turn
tubular column of steering wheel, and release it to lock the
on the rear fog lights (automatically reset), pull the switch
column to the set position.
outward again to turn off the rear fog lights, and push the
light switch inward to turn off the front fog lights
(automatically locked).
Cab overview
36
16.3 Sleeper 220V power supply
The step-on pneumatic button is installed at the lower left
part of the driver side panel in the cab. When the air
reservoir has sufficient pressure, step on it to adjust the
tubular column of steering wheel, and release it to lock the
column to the set position. The inverter power socket can
supply 220V/50Hz AC power with ≤1200W power to small
electrical appliance. Before the engine is started, the power
is limited to 150W.
LED indicator light: it is in green when normal or red when
faulty. No color is shown if it is not working. When in
protected state (overloaded or overheated), the yellow light
flickers.
！ Warning
When the light is working, do not pull the power cord.
If the power cord is damaged, repair it immediately.
Do not use your hand or any metallic object to touch
the wiring terminal on the back of the socket or the
jack on the front.
Do not use it with excessive power, for this will damage
the vehicle or cause personal injury.
37
Use of electrical appliances in the cab
II. Use of electrical appliances in the cab
1. Air-conditioning system
1.1 Control panel layout
The air conditioner control panel layout is shown below:
4
1
For the X5000 vehicle model, the air-conditioning system is a
2
cooling-heating automatic air conditioner, whose options
3
include parking air conditioner and fresh air system. The
configuration diagram of X5000 air-conditioning system is
5
6
7
8
shown below. All control actions of the air conditioner can
be done by using the control panel. The air conditioner
control panel is integrated with the multimedia big screen.
All the functions can be set by using the physical keys or the
virtual keys on the big screen and are accomplished through
electronic control.
1
2
3
4
5
9
①
Supply air opening
②
Air conditioner control panel
③
Supply air opening
④
Supply air opening
⑤
Supply air opening
10
11
12
13
14
15
16
17
1
Indoor temperature display
2
Internal and external circulation change-over
3
Economic mode
4
Time display
5
Air conditioner switch
6
Forced defrosting mode
7
Air conditioner power switch
8
Automatic mode
9
OFF/AUTO automatic mode and switch
10
A/C cooling switch
11
Internal and external circulation change-over
12
Air volume adjustment
13
SIM card/USB port/AXU port (flip)
14
Temperature adjustment
15
Return to Home
16
Return to the previous level
17
PWR/MUTE shutdown and mute
38
Use of electrical appliances in the cab
1.2 Air supply mode
Air volume adjustment
Set the air volume by turning the air volume adjustment
Gently touch the icons on the touch screen to change the air
knob (or by sliding the air volume adjustment key on the
supply mode
touch screen leftward or rightward).
a.Turn the air volume knob clockwise by one notch (slide
the air volume adjustment key on the touch screen
rightward), and the air volume will increase by 1 level. The
maximum level is 8.
b.Turn the air volume knob counterclockwise by one notch
(slide the air volume adjustment key on the touch screen
leftward), and the air volume will decrease by 1 level. The
minimum level is 1.
c.The air volume displayed on the screen is the current
Mode 1: air to face
Mode 2: air to face ＋ feet
Mode 3: air to feet
Mode 4: air to feet + defrosting
Mode 5: air to feet
Temperature adjustment:
Slide the temperature adjustment key on the touch screen
leftward or rightward to set the temperature.
a.Slide the temperature adjustment key rightward once, and
the in-vehicle temperature will increase by 1°C. The
maximum temperature is 31°C.
b.Slide the temperature adjustment key leftward once, and
the in-vehicle temperature will decrease by 1°C. The
minimum temperature is 15°C.
c.The displayed temperature is the current preset value
preset value
Use of electrical appliances in the cab
1.3 Air conditioner operation
39
Air volume adjustment knob
1.3.1 Switch on the air conditioner
Go to the application menu from the lower left corner of the
multimedia main interface.
Automatic
mode
Air conditioner
Internal and
switch
external circulation
Press the OFF button to turn on the air conditioner. Now the
air conditioner is in an ON state.
Select the air conditioner in the application menu
Note: OFF is displayed on the screen when the air
conditioner is in an off state. Press the OFF button to start
work. Then, the screen will display ON and enter the manual
mode. The set temperature, mode and the internal and
external circulation motor are in the states before shutdown.
The air conditioner control interface is as follows. Now the
air conditioner is in an OFF state.
When the air conditioner is in an ON state, press the ON
button to enter the OFF state. Then, all actuators will be
turned off and stop work (actions being executed shall be
finished).
40
Use of electrical appliances in the cab
1.3.2 Heating
1.3.4 Automatic mode button
Make sure that the vehicle is powered on and that the
Make sure that the vehicle is powered on and that the
display screen is in an operating state and then turn on the
display screen is in an operating state and then turn on the
air conditioner.
air conditioner.
Adjust the set temperature to be higher than the room
a.Press the "AUTO" touch button on the screen to enter the
temperature, or directly adjust the set temperature to the
automatic mode.
maximum temperature to enable the heating function of the
air conditioner.
b.Adjust the set temperature by the temperature setting
button.
a.Set the air volume by the air volume adjustment knob (or
the air volume adjustment button on the screen).
c.Set the air inlet mode by the "internal and external
circulation" button (or the "internal and external circulation"
b.Set the corresponding air outlet mode by touching the
touch button on the screen).
icon on the screen.
d.Press the "AUTO" touch button again to exit the
c.Set the air inlet mode by the "internal and external
automatic mode, or switch any air outlet mode, forced
circulation" button (or the "internal and external circulation"
defrosting button, A/C button, air volume adjustment
touch button on the screen).
button and ECO button to exit the automatic mode.
Note: The heating function depends on the engine water
temperature. The higher the water temperature is, the better
the heating function will be. Therefore, make sure the engine
1.3.5 Economic mode
water temperature is high before enabling the heating
function.
Make sure that the vehicle is powered on and that the
display screen is in an operating state and then turn on the
1.3.3 A/C button
air conditioner.
a.Press the "ECON" touch button on the screen to enter the
Make sure that the vehicle is powered on and that the
display screen is in an operating state and then start the
engine and turn on the air conditioner.
a.Press the button "A/C" (or the "A/C" touch button on the
screen) to enter the A/C mode. If the refrigerant pressure is
normal, enable the compressor cooling function.
b.Adjust the set temperature by the temperature setting
button.
c.Set the air volume by the air volume adjustment knob (or
the air volume adjustment button on the screen).
economic mode.
b.Adjust the set temperature by the temperature setting
button.
c.Set the corresponding air outlet mode by touching the
icon on the screen.
d.Set the air inlet mode by the "internal and external
circulation" button (or the "internal and external circulation"
touch button on the screen).
e.Press the "ECON" touch button again to exit the economic
mode, or press the forced defrosting button, A/C button,
d.Set the corresponding air outlet mode by touching the
and air volume adjustment button to exit the automatic
icon on the screen.
mode.
e.Set the air inlet mode by the "internal and external
circulation" button (or the "internal and external circulation"
touch button on the screen).
Note: During the operation of the compressor, if the
temperature at the evaporator is too low, the compressor
will be forced to shut down; after the evaporator
temperature rises again, the compressor will be started
automatically.
Use of electrical appliances in the cab
1.3.6 Internal and external
circulation switch button
41
1.3.8 PM2.5 button function
(optional)
Set the air inlet mode by the "internal and external
Make sure that the vehicle is powered on and that the
circulation" button (or the "internal and
display screen is in an operating state and then turn on the
air conditioner.
Every time the "internal and external circulation" button is
pressed, the internal/external air inlet operating state will be
a.PM2.5 is in an enabled status by default and can be
switched once.
disabled manually.
b.When the PM2.5 button is enabled, the indicator light will
1.3.7 Parking air conditioner
button function (optional)
The parking air conditioner is used when the vehicle is
parked or the engine is not started and can be turned on
when the driver and passenger take a rest in the cab.
be on and the screen will display the indoor and outdoor
concentrations of PM2.5
1.3.9 Negative ion generator
on/off button (optional)
a.Conditions for starting the parking air conditioner: the
Make sure that the vehicle is powered on and that the
hand brake is pulled up; the vehicle is powered on; the
display screen is in an operating state and then turn on the
engine is not started; and the refrigerant pressure is normal.
air conditioner.
(These four conditions shall be satisfied simultaneously)
b.The parking air conditioner status will change once when
the parking air conditioner switch is pressed down once;
c.After being turned on, the parking air conditioner is forced
to enter the blowing mode, with the water valve fully closed;
a.The negative ion button is effective on condition that the
blower air volume is not 0.
b.When the negative ion button is pressed down manually,
the negative ion generator will be turned on and the
indicator light will be on; when the button is pressed down
again, the negative ion generator will be turned off and the
d.When the evaporator temperature is lower than or equal
indicator light will be off.
to 1 °C, the compressor of the parking air conditioner
automatically stops working to prevent the evaporator from
c.When the PM2.5 button is enabled, the negative ion will
icing;
enter the automatic working mode.
e.In the case of battery undervoltage, the parking air
Note: When the engine is started, the air conditioner switch
conditioner automatically stops working to ensure the
should be in the OFF position.
vehicle starts;
f.When the high-voltage switch is disconnected, the
When the extremely high temperature in the compartment
arises from the vehicle parking during the day in summer,
compressor of the parking air conditioner shall be turned off
the windows shall be opened and the ventilating fan turned
forcibly.
on (do not turn on the air conditioner, but only the
ventilating fan) first to expel hot air in the vehicle from the
compartment, and then the doors and windows shall be
closed to turn on the air conditioner.
The condenser shall be cleaned frequently (flushed with
compressed air or cold water; hot steam spray is not
allowed).
The compressor should be started frequently in winter and
other seasons in which the air conditioner is not applicable.
It should be operated once or twice a month and for about
10 min each time.
42
Use of electrical appliances in the cab
2. Water-heated type independent
air heater (optional)
2.1 Introduction to control panel
2.2 Control the heater power-on/off
operation
After powering up, press and hold
to start the heater.
Under normal circumstances, the controller displays the
following interface in sequence:
Ignition or standby...
As shown in the diagram above, this controller panel
consists of four buttons (
,
OK
,
SET
,
) and a
Schematic diagram of controller display
when the heater is switched on
display, and all buttons are touch switches with lights. The
The controller displays as shown in the diagram below
button functions are as follows:
when the heater is burning normally.
Power on/off, exit setup
OK
Setup confirmation (manual/automatic heat
control oggle key)
SET
Parameter setting, toggle between the setting
ptions
Wednesday 06:55:52
Heater is burning normally
Setup parameter adjustment
button comes complete with a power indicator light,
which will be on after the controller is powered on.
OK SET
Schematic diagram of controller
display when the heater is burning
each comes complete with a power on/off
indicator light, which will be on when the controller has
been powered on to control the heater to start to work.
OK SET
have a flame symbol indicator light
(blue light)
The interface shown in the diagram below appears if the
heater fails:
between them, which will be on when the heater is burning
normally and will flicker when the heater fails.
Heater failure E00
Platinum resistance thermometer open
circuitor overtemperature
Schematic diagram of controller
display when the heater fails
43
Use of electrical appliances in the cab
When an interface similar to that shown in the diagram
above appears and the flame light (blue light) flickers, it
2.3.2 Set timing starting time
indicates that the heater fails. (it does not mean that the
Set the timing starting time as above, press
controller fails)
SET
to switch
to "Timing starting setting" (The factory default timing
After power-on, press and hold
again to switch off. In
starting time is 06 :30)
this case, the screen will show "Start to switch off, please
wait..." and "Please do not turn off the main power supply...".
As the heater must be cooled for a while before being
switched off, the main power supply cannot be turned off in
this case. After the heater is completely switched off, the
flame indicator light will be off and the display will be off
automatically.
Press
to adjust the value of the flickering option, (press
SET to switch between the flickering options), adjust to the
expected value, and press OK to confirm the setting. Note:
For each parameter setting,
OK must be pressed for single
parameter setting confirmation.
After pressing
OK
for confirmation, prompts like "System
time is set" or "Timing starting time is set" will appear. That
is to say, only the setting of one parameter can be confirmed
2.3 Controller setup
by pressing OK once.
2.3.1 Set system time
Power up the controller, press and hold
For instance, to set two parameters, i.e. current system time
to turn on the
and timing starting time, it is a must to:
controller, and the screen will display "Ignition or standby..."
press
or "Heater is burning normally". In this case, press
system time, and press
SET
to
enter "System time setting", as shown in the diagram below.
press
SET
SET
and
and
starting time, and press
first to properly adjust the current
OK
to confirm the system time;
again to properly adjust the timing
OK
to confirm the timing starting
time; This cannot be understood as adjusting several
parameter values at a time and then pressing
Wednesday 07:02
System time setting
Schematic diagram of controller
display for system time setting
Press
SET
to adjust the value of the flickering option, (press
to switch between the flickering options), adjust to the
expected value, and press OK to confirm the setting.
unified confirmation.
OK
for
44
Use of electrical appliances in the cab
2.4 Timing starting operation process
In the power-on condition, set the heater starting time. (If
there is no need to change the starting time after the
setting, it is not necessary to set it repeatedly. With the
power-off memory function, this parameter can be saved
even if in a power-off state)
④ Please check whether the power supply plug-in is
properly connected if the power indicator light is not on
after the power connection. In addition, the positive wire of
the controller power supply comes with a plug-in fuse for
vehicles. There is short-circuit or overcurrent if the fuse
burns out.
⑤ The controller is provided with a button cell CR2032 to
ensure sustained travel time in the absence of a power
In the standby condition, press and hold
to enable the
supply from the automotive battery.
timing starting function.
⑥ As the fuel consumption of this machine is less, the fuel
absorption rate is slow. For turning on the heater for
commissioning for the first time, sometimes the heater
cannot burn normally upon the first ignition due to the
absence of fuel in the fuel pipe. In this case, the heater
Waiting for timing starting...
needs to absorb fuel and ignite for the second time. As
there is trapped fuel in the heater, dripping and smoking
will occur at the exhaust outlet of the heater and will stop
after the remaining fuel in the heater burns out through
several minutes of burning.
⑦ Before the operation, be sure to check the electric
heating water valve and the air heater water valve to make
sure they are fully open, so as to prevent the heater from
06:30 is the timing starting time and 07:01:45 is the current
burning without water which will lead to heater damage or
time. The heater will be switched on automatically at the
may cause a fire.
starting time and will be switched off automatically after
burning for around 55 minutes. (switch off when the
cumulative burning time reaches about 55 minutes. If the
heater is put on standby after reaching a high temperature,
the standby time will not be accumulated)
Precautions and troubleshooting
① If the timing starting function needs to be realized, do
not turn off the heater power supply after enabling the
timing starting. Therefore, the heater power supply must not
be controlled by the key to the vehicle. It is suggested that
the heater be supplied with power separately. In this way, the
driver can turn off the power supplies of other components
when exiting the vehicle.
② Pay attention to waterproofing. Do not place a water cup
near the display panel, thus preventing water from entering
and damaging the controller.
③ To prevent touching the button by mistake (such as
wiping the panel), it is necessary to press and hold
power on/off, and it is also necessary to press and hold
to enable the timing starting function.
to
45
Use of electrical appliances in the cab
3. Air-heated type independent air
heater (optional)
3.1 Introduction to control panel
3.2 Fuel supply
The diesel oil specified by the automobile manufacturer or
the fuel on the market that conforms to relevant standards
can be used as the fuel for the heater.
1
2
6
If such fuel is replaced with low-temperature-resistant fuel,
7
4
the heater must operate for about 15 min first so that the
fuel system is filled with new fuel.
It is not allowed to use unauthorized fuel/mixed fuel and
3
5
fuel mixed with old oil to run the heater. Failure to abide by
this rule will probably lead to injury, functional failure or
heater damage.
Please use low-temperature diesel oil suitable for the
8
9
10
11
ambient temperature; otherwise, wax precipitation of the
fuel will occur in the fuel pipe, causing the failure of the
1
Left key
2
Spare indicator light (green)
3
Prompt of adjustment towards the left
4
Heater gear
5
Prompt of adjustment towards the right
6
Work (failure) indicator light (red)
7
Right key
8
Return key
9
Heating identification
10
Ambient temperature
11
OK key
heater to work normally. See the table below.
Fuel service condition table
Above 5 °C
Above -5 °C
Above -15 Above -30 °C
°C
0# diesel oil
-10# diesel
oil
-20# diesel
oil
-35#
diesel oil
Above -41
°C
-50# diesel
oil
3.3 Safety inspection shall be
conducted before startup
After a very long outage time, please check all components
to make sure they are placed securely (tighten the screws if
necessary). Conduct a visual inspection to check whether
the fuel system is sealed;
When the heater is put into service for the first time, the
entire fuel supply system shall be checked carefully by the
installation personnel. When the trial run of the heater is
carried out, all fuel connections shall be checked to make
sure they are sealed and placed securely;
The heater may give forth an odor for a short time when it is
used for the first time. This is normal for the first few
minutes of its operation and does not mean the functional
failure of the heater.
46
Use of electrical appliances in the cab
3.4 Power-on and power-off
Precautions for safe use
The heater shall not be used in enclosed rooms such as
Power-on: Press and hold the "OK key" for 2s to turn on the
garage or parking garage; When the heater is used for
module execution system and light the LCD up, thus
taking a rest in the vehicle at night, please partly open the
entering the default power-on interface.
window to keep proper ventilation, in order to prevent
exhaust from entering the vehicle.
The heater shall be turned off before starting operations on
the heater, thus enabling all heating components to cool
down.
The heater is permitted to be operated only with the switch
provided by the company, and using other switches may
lead to functional failures.
The heater is not allowed to be used in a place where
flammable vapor or dust can form, such as gas station, fuel
Power-on status and interface
reservoir, coal storage yard, wood storage, grain warehouse
and other similar places, and shall be turned off ten minutes
Power-off: Press and hold the "OK key" for 2s again in the
power-on status to turn off the module execution system.
before entering such places.
The heater must be turned off during refueling.
The heater is installed in a protective housing and other
confined spaces, and the air inlet of the heater and the hot
air outlet must be kept smooth and free of obstructions or
other foreign matters. In particular, fuel reserve barrels, oil
tanks, spray cans, gas cylinders, fire extinguishers, foam
Powering off.
Do not turn off the
power supply.
cloth, clothing and paper shall not be placed on or beside
the heater for storage or transportation.
Damaged fuses must be replaced with fuses with specified
safety values.
It is not allowed to interrupt the operation of the heater in
advance by operating the battery circuit breaker unless an
emergency shutdown is a must.
Please turn off the heater more than 5 min ahead of turning
Powered off
off the main power switch of the vehicle. Otherwise, the
heater cannot be cooled down and will remain at a high
temperature and thus be damaged.
3.5 Heater gear adjustment
Adjust the heater gears via the "left key and right key". The
heater gears are 1, 2, 3 and Auto respectively. When the
heater gear is Auto, the heater will enter constant
temperature control.
Use of electrical appliances in the cab
4. All-oil circuit heating system
47
4.3 Function
4.1 Main technical parameters
The heating temperature is automatically controlled within
Scope of application: all types of diesel vehicles and diesel-
the set temperature range.
fueled mechanical equipment
Overcurrent and short-circuit protection: Stop heating and
Power supply voltage: 24V (20V-30V)
give an alarm indication when overcurrent is caused by the
Maximum operating current: 20A
circuit of the connector.
turn-to-turn short circuit of the solenoid coil or the short-
Average operating current: 15A
Ambient temperature: -40°C-+70°C
Initial heating temperature: 10°C±2°C
Final heating temperature: 35°C±5°C (can be set based on
user requirements)
Overvoltage protection: Stop working and give an alarm
when the power supply voltage exceeds 30V.
Undervoltage protection: Stop working and give an alarm
when the battery voltage is lower than 20V.
Real-time monitoring of battery level. Stop working and give
an alarm indication when the electric generator or charging
Filter heating power: 120W±10%.
circuit malfunctions and does not charge the battery; stop
4.2 Operation method
is low.
heating and give an alarm indication when the battery level
Fault self-inspection function: Give an alarm indication when
Operating process: When the key switch is in ON gear, press
the fuse burns out; give an alarm indication when the
the heating control switch; when the system reaches the set
connector between the controller and the heating jacket is
temperature, it will automatically start to work; the
in poor contact; stop working and give an alarm indication
temperature setting is as follows: The system will be heated
when the temperature sensor is short-circuited or open-
and start to work when the temperature is +10°C±2°C
circuited.
(calibration can be performed depending on reality); the
system will stop working when the oil temperature rises to
+35°C±5°C (calibration can be performed depending on
reality). When the heating control switch is turned off, the
system heating function will be disabled. The indicator light
on the switch indicates the heating state. The heating switch
is shown in the diagram.
Indicator light
48
Use of electrical appliances in the cab
5. Refrigerator (optional)
6. Water dispenser (optional)
X5000 refrigerator is of drawer structure, which can be
The display part of the water dispenser control box consists of
one three-digit nixie tube and six indicator lights, as shown in
the diagram below:
opened by gently lifting the handle. See the diagram below
for the detailed operation of the refrigerator.
②
③
①
④
⑤
Door handle of
refrigerator
⑦
⑥
⑧
11
9
1
①
Temperature display area
②
Up adjustment
③
Down adjustment
④
Power-on/off key
2
3
4
10
Press and hold key ④ for 3 seconds under the standby
12
condition to power on the refrigerator.
13
1
Heating
condition to power off the refrigerator.
2
Hot water status
After the refrigerator is powered on, the set temperature is
3
Normal temperature water status
4
Power indicator
5
Display screen
6
Heat key
7
Normal temperature key
8
Water outlet key
clean the refrigerator.
9
Fixed clamp base
Magnetic objects cannot be placed in the vehicle-mounted
10
Rotary buckle
11
Power switch
12
Infrared groove
13
Water outlet nozzle
Press and hold key ④ for 3 seconds under the power-on
0°C by default: press key ③ to increase the temperature by
1°C, and the maximum set temperature is +10°C; press key
② to decrease the temperature by 1°C, and the minimum set
temperature is -15°C; press and hold key ③ or ② to increase
or decrease the temperature by 3°C per second.
Note: All power supplies shall be turned off when cleaning
the refrigerator, and strong detergent cannot be used to
refrigerator as they can affect the internal refrigeration chip.
Use of electrical appliances in the cab
6.1 Water dispenser functions
Power-on and standby functions:
To power on the water dispenser, turn the power switch key
of the control box to ON status; then, the nixie tube will
show "888" and all indicator lights will be on for 1s and then
off to indicate the completion of the self-inspection of the
control system. The water dispenser will be in standby
condition when H100 type "100" and "24V" are displayed
successively, "N" light, "P" light and LED backlight are on and
the buzzer sounds once. (If there is water in the water tank,
the water tank temperature will be displayed, and "N" and
"P" lights will be on.)
49
Water outlet key: press this key, and then the system will
initiate the water collection action; before pressing this key,
please put the water cup under the water outlet of the
control box to avoid being scalded by hot water. (as shown
in the diagram below)
The rotary buckle and fixed clamp base are connected at the
back of the control box to prevent the control box from
falling due to a rough road. The control box can be moved
freely to facilitate water collection and shall be clamped into
the fixed clamp base after water collection. (as shown in the
diagram below)
Power-off function:
Turn the power switch key of the control box to OFF status.
Then, the system will first return the water. "P" light will be
on, the buzzer will let out a short sound, and simultaneously
the nixie tube will display "---" to indicate that the system is
returning the water. The system will power off automatically
after returning the water for 80 s; if there is no water in the
heating water tank, the system will return the water for 20 s
before powering off to ensure the water in the water
dispenser and the pipeline is returned completely.
Ice melting function:
When the ambient temperature detected by the
temperature sensor is lower than 2°C, the water dispenser
will automatically enable the ice melting function and the
display screen will show ICE. In this case, there will be no
response to pressing any key, and the water dispenser will
be preheated completely. Ice melting will be stopped after
the temperature in the water dispenser rises to 20°C, and
then the water dispenser can be used normally.
6.2 Key functions
Heat key: press this key to start or stop heating. The water
dispenser is in heating status when the "H" light is on; it is in
boiled water or hot water status when the "N" light is on.
The heating water tank must be heated in full water status.
Press the heat key, and then "---" will be shown on the
display screen to indicate that the system is feeding water
(filling water into the heating water tank). After the heating
water tank is full, the real-time temperature in the heating
water tank will be displayed.
Normal temperature key: press this key, and then the system
will switch to the normal temperature water status.
Meanwhile, the ambient temperature will be displayed, "W"
and "P" lights will be on. The backlight will be on. In this
case, the normal temperature water is available for drinking
(Heating is stopped after switching to the normal
temperature status).
6.3 Water taking method
There are two water collection modes, namely infrared
rejection mode and manual key mode.
Manual key pushing mode: put the cup on the cup holder,
hold the control box in hand and align the water outlet
nozzle with the cup rim, press and hold the water outlet key
on the control box to discharge water, release the water
outlet key to intercept the water flow.
Infrared blocking mode: insert the cup wall (non-transparent
cup) into the infrared sensing groove to block the infrared
beam, and then the control box will automatically start the
water collection. The water flow is stopped immediately
when the cup is moved away from the infrared groove of
the water outlet nozzle of the control box, or it is
automatically stopped after the water in the heating water
tank is fully discharged.
Note: The cup shall not be too full of water to avoid
immersing the infrared device, which may cause constant
water outflow and thus scald any personnel. In case of such
a phenomenon, the water dispenser shall be turned off
immediately and then turned on for recovery.
50
Use of electrical appliances in the cab
6.4 Boiled drinking water
6.6 Usage of water tank
Click the heat key, and then the system will intake water
a.Unlock the container fixing strap buckle attached to the
automatically, and three bars, namely "---", will show on the
bracket and take out the water tank.
display screen. After the heating water tank is full of water,
the system will display the water temperature in the heating
water tank, and meanwhile, the "H" light, "N" light, "P" light
and the backlight will be on. In this case, the water dispenser
is in heating status. (If it is required to stop feeding water
during the feeding process, press the heat key again to stop
or suspend feeding water)
When the water temperature rises to 100°C (initial heating
takes about 10 min, and continuous heating takes about 7
min), the system will automatically alert that the heating
process is completed and it is ready for discharge. (During
the heating process, the hot water at the displayed
temperature can be collected) After collecting water, press
b.Screw off the cover of the water tank, and pour the
collected drinking water into the water tank until reaching
the maximum water level (please do not exceed the
maximum water level when filling the water, so as to
prevent the water from overflowing the water inlet of the
tank when the vehicle head is turned over).
c.Screw down the cover of the water tank, attach it to the
bracket of the water tank, and fasten the strap buckle.
d.Due to the effect of ambient temperature in winter, please
take away the water tank timely to prevent the water in the
water tank from freezing.
the "Heat" key to make the system automatically feed water
and then heat it.
When there is no operation for 10 min under the standby
condition or water available condition, the display screen will
7. Multimedia
7.1 10-inch display screen
automatically dim and turn into power-down mode.
Touch screen
6.5 Normal temperature drinking
water
Press the normal temperature key of the control box, and
then the water dispenser will automatically switch to the
normal temperature water condition, and the "W" and "P"
lights on the display will be turned on. When the display
screen shows the current ambient temperature, water can be
collected, and the water collected is the unheated normal
temperature water in the water tank.
Note: This water dispenser system suitable for plateau
regions can automatically determine the boiling point based
Physical buttons
on altitude and pressurize properly to ensure the water is
boiled.
Precautions
Do not collect too much water to cause scald.
When the driver drives the vehicle, this product shall not be
Power-on: Insert the vehicle key and turn on the ACC
power supply on the vehicle to make the machine power on
automatically and display the brand logo and safety
used, so as to avoid violation of traffic rules.
It is suggested that the water dispenser be turned off if it is
instruction interface.
not used for a long time. The water dispenser will draw the
Power-off: Remove the vehicle key and turn off the ACC
water back automatically and fully from the heating water
power supply on the vehicle to make the machine power
tank and all pipelines to avoid germinating bacteria.
Before turning off the automobile power supply in winter,
off.
please be sure to turn the power switch key of the control
box to OFF status so that the water dispenser can draw the
water back automatically to prevent water in the heating
water tank from freezing.
Use of electrical appliances in the cab
Touch screen operation:
51
① Knob:
Air conditioning temperature regulation
Turn it clockwise to increase the air volume
Click: Touch the screen gently with a finger once
Turn it anticlockwise to decrease the air volume
Swipe: Swipe left, right, up and down on the screen
Press it for 3S: turn on/off the air conditioner
Short press: automatic mode
② Press: turn on the air conditioner for refrigeration
Press and hold: Hold the target in such areas as
③ Press: switch between internal and external circulation of
desktop and list to turn to the edit mode or popup
the air conditioner
④ USB interface
menu
⑤ Traffic card interface
Drag and drop: Hold the icon with a finger and
move the finger to drag the icon to the target area
and then drop
⑥ AUX interface
⑦ Press: return to home page
⑧ Press: return to the previous level
⑨ Rotate:
Rotate it clockwise to increase the sound volume
Rotate it anticlockwise to decrease the sound volume
Automatically cancel the regulation in quiet condition
7.2 Main interface of the system
Press for 3S: screen sleep
Short press: quiet
c
b
a
7.3 Basic operation and button
description
e
d
Application menu: Click the "Application Menu" button on
the main interface to enter the menu selection, and click to
enter the application program.
g
f
2
1
3
4
5
a
Status bar
b
Bluetooth
c
Air conditioning control
d
Online weather
e
Radio
f
Application menu
g
Settings
6
7
8
9
52
Use of electrical appliances in the cab
On the application program page, click it to
Description of buttons
return to the previous page, and click it
multiple times to return to the desktop
Button
On the application program page, click it to
return to the default home page
Return to the main desktop: click the return button
Action
Function
Click
Previous, search up
Click
Next, search down
Click
Search radio
Click
Turn on/off radio
Click
Frequency of radio search
in current radio mode
(FM/AM)
Click
Radio mode switching
in
the upper left of the display screen or press the back to
desktop button
on the panel
7.4 Entertainment
7.4.1 Radio
Support FM/AM radio and can receive
radio programs. FM supports the 87.5108MHz band, and AM supports the 5311629KHz band.
Support automatic radio search. Press
Radio
and hold the blank favorites box to
collect your favorite radios.
Click
distribution.
Turn on/off the radio: The radio is OFF by default, click the
"Radio" button on the desktop to enter the radio interface to
perform related operations.
Radio search: Select the modulation mode (FM or AM) to be
searched, and click the search icon
to automatically
search and save the radio.
View the radio searched by clicking
and AM modes by clicking
, and switch FM
.
Favorites list management:
Add radio: Click the favorite icon to add the radio being
played to the favorites list;
Delete radio: Select the radio to be deleted from the
favorites list, and click the deletion icon to delete the
corresponding radio.
to adjust the sound effect and speaker
Use of electrical appliances in the cab
7.4.2 Video
53
7.4.3 Music
The video program suppor ts the
payback of USB flash disk video, and
Enter the music application and display
can play video files in multiple formats
the music playback interface.
such as mpg, mpeg, dat, vob, avi, xvid,
rm, rmvb, asf, mp4, mov, flv, ogm and
mkv. Support video playback, pause,
Video
next, previous, drag and drop.
Music
Description of buttons
Button
Description of buttons
Button
Action
Click
Click
Click
Click
Click
Click
Function
Action
Function
Click
Control play progress
Click
Open file
Click
Switch cycle mode
Click
Previous
Click
Pause
Click
Next
Click
Playlist
Click
Sound effect control
Previous video
Play
Pause
Next video
Playlist
Sound effect control
Note: In order to ensure driving safety, it is prohibited to
play video during driving.
54
Use of electrical appliances in the cab
7.4.4 Image
Enter the image application and display
the image viewing interface.
Image
Description of buttons
Button
Action
Function
Click
Previous image
Click
Play/Pause
Click
Next image
Click
Rotate counterclockwise
Click
Rotate clockwise
Click
Zoom in
Click
List mode
7.4.5 USB device support
Support USB flash memory (USB 1.1/2.0).
USB files support the following formats:
Audio: MP3, WMA, AAC, FLAC and WVA
Video: MPEG4, AVI, 3GP, FLV, RM/RMVB and DivX
Image: JPEG, BMP and PNG
Support Fat32 memory files.
It is recommended to use a USB storage device with a
capacity of less than 32GB, less than 500 songs and less
than 30 folders to achieve the best playback effect.
Use of electrical appliances in the cab
55
7.5 Bluetooth
As a short-distance wireless transmission mode, Bluetooth
enables connection between the host and the mobile
phone, as well as Bluetooth hands-free and Bluetooth music
functions.
Click the icon
on the application menu interface to
enter Bluetooth mode.
Bluetooth setting
This device can serve as a hands-free handset for a
Bluetooth mobile phone. You can dial the phone directly
Note: Due to the variety of mobile phones and Bluetooth
with this device, and you can talk through the built-in
compatibility, this Bluetooth function does not guarantee to
microphone and loudspeaker.
Note: Not all Bluetooth devices support all Bluetooth
functions.
support all mobile phones. In case of any problem in
Bluetooth connection, please turn off Bluetooth on the
mobile phone first, and then restart the Bluetooth function
of the mobile phone.
Turn on/off Bluetooth
Bluetooth is turned off by default, with a memory function
after it is turned on. It is turned on at the same time when
Bluetooth phone
the device power supply is turned on. Turn on the mobile
phone Bluetooth, search [Bluetooth-Setting-Bluetooth
Device] in the Bluetooth application to find the Bluetooth
name of the mobile phone to connect, and confirm the
connection on the mobile phone side. Wait for a successful
connection…
Specific connection mode:
1. Users need to actively connect this device with their
mobile phones, and their mobile phone Bluetooths are
ensured to be turned on.
2. Search for Bluetooth device through the mobile phone
① Match with mobile phone
Match refers to the process of mutual confirmation when
two Bluetooth devices communicate for the first time. Once
the two Bluetooth devices are matched, the subsequent
communication connection shall not be confirmed every
time. In order to ensure safety, Bluetooth devices will not
communicate with each other until they are paired.
② Auto answer
The Bluetooth is turned off by default. Upon connection
with the mobile phone, the phone is connected
automatically when there is an incoming call.
until the mobile phone finds the device name, e.g. SQ-BTD,
and confirm the connection of this device with the mobile
phone.
3. Search for the mobile phone Bluetooth name on the
central control screen [Bluetooth-Setting-Bluetooth Device].
4. After the mobile phone is successfully connected to the
navigation device, the name of the corresponding device will
be displayed in the pairing list with "connected" status. At
this time, the connection is completed.
You can click the [Disconnect] to disconnect from the mobile
phone.
③ Automatic phone book synchronization
The Bluetooth is turned off by default. Upon connection
When you do not click [Disconnect] to disconnect the
with the mobile phone, the phone book is automatically
mobile phone, the mobile phone will receive the automatic
synchronized to the vehicle terminal.
connection confirmation message of Bluetooth signal when
it is close to the central control screen device.
56
Use of electrical appliances in the cab
Door lock and window
Door lock: Touch the open/close icon to open/close the
door locks on both sides.
Window: Touch the up/down icon to open/close the
windows on both sides.
④ Dialing
Turn on Bluetooth: On the main interface of the system, click
the [Bluetooth] to enter the Bluetooth interface. Whether
call records are synchronized is different from the
communication interface.
"Bluetooth device not connected" shown on this interface
means that your mobile phone is not connected to the
navigation device Bluetooth, and you can't use Bluetooth
yet. In this case, you click "Bluetooth Setting" to set it and
Light
Touch the "low beam light" icon to turn on the low beam
light.
Touch the "fog light" icon to turn on the fog light.
then connect your mobile phone.
Touch the numeric keyboard to enter the phone number,
and then press the dial button to make a call.
Auxiliary switch
(Require relevant configurations)
Touch the corresponding auxiliary switch to
make the corresponding message sent out.
7.6 Assistive touch
Click the assistive touch icon in the
multimedia touch screen application
menu to enter the assistive touch
interface.
Assistive touch
Use of electrical appliances in the cab
7.6.1 Car doctor
Click the car doctor icon in the
multimedia touch screen application
menu to enter the car doctor interface.
Car doctor
The car doctor provides the following
functions:
① Vehicle information inquiry
② Fuel economy inquiry
③ Maintenance service inquiry
④ Fault inquiry: Current equipment fault &
historical fault inquiry and fault symbol
analysis.
57
58
Vehicle use
III. Vehicle use
1. Vehicle appearance and vehicle No.
1
Rear view mirror
2
Automatic light and rain sensor
3
Front cover
4
Front combination headlight
5
Front vehicle window
6
Windshield wiper
7
Bumper
8
Main fuel tank
9
Traction saddle
10
Air reservoir
11
Flat intake pipe
12
SCR box
13
Battery box
14
Urea tank
15
Auxiliary fuel tank
1.1 Vehicle appearance
1
5
2
6
3
4
7
11
The user must accurately and completely indicate the
9
vehicle number when applying for compensation, ordering
12
spare parts or contacting the maintenance department. The
filled vehicle number shall include the followings:
Model
Vehicle identification number
13
14
8
10
15
Engine No.
Date of manufacture
59
Vehicle use
Vehicle label position:
1.2 Model
Position 1: Indicated by serial number 1 at the upper left
corner of the cab front panel (the front cover shall be
The model is numbered as follows:
opened).
1
6
2
7
3
8
4
9
5
Letter
10
Number
Letter or digit
Added when required
1
Enterprise name code
2
Vehicle class code
3
Main parameter code
4
Vehicle emission code
5
Cab type (or body load type or trailer type) code
6
Variant model
7
Other major feature codes of vehicle
8
Drive type or trailer braking type code
9
Wheelbase code (dm)
10
Engine power or trailer axles code
Cab front panel (right side of cab)
2
1
Position 2: At SHACMAN on-board unit
示例：SX425843324
Example: Sx425843324
Note: The on-board unit is equipped with microchip, in
which detailed information and vehicle identification
number of the vehicle are recorded. The user may check the
information on the vehicle through the handset information
management system with GPS and GPRS communication
function. Please protect it properly against any loss or
destruction. Otherwise, you will be responsible for all the
consequences caused.
60
Vehicle use
1.3 Engine nameplate and cylinder No.
ISM engine cylinder block number location
WP12/WP13 engine nameplate location
WP12/WP13 engine cylinder number location
X12N engine nameplate location
ISM engine nameplate location
X12 engine cylinder block number location
Vehicle use
WP13NG engine nameplate location
WP13NG engine cylinder block number location
61
62
Vehicle use
Print location: As shown below, the vehicle identification
1.4 Location of microwave window
number is printed on the right frame web at the front axle
Microwave window of 120mm×70mm is located 160 mm
centerline
away from the upper edge of front windshield at the inner
side and distributed symmetrically along the central axis of
the front windshield. It is as shown below. The user must
post the vehicle electronic identification required by the
vehicle administration office within the microwave window.
2. Door opening and locking
2.1 Operation outside the vehicle
1.5 Vehicle identification number
Opening the door: insert the key into the keyhole, turn the
Numbering form:
key (to the direction of vehicle head), after hearing a click,
pull out the key and pull out the exterior handle of the door
to open it.
1
6
7
2
Locking the door: close the vehicle door, insert the key into
the keyhole and then turn the key (to the back of the
vehicle), after hearing a click, pull out the key to lock the
8
3
4
9
door.
Note: After the vehicle door is locked, pull out the exterior
handle to ensure that the door has been locked, and then
5
10
leave the vehicle. The left and right doors should be locked
respectively.
1
World manufacturer identification number
2
Vehicle brand code
3
Maximum total design mass
4
Body type code
5
Engine type
6
Production S/N
7
Assembly plant code
8
Year code
9
Check bit
10
Driving type
63
Vehicle use
3. Use of seat and seat belt
2.2 In-vehicle operation
3.1 Seat style
2
1
9
1
Press the lock button ① to lock the door, or pull the interior
handle for two consecutive times and then push the door,
2
then the door is opened.
Press the unlock button ②, pull the interior handle and then
push the door, then the door is opened.
8
Note:
When the door is semi-locked, the door is open and the
4
6
5
7
alarm light is on, and the vehicle is prohibited to run under
10
3
this status.
It is forbidden to open the door when the vehicle is running.
When the driver leaves the vehicle, he/she should lock the
door outside with the mechanical key or remote control key
and leave after ensuring that the door is locked.
Item
Seat adjustment function
1
Seat back angle adjustment
2
Lumbar support adjustment
3
Seat height adjustment
4
Damper hardness adjustment
5
Cushion angle adjustment
6
Quick drop switch
7
Seat levelness adjustment
8
Potty seat extension adjustment
9
Handrail angle adjustment (optional)
10
Single ventilation, single heating and ventilation
& heating adjustment (optional)
64
Vehicle use
3.2 Seat adjustment function
④ Damper hardness adjustment
Adjust the damper hardness by flipping
the switch upwards/downwards:
① Seat back angle adjustment
Unlock the seat back by pulling the
The damping force will become smaller
handle forward, so as to fold it forward
when pulling the button upwards, which
and backward, and lock it after releasing
is suitable for smooth roads.
the handle
The damping force will become larger
when pulling the button downwards,
which is suitable for tough roads.
② Lumbar support adjustment
Press the lumbar support switch to inflate
and deflate the upper and lower air bags
of the lumbar support.
⑤ Cushion angle adjustment
Lift the handle upwards to adjust the
seat elevation and lock it after releasing
the handle.
③ Seat height adjustment
When the handle is lifted upwards, the
seat height can be adjusted and kept
stable after the handle is released.
⑥ Quick drop switch
The seat is quickly deflated by flipping
the switch downwards.
Vehicle use
⑦ Seat levelness adjustment
⑩ Single ventilation, single heating and ventilation &
Method: Pull the handle upward, move the
heating adjustment (optional)
65
seat forward (backward) to the desired
position, and then release the handle. At
this time, you will hear a slight "click" sound,
and the slide rail is locked.
⑧ Potty seat extension adjustment
Unlock the potty seat by pulling the button
upwards, adjust the potty seat back and
forth until the passenger feels comfortable,
and lock it after releasing the button.
Enable the seat ventilation or heating function by operating
the knob switch, so as to improve the seat comfort.
(1) Seat ventilation switch: Enable the seat ventilation by
rotating the knob (0=off; 1=low ventilation gear; 2=high
ventilation gear)
(2) Seat heating switch: Enable the seat heating by rotating
the knob (0=off; 1=low heating gear; 2=high heating gear)
(3) Seat heating/ventilation switch: Enable the seat heating
by rotating the knob (0=off; 1=low heating gear/ventilation
off; 2=high heating gear/ventilation off; -1=low ventilation
gear/heating off; -2=high ventilation gear/heating off)
⑨ Handrail angle adjustment (optional)
The downward tilt angle of the handrail is
controlled by rotating the roller at the lower
part of the handrail.
66
Vehicle use
3.3 Safety warning
3.5 Use of seat belt
To avoid injury, nothing shall be placed in the seat moving
The driver seat and front passenger seat are equipped with
area.
integrated seat belt. Please fasten the seat belt to ensure
Before seat adjustment, any possible packaging material on
the seat cushion and back cushion must be removed.
In order to avoid accidents, it is necessary to inspect
whether all the adjusting devices are properly engaged
before the vehicle runs.
Do not operate the seat adjustment device during driving.
For back cushion removal, the back cushion can only be
adjusted if the backrest plate is supported by hands.
Otherwise, it will increase the risk of injury by bouncing
forward against the backrest plate.
the driving safety. After starting the engine, if the driver
fails to fasten the seat belt properly, an image warning will
show at the instrument position together with audio alarm
(not applicable if the seat belt use alert function is not
configured). Before use, the driver should put the seat belt
over the shoulder for adjustment, but not put pen, glass or
other firm and fragile articles in the coat pocket to avoid
unexpected situation. When buckling up the seat belt, hold
the lock catch and press the latch into the lock tongue until
it clicks, when removing it, press the red button on the lock
catch in the arrow direction of the figure, hold and press the
latch to.
Any change to the standard state of the seat (for example,
retrofitting with non-original accessories and spare parts)
may invalidate the tested state of the seat. This may affect
the seat function, thus threatening your safety.
Do not hold the cover plate to lift the seat. Otherwise, the
accident risk will be increased because the cover plate is
loose or broken.
3.4 Seat maintenance
For every 10,000 kilometers of vehicle travel, pay
attention to the followings:
Inspect whether the bolts and nuts in all parts of the seat are
loose, and tighten them in time if they are loose.
Dirt on the adjustment mechanism shall be cleaned up
regularly and add lithium-based lubricating oil shall be filled
in the slideway
The seat damper shall be inspected for oil leakage. In case of
oil leakage, please contact the after-sales ser vice
department in time for maintenance and replacement.
The seat is composed of shock absorption system, lifting
mechanism, slideway, angle adjuster, etc., all of which are
connected by bolts. If any mechanism is damaged, the
mechanism sub-assembly can be replaced at the
maintenance point.
Wearing parts such as angle adjuster handle, guard and lifter
adjusting handle can be replaced separately at the
maintenance point.
Note:
To ensure the safety and reliability of the seat belt, please
pull the seat belt hardly and suddenly for use, the seat belt
should not extend, otherwise, the seat belt lock should be
replaced.
The seat belt should be kept clean and dry normally, and
not coiled up. The seat belt subject to unexpected damage
must be replaced, and the seat belt catch must be checked.
Vehicle use
4. Preparation before driving
4.1 Routine inspection before each drive
67
The urea meter is suitable for vehicles with China IV, V and
VI vehicle emission standards, and is displayed in the
instrument LCD area, as shown below:
Preparations before driving mainly include: routine
inspection and engine self-inspection before starting.
① Turn the master power switch of the battery to the ON
position.
② Inspect whether the cab is locked. If the cab is not locked
in position, the cab locking warning light is lit.
③ Inspect the coolant level and fill it. The aluminum radiator
of this vehicle must be filled with JFG long-term antifreeze
for heavy-duty vehicle, which meets the requirements of
SH0521-1999. Check the coolant level on a daily basis, and
the vehicle should be parked on a flat site. When the engine
is cooled, the coolant level shall not be lower than the
The urea tank is filled with 32.5% aqueous urea solution
minimum level mark of the expansion tank. Always check the
(conforming to the standard GB29518). The "urea tank"
amount of coolant in the expansion tank, and fill it in time
filled with 32.5% aqueous urea solution (conforming to the
between the maximum and minimum marks. Fill the coolant
standard DIN70070) is installed at one side of the fuel tank.
from the filling port of the expansion tank. Find out the
reason of coolant loss and solve it. If the system is
The meter can display the liquid level of aqueous urea
overheated due to a large loss of coolant, do not fill the cold
solution, and both the aqueous urea solution liquid level
coolant immediately because a large difference in
meter and fuel gauge are integral. The fuel quantity is
temperature will damage the engine.
shown by the instrument mark and the aqueous urea
solution capacity is shown by green light on the side. The
Note: Do not fill or mix with other brands of antifreeze. The
aqueous urea solution capacity in the urea tank can be
engine damage will be caused by violating the operating
judged by such a small light.
regulations (if any).
④ Check the fuel quantity and urea quantity, turn on the
master power switch, turn on the power key switch in the
Note:
Only 32.5% aqueous urea solution (conforming to the
cab, and check the fuel quantity based on the fuel gauge. In
standard GB29518) can be filled.
case of inaccurate indication, check the fuel gauge and
sensor.
The maximum filling amount is 45L (60L, 35L or 20L for
some models).
Filling may be carried out when the engine stops
running.
Fuel, water or other mixtures are not allowed to be
filled.
Note: Do not run out of fuel. Otherwise, you will have to
vent the air from the fuel system. Discharged the precipitate
from the oil drain of the oil tank irregularly.
68
Vehicle use
⑤ Check the engine oil quantity
⑥ Fill engine oil
When the car is parked on a level ground and the engine
To fill the engine oil, turn back the cab, open the engine oil
stops for half an hour, open the front cover of the cab and
filler cap, and fill the engine oil of the specified model. The
pull out the dipstick at the position shown in the figure. The
WP10 engine oil filler is on the right side of the cylinder
oil level shall be between the upper and lower dipstick
block, WP12/WP13 engine oil filler is on the fifth cylinder
marks (the oil quantity between the upper and lower marks
on
is about 3L). If the liquid level is lower than the lower mark,
WP9H/WP10H/WP10.5H engine oil filler and WP7/WP8
the
engine
cylinder
head,
and
both
it is necessary to fill the specified engine oil from the fuel
engine oil filler are on the fifth cylinder on the engine
filler, and cover the engine oil filler cap tightly after filling it
cylinder head. Meanwhile, both WP7 engine oil filler and
to the specified position.
ISM engine oil filler are at the front top of the engine
cylinder head. Tighten the engine oil filler cap after filling.
Note: The engine cannot be started when the engine oil
filler is opened or the engine oil dipstick is pulled out.
Engine oil model:
1. Engine with China V vehicle emission standard: CI-4
15W/40
2. Engine with China VI vehicle emission standard: CK-4
15W-40
69
Vehicle use
⑦ Drain the water from the air reservoir of the braking
Filling port
system.
Pull or push on the drain valve to drain the water from the
air reservoir.
⑨ Inspect the tyre pressure and, if necessary, inflate the
tyres with the tyre inflation joint or with the inflation
connector fitted on the air reservoir.
Drain valve
⑩ Inspect the operation of the whole circuit system.
11
Inspect the leakage of lubricating oil, coolant, and air
circuits.
12
Check that when the air filter is used in the cold winter
and dusty conditions, the dust cup shall be emptied and
cleaned every day (the sealing performance is poor when
the dust cup sleeve falls off and is damaged, and the
filtering effect becomes worse). Otherwise, the early
abrasion of the engine and turbocharger will be caused.
13
Check whether the cab is locked. The cab must be locked
during driving. When the cab is not locked in position, the
Drain valve
cab lock warning light is lit. At this time, the driver shall stop
driving and lock the cab.
⑧ Check whether the liquid level of brake fluid in the liquid
14
Check the oil level of the steering fluid reservoir. When
storage tank of the clutch master cylinder is between the
the engine is running/not running, the oil level shall be
"MAX" and "MIN" marks. If the liquid level is too low, fill the
between the "MAX" and "MIN" marks. If the liquid level is
brake fluid through the filler to make the liquid level reach a
lower than the "MIN" mark, the cab shall be turned over and
suitable height, as shown in the figure below. (SAFETY 909
the hydraulic oil shall be refilled in time.
brake fluid for automobiles from SHACMAN is
recommended)
DOT3 or HZY3 synthetic brake fluid is adopted for the clutch
hydraulic system, and must be cleaned up during
maintenance, and the same batch and brand of brake fluid
shall be used.
If the brake fluid is found to be turbid, the master cylinder,
the wheel cylinder, the oil pipe and the joint should be
cleaned and the brake fluid of the above brand should be
replaced; Change the brake fluid every two years or 180,000
kilometers of travel.
70
Vehicle use
4.2 Engine self-inspection before
startup
The engine electronic control unit (ECU) reserves a
standby mode for starting failure. When the neutral
protection switch or connecting line on the vehicle
Insert the key into the lock hole of the directional/starting
transmission fails, turn the ignition key switch from
lock, turn the key switch to the power-on position"1", and
position "2" to position "3" for more than 3s. Then, the
turn on the power of the engine ECU. At this time, all three
engine electronic control unit (ECU) turns on the starter
alarm lights in the instrument panel signal light assembly
relay, and the engine can still start normally! (Note: When
shall be lit immediately (the engine electronic control system
the neutral signal of Woodward OH6 engine indicates in-
performs self-inspection).
gear and the clutch signal indicates clutch-in, the engine
can be started.)
Both alarm lights go out after 2 seconds (self-inspection is
completed), which means that the engine electronic control
system is all right and the engine can be started.
Put the gear shift lever in the neutral position and turn the
key to position "3". At this time, the starter shall start
working. Af ter the engine star ts, the star ter will
automatically stop. If it fails to start for the first time, release
the key to make it rebound to position "2", then return to
position "0", repeat the above steps after a time interval of 2
min, and release the ignition key quickly after the engine
starts.
Operating states of electronic control system signal lights
Signal light
names
Signal light
symbols
Function
Yellow alarm light
(cold start signal
light)
Indicate the operating state
of intake heating device.
Red alarm light
(fault diagnosis
l i g h t ) E D C e l e c t r o n i c
controlled diesel
engine
Indicate electronic control
system faults and output
fault codes
Blue alarm light
(oil-water mixed
signal light)
Give an alarm for excessive
water in the coarse filter.
Yellow alarm light
(OBD alarm
signal light)
Aftertreatment system fault
Blue alarm light
(urea level alarm)
Low urea level
After the engine is started, the LCD screen shall
immediately display the engine oil pressure, and the engine
oil pressure indicator light shall go out. When the engine is
cold-started, the LCD screen will display a high oil pressure
of 4.8 bar. Once the engine has been heated and operated
at the rated speed, the LCD screen will display a pressure of
Note:
The transmission is equipped with a neutral switch, whose
about 3.5 bar, and the minimum oil pressure can be
signal is input to the electronic control unit (ECU)
reduced to 1.8 bar at idle speed, so the engine will not be
controlling the starting relay. If the gear shift lever is not
damaged. If the engine oil pressure is too low, turn off the
in the neutral position, the engine will not start.
engine immediately! Find out the reason, check the oil level,
If it fails to start for the first time, turn the ignition key
has a turbocharger, you must pay attention to it during
switch to position "0", and then start it again. Otherwise,
operation.
and then adjust it to the required one. Because the engine
the engine cannot be started! If the ignition key switch is
repeatedly rotated from position "2" to position "3", the
ignition key switch may be easily damaged.
Vehicle use
71
5. Start and gear shift
5.1 Use of ignition key switch
5.2 Gear shift of Fast 12-gear
mechanical transmission
It is shown in the following figure:
0 position is the LOCK position (shutoff position): the
Fast 12-gear mechanical transmission has 12 forward gears
position to insert or pull the key
and 2 reverse gears, and its control mechanism is shown in
R position is the ACC position (stop position): some of the
the figure below.
electric equipment can still work (radio and tape player,
cigarette lighter, charging socket)
1 position is the ON position (travel position): the electric
equipment of the vehicle can still work
There is no 2 position
3 position is the START position (start-up position):
precautions upon start-up of engine: do not turn off the key
switch when the vehicle is traveling
Start: After the engine is started, the barometer on the
instrument shows the air pressure in the air reservoir. The
vehicle can start only when the air reservoir pressure is
greater than 5.5 bar. When the vehicle starts, put up the
handbrake handle to the appropriate position for starting,
and the STOP light will go out at the same time. When the
vehicle stops, pull down the handbrake handle in place, and
the STOP light will light up.
Barometer
The transmission is subject to single-H operation, and the
high-low gear shift (upward for high gear and downward for
low gear) is realized by the pick below the ball knob. When
the transmission is in low gear, the low gear indicator light
on the instrument panel lights up.
72
Vehicle use
Operation method:
Note:
When the gear shift lever is in the neutral position, do
① Shift from the low gear to the high gear
not move it laterally at will to avoid unnecessary
Low gear
abrasion.
High gear
When the vehicle is towed, the transmission shaft shall
be removed. Otherwise, it is easy to damage the
transmission! It is forbidden to tow or slide the vehicle
with the transmission in the neutral position. Towing
Drive in low gear
Pre-select
high gear
Step on the
clutch pedal
Upshift to t
he high gear
5.3 Gear shift of Fast 16-gear AMT
transmission
② Shift from the high gear to the low gear
High gear
speed: no more than 40km/h (kilometer/hour)
Low gear
The function of gear shift handle used in AMT is shown in
the figure.
Drive in high gear
Pre-select
low gear
Step on the
clutch pedal
3
Downshift to
the appropriate
low gear
1
Precautions for gear shift:
4
To shift the gear, step on the clutch pedal until it reaches the
bottom to the separation point, so as to completely
disengage the clutch. Avoid failure in gear shift and early
wear of the shift collar or the synchronizer. Check correct
clutch disengagement and specified pedal clearance on a
2
regular basis.
Select the first gear or creeper gear when you start the
vehicle with full load.
①
Position selector switch
②
Power mode selector switch
vehicle with full load or run on the road with severe
③
Auxiliary brake position selector switch
conditions. Never select the reverse gear or creeper gear
④
Power mode selector switch
The creeper gear is only used to run on a ramp, start the
unless the vehicle has stopped.
During the gear shift, the gear shift lever must be pulled
steadily until the gear is fully engaged.
When shifting gears, the driver shall completely separate the
clutch and deliberately make the gear shift lever stop for a
moment (1~2s) when it passes through the high gear gap
(or the low gear gap), so that the auxiliary transmission
enables the shift between the high gear and the low gear.
Transmission operation
① Shift between neutral and forward gears
Move the handle gear selector switch upward from position
N to shift into the forward gear. After a successful gear
shift, the instrument displays "N" off and "D" on, and vice
versa.
② Shift between neutral and backward gears
Move the handle gear selector switch downward from
For stopping, you must remove the gear (namely, put the
position N to shift into the forward gear. After a successful
shift lever in the neutral position), but shall not leave the
gear shift, the instrument displays "N" off and "R" on, and
vehicle stopped in gear.
vice versa.
Vehicle use
③ Shift into the economical power mode
Initially, the system default mode is economical mode. Push
73
⑦ Manual intervention in automatic mode
In the automatic mode, the AMT system will automatically
the "E/P" button to the right. Upon shifting into the power
select and shift gears according to the operational state of
mode, push it back to the left to the economical mode. In
the vehicle. The driver can also manually intervene in gear
power mode, the shift point is high, with good acceleration
shift according to the actual situations.
property and climbing performance. In the economical
mode, the shift point is low, with low fuel consumption.
Manual intervention can only be performed when the
operational state of the vehicle meets the gear shift
It is recommended that mode E shall be adopted for good
requirements. Moreover, manual intervention is only
road conditions such as flat roads and small ramps, and P
effective for AMT for a certain period of time and the
mode shall be adopted for large ramps and mountain roads.
automatic mode will not be quit.
These modes shall be shifted by drivers according to the
actual situations.
④ Shift between manual and automatic modes
Initially, the system default mode is automatic mode. Press
the "A/M" button to shift into manual mode, and then press
it again to shift into automatic mode.
⑧ Manual mode
In manual mode, any shift request must be made by the
driver. That is to say, the driver chooses the gear.
Shifting is possible only when the operational state of the
vehicle meets the gear shift requirements. If the gear
requested by the driver is not suitable for the current
⑤ Automatic neutral taxiing
When the vehicle is driving on a flat road, if the driver
to remind the driver that the gear shift request is rejected or
doesn't step on the accelerator, brake, turn or provide
the transmission is automatically shifted into a suitable gear.
operational state, the instrument will give a warning sound
assisted braking, the transmission will automatically be in
It is recommended to adopt a manual mode in off-road and
automatic neutral taxiing mode according to the situations,
poor road conditions.
and the instrument will display gear N to save fuel. It will
automatically quit neutral taxiing according to the change of
road conditions.
⑥ Shift up and down
A
B
A: In the travel gear (gear D) manual mode, push the right
switchgroup up 1 time to increase the position by 1.
B: In the travel gear (gear D) manual mode, press the right
switchgroup down to decrease the position by 1.
74
Vehicle use
Precautions for use:
6. Use of braking system
6.1 Service braking
After the AMT-equipped vehicle is put into the starting
gear at rest (a touch on the brake is required), there
X5000 has the following four sets of braking systems:
will be power output as the accelerator and the clutch
Service brake (foot brake), assistant brake (exhaust
gradually combine with each other with the accelerator
brake), emergency and parking brake (hand brake) and
stepped, so it must combine with the handbrake for
trailer brake (optional device).
hill-start. For hill-start, it is forbidden to release the
handbrake immediately after being put into the
starting gear to prevent the vehicle from slipping.
Before starting the vehicle, make sure your seat belt is
fastened and the transmission is in neutral position "N"
(the handle is also in the position "N") and the
handbrake is in braking position. When the vehicle
Working conditions:
a. It is a pedal-operated dual-circuit pneumatic brake.
b.The free travel of the brake pedal is about 17mm-21mm.
c.The maximum rated operating pressure and the cut-off
pressure of the pressure regulating valve shall be 1MPa or
above.
instrument gives a prompt of "low working pressure of
the transmission", it is necessary to idle the engine or
increase the engine speed for a period of time before
filling air and then start driving when such a message
disappears.
Note:
The primary circuit acts on the wheels on the rear axle (or
dual rear axle) and the secondary circuit acts on the
wheels on the front axle. Once the pressure in one of the
Before parking, vehicle maintenance or temporary
two circuits drops below 0.55MPa (5.5 bar), the pressure
departure during engine running, be sure to make the
indicator light
will light up. At this moment, you
transmission and control lever in the neutral position
must stop the vehicle immediately and identify the
and pull the handbrake to prevent the vehicle from
reason for pressure leakage. If the pressure indicator light
slipping.
of the air reservoir lights up, you must stop the vehicle
immediately and identify the reason for pressure leakage.
Ensure that the air pressure in the air passage of AMT
If the vehicle is braked fully and continuously for many
system is not less than 8 bar. The instrument will give a
times, it may also cause the pressure to drop below 0.55
prompt of "low transmission air pressure" when
MPa (5.5 bar).
detecting that the air pressure in the air passage is less
than 7 bar.
Leakage inspection: After the engine is shut down and
When the vehicle is running, especially during gear
hand brake is initiated, the maximum pressure drop shall be
shift, please keep the accelerator pedal in an
0.05 MPa (0.5 bar) within 2h or 0.01 MPa (0.1 bar) within 30
appropriate place to step on it without releasing the
min. If the pressure drop value exceeds such a limit, there
accelerator. This is different from the vehicle equipped
may be brake circuit pressure leakage.
with manual mechanical transmission.
If the position of the gear shift lever is inconsistent
with the actual gear shown on the instrument, the
actual gear shown on the instrument shall prevail.
Meanwhile, look for an opportunity to stop the vehicle
safely within the site. After putting the handle in the
neutral position, put the transmission in the
appropriate gear again and start driving.
Vehicle use
6.2 Assistant brake
The auxiliary braking device includes engine exhaust
auxiliary braking device and hydraulic retarder.
① Exhaust brake
75
When the vehicle is heavily loaded and is going downhill, set
the brake gear switch to the "high" position if the road is dry
and has great tractive force.
In case of an emergency, press the main brake pedal at the
same time (namely the foot brake of the truck). At this time,
The button valve on the front ground at the front left side of
the braking power will be superimposed and
the driver in the cab is used for operation. At this point, the
the braking effect will be better.
running vehicle can initiate auxiliary braking function with
the energy consumed by the engine. When the vehicle goes
Working conditions for Ennova brake:
downhill, the exhaust brake function shall be applied. When
a.Oil temperature: Make sure that the engine oil
meeting other vehicles or passing through rough road, the
temperature >85°C before use.
vehicle can initiate exhaust brake function to reduce the
b.Speed range: Under normal circumstances, the operating
speed in advance.
speed for Ennova brake ranges from 1100rpm to 2100rpm.
Do not make the engine speed lower than 1000rpm. The
The exhaust brake function can be used to reduce the
brake will be automatically released to avoid the engine
frequency of using main brake, reduce wear and heating
speed from exceeding 2100rpm, so as not to damage the
between tyre and wheel brake, extend its service life, reduce
engine.
oil consumption and improve travel security.
c.Make the clutch pedal released, the transmission in gear
(not in neutral position) and the master switch of braking
When using the exhaust brake, the following notes shall
system master turned off.
be noted:
a.The engine speed shall not be greater than 2000 rpm.
Precautions for use of Ennova brake
b.When the transmission gear is low, the exhaust brake
a.Ennova braking system is a kind of auxiliary braking
efficiency is high.
device, which is mainly used for auxiliary braking of vehicle
c.It is forbidden for the vehicle to slide in neutral, and there
continuously going down a long ramp under heavy load
is no auxiliary braking effect in neutral.
conditions.
d.For terrible road conditions such as raining, snowing and
b.The service brake can be used at the same time, but it
slipping, exhaust brake shall be used with caution to avoid
cannot replace service braking for emergency braking or
accidents such as sideslip and drift.
parking braking.
e.Pressing the clutch or accelerator pedal will disable or
c.It is forbidden to use the Ennova braking system for
deactivate the exhaust brake, which may affect driving.
overspeed. If the engine speed is close to or reaches the
Please be careful.
maximum allowable value, the service brake must be used
to reduce the speed.
② Ennova brake
The vehicle can use Ennova braking function in the process
③ JACOB brake
of driving, if it needs to slow down on a long slope or on the
When the engine speed is greater than 900 rpm and the
urban road.
vehicle speed is greater than 0km/h, after turning on the
engine brake switch, the engine brake will start to work as
Ennova braking system has two gears: The first gear: 3
long as the clutch pedal and the accelerator pedal are
cylinders for braking, generating 75% engine braking power;
released. The driver can choose the brake gear as required
The second gear: 6 cylinders for braking, generating 100%
(50% and 100% gears are available).
engine braking power. The driver can select the "High" or
"Low" position according to the actual situation.
When the driver steps on the clutch pedal or accelerator
pedal, the engine brake will be released immediately. After
If a vehicle driving on a flat and open road, set the braking
the driver releases the clutch pedal and the accelerator
gear switch to the "low" position if the vehicle is lightly
pedal, the engine brake starts to work again.
loaded and a large braking force is not required. If you find
that you are still using the service brake, put the gear switch
When the driver steps on the brake pedal, the engine brake
in a higher gear until you don't need to use the service
still maintains the braking effect. Under the combined action
brake.
of engine brake and service brake, the vehicle can obtain
greater braking force.
76
Vehicle use
Precautions for use of JACOB brake
Gears 0-5 are used as follows:
JACOB brake is a kind of auxiliary braking device, which is
When the vehicle is ignited, the retarder is on standby.
mainly used for auxiliary braking of vehicle continuously
going down a long ramp under heavy load conditions.
When it is necessary to slow down, pull the handle of
manual switch to the required gear step by step to achieve
The service brake can be used at the same time, but it
the purpose of slowing down (the retarder indicator light
cannot replace service braking for emergency braking or
shall be on at the time, except that the indicator of the
parking braking.
constant speed gear of Gear 1 is not on).
When JACOB brake works, choose a reasonable gear to keep
Pull the handle of manual switch back to Gear 0 to cancel
the engine speed at 1600-1900 rpm. Do not make the
the deceleration command.
engine speed lower than 1000rpm. Otherwise, the brake will
be automatically released to avoid the engine speed from
exceeding 2100rpm, so as not to damage the engine.
The constant speed gear is used as follows:
Before enabling the constant speed function when going
down a long slope, first reduce the vehicle speed to a safe
④ Retarder brake
speed value. When reaching the speed you want to
The retarder has two operation modes: handle and pedal.
maintain, turn the manual switch of the retarder to the Gear
Manual operation is completed with constant speed gear,
1 of the constant speed gear.
while pedal operation is completed with constant speed
gear.
If the constant speed gear is used, use the auxiliary brake to
slow the vehicle if the speed is still increasing.
6.2.1 Handle operation
When the switch is turned back to Gear 0, the constant
speed function is released.
The driver controls the retarder by pulling the handle of the
manual switch step by step. The manual switch has five
gears, and the retarding effect of each gear is as follows:
2
1
0
0
Gear 0 - retarder off
1
Gear 1 - constant speed gear of retarder
2
Gear 2 - 1/4 of the maximum retarding torque
3
Gear 3 - 1/2 of the maximum retarding torque
4
Gear 4 - 3/4 of the maximum retarding torque
5
Gear 5 - maximum retarding torque
5
4
3
2
1
0
Vehicle use
6.2.2 Foot pedal operation
77
6.2.3 Display of indicator light
When the retarder works and fails, the drive indicator is on,
and the indicator is integrated in the instrument. The
indicator lights of the X5000 model include the working
indicator and the fault indicator. The working indicator turns
yellow when it is on while the fault indicator turns red when
it is on, as shown in the figure below:
The operation mode of the foot pedal is
shown in the figure below:
Working indicator light
A
A - The retarder works alone
B
B - The retarder and the service brake work together
1
1 - Brake gear 1
2
2 - Brake gear 2
3
3 - Brake gear 3
Fault indicator light
Note:
In order to ensure the continuous use of the
retarder for the longest time, please always shift into a
In the foot mode, it is controlled by the foot brake master
gear of the transmission when using the retarder, and
valve, which is divided into three stages of deceleration.
try to shift to a lower gear to keep the engine speed
When the effective travel of the brake pedal is 8mm, Gear 1
always higher than 1,500rpm. It is forbidden to use the
of the retarder starts to work. When the effective travel of
retarder in neutral. The retarder is an auxiliary braking
the brake pedal is 18mm, Gear 2 of the retarder starts to
device. Please use it as expected. In case of emergency,
work. When the effective travel of the brake pedal is 28mm,
use the main brake to slow down.
Gear 3 of the retarder starts to work. Pedal operation of
retarder brake gear is basically the same as that of the
handle operation.
78
Vehicle use
6.3 Emergency and parking brake
6.4 Precautions for Use of Brake
System
① Emergency release of spring brake cylinder
If the pipe connecting spring brake cylinder automatically
brakes due to leakage, screw out the bolt on the cylinder to
position and the brake will be released. Before releasing the
spring brake cylinder, put the transmission into gear 1, and
check whether the foot brake works normally. When you
release the spring brake cylinder on the road with a certain
slope, block the wheels in case the vehicle may slide from
the ramp.
Hand braking includes both emergency braking and parking
braking. It works through the spring energy storage brake
cylinder on the rear axle (or dual rear axle). The parking
braking is realized by operating the handle of the hand
braking valve. When the braking system fails, the emergency
braking is automatically realized by pushing the energy
storage spring.
Only when the pressure of the braking system reaches
0.55MPa (5.5 bar) and the hand braking signal light is off,
the spring brake can be fully released.
② Maintenance of brake line
a.Welding, cutting and drilling near the plastic pipe for
braking shall comply with the following regulations:
b.Release pressure in the pipe.
c.Cover the pipe in case it may be damaged by sparks,
Note:
Before starting the engine, the handle of the hand brake
flames or hot cuttings.
valve must be placed in the braking position; otherwise,
temperature for heating is 130°C and the duration is 1h.
d.For the pipe without pressure, the maximum allowable
the original parking braking effect will be eliminated
after the pressure of the braking system increases. No-
③ Dryer maintenance
load vehicles shall not park on a slope of >20%, and
Air dryer failure judgment: Pull the blowoff valve under the
fully-loaded vehicles shall not park on a slope of >18%.
When the vehicle is parked on a ramp with a trailer, pull
the hand braking handle back to the "Inspection
air reservoir to observe whether water is discharged. If no
water is discharged, it indicates that the dryer functions
normally and there is no need to replace the drying cylinder.
position". At this time, only the spring energy storage
braking of the main vehicle works. The fully loaded
vehicle shall be able to stop stably on the ramp with a
slope of 12%.
Drain valve
79
Vehicle use
Maintenance of air dryer:
For the continuous oil discharge of the air compressor,
timely maintenance and servicing of the air dryer are
required.
6.5 ABS electronic control system
ABS is an electronic control system that monitors and
controls vehicle speed during braking. Its mission is to
prevent wheel lock due to excessive braking force (especially
Daily maintenance: Check the drainage of the air reservoir
on slippery road surfaces), so that lateral tractive force can
during daily off-running, and check whether there is oil stain
be maintained even with full braking, ensuring the driving
or water discharge from the blowoff valve on the air
stability, steering control of the vehicle and the best effect of
reservoir. If any water or oil stains are found, drain the water
braking coordination of the main trailer. At the same time, it
or oil stains and immediately replace the drying cylinder at
ensures the optimization of available braking friction
the service station.
between tyre and road, vehicle deceleration and braking
During maintenance, only replace the drying cylinder, as
system to improve the active safety of the vehicle.
distance. ABS works through the conventional braking
there is no need to replace the whole dryer. Procedure for
replacing the drying cylinder: vigorously rotate the drying
cylinder to the left, remove the drying cylinder, clean the
stains on the surface of the dryer body before installing the
① Use of ABS
Power-on inspection of ABS
new one, and finally tighten the drying cylinder clockwise
After the vehicle is powered on, the driver shall observe the
(15N/m).
ABS indicator light
on the instrument. The function of
the ABS indicator light is to let the driver know the ABS
state. ABS works as follows:
When the
The ABS indicator
Indicate that
ignition switch
light turns on
ABS is normal
is turned on
momentarily
(about 3s) and
then turns off.
If the vehicle speed is
④ Ensure that the brake reaction time is within the value
greater than 7km/h and
limit range
the light is off, it
The operation mode of the foot pedal is shown in the figure
indicates that the ABS
below: Brake reaction time of the main vehicle: The reaction
time from pressing the brake pedal to the most unfavorable
After the vehicle
ABS light stays on
starts
or off according to
the vehicle speed.
brake chamber is not greater than 0.6s.
system is normal. If the
vehicle speed is greater
than 7km/h and the
indicator remains on, it
indicates that the ABS
Brake reaction time of the main vehicle with traction
system is faulty.
function: The reaction time from pressing the brake pedal to
the end of the extension of the air pressure control pipeline
connector between the main trailers is less than or equal to
0.4s.
Note: After the vehicle is started for the first time or the
The trailer brake reaction time of the vehicle with traction
until the vehicle speed is greater than 7km/h (if the
system is diagnosed, the ABS indicator will not turn off
function: The reaction time from the air pressure control
system is not faulty). After turning on the ignition switch
pipeline connector between the main trailers to the most
for the second time, follow the above rules. At the same
unfavorable brake chamber is less than or equal to 0.4s.
time, after the vehicle is powered on, the ABS solenoid
valve will perform a self-inspection. When the driver
steps on the brake pedal and turns the key switch to
position "ON", you may hear the exhaust sound of the
ABS solenoid valve.
80
Vehicle use
Emergency braking
ABS will be enabled at emergency braking and wheel lock.
Generally speaking, ABS works just as a driver "brakes"
quickly and frequently. For vehicles equipped with ABS, in
case of emergency braking in danger, first quickly step down
the clutch, then slam on the foot brake, and turn the
steering wheel at the same time to avoid obstacles. If the
ABS indicator light turns on during driving, it indicates that
6.6 EBS system (optional)
EBS refers to electronic braking system, including ABS
function, ASR function, EBL function, ESC and hill-start
assist start function, which can effectively prevent instability
problems such as braking lock, tail swing and rollover and
ensure driving safety under emergencies.
the ABS is faulty, but the conventional braking is still in
When the vehicle is powered on, the driver shall observe
effect. It is required to perform diagnostics and repair at the
the EBS indicator light on the instrument. If the EBS
designated service station to make the ABS system back to
indicator light is on, it indicates that the EBS system is
normal.
faulty, and it is required to perform diagnostics and repair
② Precautions for use of ABS
back to normal. ABS will be enabled at emergency braking
at the designated service station to make the EBS system
a.ABS controller shall be disconnected to prevent the
and wheel lock. In case of emergency braking in danger,
controller from being damaged when the battery is charged
first quickly step down the clutch, then slam on the foot
with external high voltage.
brake, and turn the steering wheel at the same time to
b.The power supply shall be turned off to prevent the
avoid obstacles.
c o n t ro l l e r f ro m b e i n g d a m a g e d b y t h e re v e r s a l
electromotive force when components of ABS system are
disassembled or reassembled.
6.7 AEBS system (optional)
c.ABS controller shall be disconnected to prevent the
c o n t ro l l e r f ro m b e i n g d a m a g e d b y t h e re v e r s a l
The AEBS system detects traffic target information such as
electromotive force during welding operation for the
vehicles and pedestrians in front of the vehicle in real time
vehicle.
through the camera and millimeter-wave radar, and judges
d.Always check whether the voltage of the generator is
potential collision risks based on the state of motion.
stable to prevent the controller from being damaged by the
According to the different collision risk levels, the system
reversal electromotive force.
prompts the driver through the alarm icon, prompt tone
e.Do not change the capacity of ABS fuse at will.
and brake pulse. When the collision risk is very emergency,
the vehicle will perform emergency braking automatically,
③ Self-diagnostic function
thus assisting the driver in avoiding collision or reducing
ABS has the fault self-diagnosis function. When the
the severity of collision.
electronic control system fault is detected, the system can
generate the corresponding fault code and output, and the
corresponding indicator light on the instrument will turn on.
Besides, the fault code can be displayed on the LCD, and the
form of fault code is SPN+FMI.
If the ABS system of the trailer has a fault, the ABS indicator
light
of the trailer will be lightened as an alarm.
81
Vehicle use
① Enable or disable AEBS
② Working process of AEBS system
Operate the button on the instrument to enable or disable
the AEBS system.
AEBS
When the AEBS system is disabled, the yellow alarm light
Distance between vehicles
on the instrument is on.
The sensor
monitors the
vehicle
The function is enabled when AEBS switch is turned on, and
the speed is higher than 15km/h. The green indicator light
on the instrument
is on.
Stage 1
Pre-collision
alarm
The vehicle
Even if the AEBS system is turned off during the last driving
Vehicle in front
cycle, AEBS is enabled by default every time the vehicle is
powered on.
Risk of
collision
with the
vehicle
in front
Sound and
image
warning
Brake
Auditory
and visual
warning.
The yellow
light for
vehicle
collision
on the
instrument is
flashing, and
there is a
short interval
buzzer
warning
Auditory
and visual
warning. The
red light for
The vehicle
Stage 2
Collision
alarm
The collision
Vehicle in front
risk increases,
and the
response
time
decreases
vehicle
collision on
the
instrument is
Slight
braking
pulse
flashing, and
there is a
continuous
buzzer
warning. The
warning
sound is
The vehicle
Stage 3
Emergency
braking
Vehicle in front
more urgent
Confirm
the collision
is inevitable
than that in
Stage 1
Full
braking
82
Vehicle use
7. Use of air suspension system
(optional)
7.1 Introduction to air suspension system
7.2 Height valve adjustment
Height valve adjustment has been completed when the
vehicles leave factor y. Unless the connecting rod
mechanism of height valve is accidentally damaged during
The air suspension is a suspension system in which the air
the use of the vehicle, users shall not adjust the connecting
spring is used as an elastic component. Compared with the
rod mechanism of height valve without permission. If
traditional leaf spring suspension, the air suspension has the
necessary, the adjustment of the height valve shall follow
features of long design life, working stability and good
the following principles:
comfort. Besides, the fatigue resistance of air suspension is
a.The distance between the lower wing surface of the frame
also very good, it can still ensure a long service life even in
and the center surface of the axle is 200mm, and part a
the case of large bearing capacity. Moreover, the suspension
should be horizontal;
height can remain unchanged and vehicle bounce is small
b.The pendulous axis (part c) on the height valve has an
under different bearing capacity or potholed pavement
arrow diagram, and part a shall be inserted from the arrow
through the height adjusting device. So, it is very applicable
end;
to transport glass products, precision instruments and other
c.The pins between the connecting rods should be parallel
goods. Because the air spring does not friction parts (seals),
to each other, and rotate sensitively, without stuck
so it will not be worn even in the environment of dust,
phenomenon;
particles or many precipitates, and the maintenance cost is
d.In the process of axle bounce, the larger the swing travel
low.
of part a, the better.
Air spring
e.The recommended effective length of par t a is
180~190mm.
f.When the height is adjusted well, the recommended angle
between part a and part b is 70°;
g.The height valves on the left and right sides of the axle
are installed symmetrically, and the corresponding length of
each rod is the same.
a
Precautions:
a.Ensure that the airbag does not contact hydraulic oil,
lubricating oil or solvent for a long time;
b.The vehicle shall not overload by 10% even in the fine
pavement such as expressway and Class 1 highway;
c.Please conduct maintenance as required to ensure the
service life of air suspension;
d.The height control mechanism is an important
component and has a direct impact on vehicle safety, so
users shall not disassemble or change settings without
permission to avoid safety accidents;
e.The airbag and air pipeline shall be well protected
during vehicle welding and spark cutting;
f. W h e n u s e r s s e t u p t h e s u p e r s t r u c t u re , a n y
superstructure part shall not affect the motion space of
height regulating mechanism, and there shall be no
obstacles within 30mm of the circumference of the
airbag (when the suspension height is at the initial
position).
b
c
Vehicle use
7.3 Precautions for use
① Carry out routine inspection every day or before
83
8. Use of ECAS system (optional)
8.1 Introduction to ECAS system
departure. The routine inspection contents include:
a.Conduct visual inspection to judge whether the air
The ECAS system is applicable to highway traction/truck and
suspension is fully inflated and balanced;
consists of the controller, combined solenoid valve, height
b.Suspension height is normal and there is no leakage for
sensor, instrument display and switch, etc. The working
the system.
principle is as below: The height sensor is installed on the
c.A simple inspection method is as below: When vehicles are
frame and connected with the axle through the rod of
used for the first time, the vehicles under good conditions
pendulum. When the vehicle body and the axle height
are parked above ground. Four easily measured points
change, induced current is generated in the height sensor.
(these points should be lower than the lowest point of the
The electric signal is transmitted to ECU, and ECU compares
airbag) should be selected all around the suspension, and
the height change and the set height, gives a signal to
the distance between the point and the frame is measured
control the solenoid valve to inflate or exhaust the airbag so
and recorded. In the subsequent inspection, it is only
as to achieve the constant control of body height. The main
necessary to park the vehicle on a level surface and measure
features of the air suspension are as below:
the distance from the four points to the frame. If the value
①Cab damping function - The cab and the chassis are
changes little, the suspension height is normal and there is
separated to reach the damping effect
no leakage for the system.
②Chassis damping function - The improved chassis
② If the vehicle fails to pass the inspection, it is required to
damping function can provide good protection of load
find out the reason and repair, if necessary.
cargo
③ Safety inspection shall be performed regularly (Interval
③Load/no-load height memory - During loading and
mileage 2000-3000 km). During inspection, the vehicle shall
unloading, the vehicle chassis will be maintained at a
be parked on a clean and flat road and braked. The
constant height equal to the loading platform
inspection items are as below:
④Automatic height adjustment during driving - The vehicle
a.No looseness is found in fasteners;
will automatically adjust to normal altitude when it reaches a
b.At the air pressure of no less than 6 bar, the air spring is
certain speed
inflated normally and the airbag on both sides of the same
⑤Different driving height adjustment - A maximum of 2
axle is of the same degree of integrity; the air spring is free
different driving heights can be set
of wear, damage and inappropriate bulging and there is a
⑥Drive assist - Maximize drive assist control within the
surrounding space of 30 mm or more.
allowable range of the shaft load
c.The shock absorber is free of oil and damage and works
⑦Remote control function - The remote controller can make
properly. A simple judgement method is as below: When
the rising and lowering operation more convenient and
there is no obvious fault, the heat of the shock absorber
rapid
after running indicates normal operation (may be hot).
⑧User-defined switch control - The driver can conveniently
d.No crack is found for all parts and welds.
and quickly carry out the rising and lowering operation
through the instrument panel switch
84
Vehicle use
8.2 Operation and function of ECAS
system remote controller
ECAS remote controller is shown as below. It is usually set
up near the main cab seat, and the meaning of its indicator
light and button functions are as below:
Press button ④ to enable the control of rear axle. Judge
whether the control function is enabled through observing
1
3
2
whether the corresponding indicator light is lightened.
When the indicator light is on, press button ⑧ or ⑩ to
control the axle suspension system up or down.
4
5
Memory height storage: After the vehicle is adjusted to a
certain height, press button ⑨ and ⑥ or ⑤ at the same
time, and the current height of the vehicle will be stored as
6
7
the corresponding memory height.
8
9
vehicle will automatically inflate and deflate to the memory
Use of memory height: Press button ⑥ or ⑤, and the
height stored in the button ⑥ or ⑤ last time.
10
Press button ⑦, and the vehicle will automatically inflate
and deflate to the normal driving height.
1
Indicator light for rear axle control
2
Indicator light for front axle control
3
Indicator light for hoisting axle control
4
Rear axle control switch
5
Memory height 2
6
Memory height 1
7
Reset button
8
Up button
9
Stop button
10
Down button
Press button ⑨, and the vehicle will immediately stop the
current altitude adjustment for the time being.
Note: The system will prohibit the use of the remote
control for up/down adjustment after the speed exceeds
a limit (generally 30Km/h), except the return to the
normal height.
！ Warning
Rising operation is prohibited in the running process!
Vehicle use
85
8.3 Operation and function of ECAS
rocker switch
Hoisting axle
control switch
Drive help switch
Drive help switch
Hoisting axle control switch
If the vehicle is equipped with the drive help switch, the
If the vehicle is equipped with the hoisting axle control
drive help function can be enabled by the switch. Press
switch, the lifting and descending of the hoisting axle can be
above the switch to enable drive help, and press below the
controlled by the switch. Press above the switch to lift the
switch to cancel drive help.
hoisting axle, and press below the switch to lower the
hoisting axle.
The drive help function is a special auxiliary function
provided by the electrically controlled air suspension
It should be noted that there are only two states for the
system. After this function is enabled, the system will
position of the hoisting axle: hoisting and descending. After
transfer the load on the hoisting axle or following axle to the
pressing the switch, the hoisting axle will automatically and
drive axle until the drive axle reaches its maximum load. In
continuously inflate and deflate to the appropriate position.
this way, the positive pressure of the drive axle against the
It is impossible to keep the hoisting axle in the middle
ground can be maximized, thus maximizing the driving force
position by the switch.
of the vehicle.
Users can know whether the current hoisting axle is in the
Usually when the speed is lower than 30 km/h (including 0
state of motion through the corresponding indicator light
on the instrument.
km/h), the drive help switch is allowed to be enabled. After
the speed exceeds 30 km/h, the drive help function will be
disabled automatically.
Note: The upper limit of the hoisting axle is the rubber
stopper on the lower wing of the frame near the hoisting
axle.
86
Vehicle use
③ Sleeping berth combination light
9. Use of lighting system
9.1 Interior light
① Interior light
a
b
c
a
b
d
e
f
c
Touch the control panel b to control the master light a.
Switch a controls the left spotlight d to achieve interior
Lightly touch it, and the master light is on. Touch it lightly
lighting
again, and the master light is off.
Switch c controls the right spotlight e to achieve interior
The switch d controls the small light. The illumination
lighting
direction of the small light can be adjusted at any angle
through the light adjusting lever.
Push switch b to the left gear, open the door and the
reading light f is lightened.
c is the USB power supply interface that can provide 5V DC
power with the maximum current of 2.1A. The interface only
Push switch b to the right gear, and the reading light f is
provides the charging function, without data
lightened.
communication function.
② Roof light
④ Sleeping berth light
The roof light is controlled by the independent rocker switch.
Press the switch and the roof light is on. press the switch
again, and the roof light is off.
The sleeping berth light is used for sleeping berth lighting.
The sleeping berth light is used to control the light. Press
the switch, the sleeping berth light is on; Press the switch
again, the sleeping berth light is off, and the light mirror can
be rotated to adjust the lighting direction.
87
Vehicle use
⑤ Overhead box light
9.2 Front combination headlight
The front combination headlight is used for driving lighting
and signal indication. The light is an integrated headlight,
and LED light source is used. Its layout is as below (The left
headlight is taken for example. The right headlight and left
headlight are symmetrical.)
When the overhead box is opened, the overhead box light is
2
1
on for overhead box lighting. When it is closed, the
overhead box light is off.
3
⑥ Door light
4
5
The door light is on when the left or right door is opened.
The overtime period is 15 minutes. After 15 minutes, the
1
Position light/turn light/daytime running light
2
High beam light
3
Low beam light
4
Auxiliary high beam light
5
Front fog light
light will be automatically off. When the left and right doors
are closed and any door is opened again, the door light is on
again.
Function
Power
Low beam light
30W
High beam light
18W
Auxiliary high beam light
7W
Daytime running light
22W
Turn light
22W
Position light
3.5W
Front fog light
8W
88
Vehicle use
All lights of the front combination headlight are basically
① Control logic of low beam light
controlled by the light knob switch and left operation
Manual: The light switch is manually placed in II position;
lever.
Auto: When the light switch is in AUTO position, the light
sensor sends a signal to the controller according to ambient
light intensity so as to lighten the left and right low beam
Left control lever
lights, without manual operation.
II position of
light switch
Key switch ON
OR
And
Lighting knob switch
a
b
c
Exterior low beam
light and high beam
light control signals
Automatic light
request signal when
the light is Auto
OR
d
Low beam light ON
② Control logic of high beam light, auxiliary high beam
g
light and overtaking light
The high beam light cannot be on automatically. The driver
e
should manually turn on the high beam light according to
f
the driving environment when the low beam light is on.
Item
Description
When the controller receives the switch signal, the left and
right high beam lights are on.
a
AUTO position of light switch
b
0 position of light switch
In the driving process, the driver should operate the
c
I position of light switch
overtaking light switch for overtaking, and the high beam
d
II position of light switch
e
Indicator light for front fog light
f
Indicator light for rear fog light
g
Height adjustment knob of low beam light
light is on.
Up
ON position of key
switch
The position II signal of
light switch or low
beam light request
signal is valid
And
Exterior high
beam light control
signal
OR
Right
High beam light ON
Auxiliary high beam light ON
Down
Left
High beam light
switch signal
89
Vehicle use
③ Control logic of daytime running light
⑤ Control logic of position light
After the vehicle starts, release the parking brake. If the
Manual: The light switch is manually placed in I position;
position light, low beam light and turn light are not turned
on, the controller drives the daytime running light to be
Auto: When the light switch is in AUTO position, the light
lightened.
sensor sends a request message to the controller according
to ambient light intensity so as to lighten the position light
of the vehicle.
Parking brake switch
signal is valid (AMT
is in P position)
High beam
light
All
Not
ON position of
key switch
Right turn light
OFF
Low beam
light /position II
of light switch
I position of
light switch
Front fog light
II position of
light switch
And
The speed is
greater than the
preset speed
threshold
Exterior light
control command
or
AUTO position
of light switch
And
Left turn light
OFF
And
Right daytime running
light ON
ON position
of key switch
Left and right position lights,
rear position light and interior
back light are on, and the
position light relay of the trailer
is enabled.
And
The light sensor
perceives low
brightness
Left daytime running
light ON
④ Control logic of turn light
⑥ Control logic of front fog lightt
When the ON position of key switch is effective, the left and
When the ON position of key switch, I position of light
right turn light switch is turned on, and the controller drives
switch and the switch signal of front fog light are effective,
the left or right turn light to be lightened.
the controller drives the front fog light to be lightened.
The turn light drive blinks at least 5 times at a frequency of
90 times per minute.
ON position of
key switch
Exterior front fog
light control
command
When a fault happens to the turn light, the turn light
indicator signal on the fault side will blink at a frequency of
I position of
light switch
180 times per minute to prompt the driver.
ON position
of key switch
Left turn
switch
Right turn
switch
And
And
Trailer
judgment
Trailer
judgment
Trailer setting
Main vehicle right
turn light
Main vehicle left
turn light
And
And
Trailer left turn light
Trailer right turn light
And
Left / right
front fog light
or
Front fog light
switch signal
90
Vehicle use
⑦ Curve light
The front fog light on the corresponding side is used to
realize this function. When 0 < speed ≤ 40 km/h, the light is
in Ⅱ position or the low beam light lightening request signal
of AUTO position is effective, the left (right) turn switch
signal enables the curve lighting function. The left (right)
front fog light on the corresponding side is on, and the
operating state of curve lighting is indicated.
Brake light
Front fog light
switch is invalid
Reverse light
Rear fog light
Turn light
① Control logic of brake light
0 < vehicle
speed = 40 km/h
When the ON position of key switch is effective, step on the
brake pedal, and the controller drives the brake light to be
lightened.
The position II or AUTO
of light switch or low beam
light request signal is valid
Left ( right )
front fog light
And
In case of retarder braking or engine braking, even if the
brake pedal does not act, the brake light will be on.
ON position of key
switch
When the brake light cannot work normally due to a fault,
Left ( right ) turn light
switch signal
the rear fog light will be lightened instead of the brake
OR
light.
The wheel speed difference
between the left and right
front axles is greater than
0.65 km/h .
When the speed is greater than or equal to 50 km/h and
emergency braking happens, the brake light blinks at a
frequency of 4 Hz to warn the outside environment.
9.3 Combination tail light
The combination tail light is installed on the tail of the
Brake light
switch
CCVS_ 00
message
vehicle, and used for signal indication and reversing lighting.
EBS pedal
switch
signal
Retarder
working
signal
Exhaust brake
working signal
Foundation
BrakeUse
signal
The function layout is as below.
OR
(The right rear tail light is taken for example. The left rear tail
light and right rear tail light are symmetrical.)
Vehicle speed signal
Function
Power
Outline marker light
LED/2W
Reverse light
Halogen light bulb /21W
Brake light
LED/4W
Turn light
Halogen light bulb /21W
Position light
LED/2W
Rear fog light
Halogen light bulb /21W
Side marker light
LED/0.5W
Licence-plate light
LED/0.5W
Y
Emergency
braking j
udgement
ABS working signal
Brake light ON
Brake light flashing
indication
Emergency braking status
Vehicle use
91
② Control logic of reverse light
The outline marker light is a lamp used to indicate the width
After the engine starts, the transmission is placed in the
of a vehicle. For some vehicles and trailers, it is used to
reverse gear, and the controller drives the reverse light to be
supplement the front and rear position lights so as to arouse
lightened.
special attention to the whole vehicle at night and ensure
the driving safety at night.
Engine speed
signal
Key switch ON
signal
Current position
signal
Reverse switch
signal
AND
Reverse light
③ Control logic of rear fog light
When the ON position of key switch is on, the low beam
light or front fog light is on, and the rear fog light switch is
on, the controller drives the rear fog light to be lightened.
ON position of
key switch
Side turn light
The turn-signal light is a lamp used to indicate left or right
turn to pedestrians and other vehicles on the road so as to
II position of light
switch
remind driving safety.
or
Front fog light
switch signal
Rear fog light
switch signal
or
and
Exterior rear fog light
control command
Rear fog light
Trailer rear fog light relay
9.4 Exterior signal light
Side marker light
The side marker light is a lamp used to indicate the
existence of a vehicle.
Outline marker light
92
Vehicle use
10. Use of environmental monitoring
system (optional)
10.2 Driving image
10.1 Function introduction
For vehicles equipped with such
function, when the key switch is in ON
position, click "360° view" in the
application menu to enter.
1
In the driving process and under the 360° view interface, the
2
display screen automatically switches and displays the
3
image information of the front camera and 360° view
information when the speed is greater than 20 KM/h.
4
Or manually click "Driving" button on the screen to switch
5
to the driving image.
6
7
Please pay attention to the actual
surroundings to ensure safety!
10.3 Reversing image
1
Quit the environmental monitoring system
2
Driving image
3
Reversing image
4
Trailer connection image
5
In container image
6
Recover auto mode
7
Playback
Auto mode: The system is in automatic mode by default.
After entering the application, the corresponding image is
In the reverse gear and under the 360° view interface, the
displayed automatically according to the driving condition
display screen automatically switches and displays the
of the vehicle.
information of the reversing image and 360° view
information.
Manual mode: Click the corresponding button to display
the corresponding image (360° view/running/reversing)
Or manually click "Reserve" button on the screen to switch
to the reversing image.
Click button ⑦ to switch to auto/manual mode.
93
Vehicle use
10.4 Left and right turn image
At the left/right turn and under the 360° view interface, the
display screen automatically switches and displays the image
information of the left rear/right rear camera.
11. Use of ADAS system (optional)
11.1 Application method
The ADAS system mainly realizes such functions as lane
departure warning (LDW), front collision warning (FCW),
pedestrian collision warning (PCW), high beam light and low
beam light switch (IHC) and traffic sign recognition (TSR).
The system functions can be manually enabled and disabled
through instrument settings. All functions are enabled by
default, and the sensitivity level is Class 2 by default. Se the
instrument instructions for instrument settings.
1
2
3
4
5
10.5 Playback
6
7
Click the "Playback" button on the screen to view back the
8
image stored in the environment monitoring memory card
last time.
Video playback image
Playback
1
Southeast
2
Driving information /aided driving
3
Smart driving
4
Smart ADAS
5
ADAS sensitivity
6
Gear shift prompt
7
Tyre pressure monitoring
8
Press OK button to set
94
Vehicle use
1
2
When the ADAS system has an external physical fault, the
instrument displays a yellow warning icon, the text prompts
"front camera fault" for 5s and the loudspeaker gives an
3
alarm for 2s.
4
5
6
1
Southeast
2
Aided driving /ADAS sensitivity
3
Sensitivity 1
4
Sensitivity 2
Front camera faulty
When the speed is ≥ 60km/h, the LDW system is activated.
The lane line is displayed according to the actual detection
5
Sensitivity 3
6
Press OK button to save
situation, and the main interface is as follows:
When the engine starts, and the ADAS warning system is
enabled, the instrument prompts "the radar and camera are
in place and the ADAS warning system is enabled" for 5s.
When the ADAS warning system is disabled, the LED
prompts "the ADAS warning system is disabled" for 5s.
The radar and camera are in place
and the ADAS warning system is
enabled
Double lane line detected
The ADAS warning system
is disabled
No lane line detected
95
Vehicle use
Only right lane line detected
When the speed is ≥40 km/h, the light is in AUTO position.
When night intelligent high beam light control system is
enabled, the blue indicator light on the instrument is on.
Only left lane line detected
When the LDW system is activated, the vehicle deviates from
When a speed limit sign is recognized, the LED displays the
the lane line, the main interface of the instrument is
limit value. The instrument prompts "The speed limit on this
displayed as below. When the vehicle deviates from the lane,
section is XX km/h. Please note the speed" for 5s. When the
it displays red flashing (0.5s on, 0.5s off ), and the
speed on the instrument exceeds the limit, the instrument
loudspeaker gives an alarm.
prompts "You have exceeded the speed limit. Please control
your speed" for 5s, and the loudspeaker gives an alarm for
1s.
Southeast
Right deviation
Please note the speed
The speed limit on this section is 120 km/h
When the turn light is on or the emergency warning switch
works, the LDW system is inhibited. There is no alarm when
lane departure happens, and only the actual lane line
detected is displayed:
96
Vehicle use
Southeast
Southeast
Front camera /radar fault
Please control the speed
You have exceeded the speed limit
When the speed limit sign is lifted, the limit value is not
When the system detects a collision risk, and the collision
displayed, and the text prompts "Speed limit has been lifted
conditions are met, PCW/FCW warns: Class I: yellow
warning light blinks (0.5s on, 0.5s off), and the loudspeaker
for this section".
warns. Class II: red warning light blinks (0.5s on, 0.5s off)
and the loudspeaker warns (the sound is more urgent).
Southeast
When the brake or clutch pedal is pressed down, the system
will suppress and the warning will be terminated.
Southeast
Speed limit has been
lifted for this section
When the speed is ≥ 15km/h, PCW /FCW works, and the
collision indicator light is on (green).
In case of PCW/FCW system fault, the collision indicator
light is on (yellow)., and the text prompts "Front camera
/radar fault" for 5s; the loudspeaker warns for 2s.
Vehicle use
Note: The system will be affected under the following
conditions:
Curve with a radius of curvature less than 250 m;
Very harsh weather conditions and poor visibility, such as
fog, haze, rain and snow;
Severe reflection or sharp light changes within the field of
97
12. Use of tyre pressure monitoring
system (optional)
TPMS refers to an integrated tyre pressure monitoring
system. The system will continuously monitor the pressure
of all tyres through the pressure sensor. In case of any error,
the driver will obtain the warning information on the
view of the camera due to, such as pavement reflection,
instrument. The significance of tyre pressure monitoring is
reflection inside the front windshield, and going in and
as below: by selection of the right tyre pressure and proper
out of the tunnel;
maintenance, the tyre can maintain the correct inflation
pressure, and the service life of tyres can be effectively
Vehicles run on a continuous uphill or downhill section or
extended. Besides, fuel consumption can be lowered so as
a sharp uphill or downhill section;
to reduce the use cost of each vehicle every year. According
Vehicles enter highway entrances and exits, service areas,
highway intersections, toll stations and other sections;
The light within the field of view of the camera is
insufficient or the camera is blocked by snow, ice, dirt,
standing water, fog or other objects;
to statistics, recommended 15% tyre pressure deviation will
reduce at least 10% of tyre service life, and the tyre pressure
reduction of 17% will cause a 2% increase in fuel
consumption.
The TPMS system includes electronic control unit, vehicle
wheel module and display module.
The vehicle runs in parallel with the wall and guardrail,
etc.
There are metal objects on the road and structures on the
above in the detection area; Vehicle refitting causes the
vehicle to tilt;
Tyre exception (such as improper inflation of tyre and
wrong mounting dimensions of tyres);
12.1 Electronic control unit
Each wheel continuously transmits the actual tyre pressure
to the electronic control unit (ECU). Then, the ECU calculates,
assess signals of all tyres and transmits them to the
instrument and Tianxingjian for display. The vehicle module
measures the normal pressure value of each wheel every 15
minutes and transmits it to the ECU. If the pressure change
An obstacle suddenly appears in front of the vehicle, and
received by ECU is close to the critical point, the vehicle
is close to the vehicle;
module will send tyre pressure of each wheel in a shorter
The appearance of the vehicle in front is special, such as
forklift and crane;
The vehicle does not turn on its headlights or the vehicle
in front does not turn on its tail lights at night or in a
tunnel;
The color of the vehicle in front is close to the
background color;
period of time.
When the measured actual value is much greater than the
allowed value, the system will send low pressure alarm
information. The ECU will distinguish from the floating tyre
pressure whether there is real leakage or whether the vehicle
is driving on a bad or uneven road. In the even of any
irregular circumstance, the alarm information can not only
be reported on the instrument and Tianxingjian, but the
position of the wheel in problem will also be indicated. The
There is a vehicle-like object or shadow in front of the
ECU can accept and process the data from less than 16
vehicle;
wheel modules and other electronic control modules. The
A vehicle with high bumper and low chassis appears in
front.
double tyres will be equipped with a sensor respectively. The
sensor pressure is between 2 and 14 bar, and the
corresponding nominal tyre pressure is 3-10.5 bar.
98
Vehicle use
12.2 Vehicle wheel module
13. Other vehicle operations
13.1 Steering wheel adjustment
The steering wheel can be adjusted only when the vehicle is
parked. X5000 steering column adjustment locking
mechanism is a pedal pneumatic locking mechanism,
therefore, the vehicle must be adjusted under sufficient
pressure in the air reservoir. For adjustment, the operator
Under normal operation of the sensor, the service life of the
battery is not less than 6.5 years. If the battery is exhausted,
the module will no longer transmit any information and a
new battery should be used immediately.
The special identification code of each wheel allows being
uniquely assigned to the specified vehicle wheel module.
The vehicle wheel module will report the identification code
used by the ECU. This can ensure that tyre pressure signals
should press down the pneumatic adjustment switch button
at the bottom left of the steering column with foot to
adjust the steering column in longitudinal and vertical
directions. After the steering column is adjusted, the
steering column is automatically locked after the foot is
released.
The adjusting range of steering column is as shown in
the following table:
other than other vehicles are sent to the system. Once the
module is manufactured, the identification code will be
determined and can no longer be changed. During trial run
of the vehicle, the identification code will be imprinted on
the tyre. During the change of the tyre, wheels and wheel
modules must be maintained independently. Once tyres are
confused, a tyre under pressure will be mistakenly installed
on other axles, and the IVTM will not send an alarm signal.
The identification code assigned to each wheel is
determined through the diagnosis software during vehicle
trial.
Model
Left
Adjustment travel
±25
Range of adjustment angle
±5°
Model
Right
Adjustment travel
±25
Range of adjustment angle
±5°
Note: Frontward adjusting angle is minus and
backward plus as stipulated. Downward adjusting
12.3 Display module
Tyre pressure and temperature information are displayed
travel is minus and upward plus as specified. The
initial adjustment position is the middle position at
design status.
through the instrument or multimedia display screen. Once
the pressure or temperature of a tyre is abnormal, the
display interface will remind the driver of paying attention to
the tyre state with red highlight. The figure shows tyre
pressure and temperature information.
Step-on pneumatic button
Vehicle use
13.2 Use of sleeping berth
99
a
① If the user wants to use the upper sleeping berth, please
press the ladder button. When the ladder automatically falls
down and holds still, the user may climb the ladder to the
upper sleeping berth, and push the ladder manually to fold
it (as shown below).
b
c
a Height adjustment lock catch for protection net (each on
both sides)
b Climb button
c Sleeping berth up and down adjusting button (each on
both sides)
Up and down button
Climb button
Precautions for use:
To ensure the safety, the upper sleeping berth is only
available under parking status. Please do not use the
upper sleeping berth during the running process.
Before the use of a new vehicle, please remove the
external plastic film of the sleeping berth, otherwise it
would cause the sleeping berth mattress to slip.
Ladder
The upper and lower sleeping berths can be wiped via
wet towel to keep the cab clean.
The exterior fabrics of the lower sleeping berth can be
unzipped and put into the washing machine for cleaning.
Forbid to smoke on the sleeping berth to avoid fire.
② Lift and put down the upper sleeping berth as shown in
the figure, and press and hold the lift and fall button by
hands to lift and put down the sleeping berth freely.
The cushion filling of sleeping berth is made of
polyurethane material, which can be washed with water
but might have certain deformation and wrinkle.
Sunroof opening and closing
Opening: anticlockwise rotate the handle, the sunroof is
automatically lifted and opened.
Closing: clockwise rotate the handle, the sunroof is
automatically closed.
Push and pull the handle along the cab direction to open
and close the insect-proof screen.
③ For height adjustment of protective net of upper sleeping
berth, force the adjustable lock catch of the protective net
apart by hands to adjust the height freely.
100
Vehicle use
13.3 Front cover opening and closing
X5000 series vehicle model is designed with front cover
lock so that the front cover can be lifted only after the
front cover is unlocked. The opening mode is as below:
Pull up the front cover lock handle at the bottom left corner
13.4 Cab tilt
13.4.1 Preparation before tilting
During vehicle maintenance or overhaul, it may be
necessary to tilt the cab. Before tilting, the following
preparations should be made:
of instrument platform of the cab to open the front cover
lock.
Oil pump plug
In the front of the cab, hold the lower position at the middle
of the front cover and turn the cover through the dead
center position of the front cover, then the cover is
automatically opened under the effect of air spring after the
hand is released.
Manual turnover
device
Change lever
Front cover lock handle
Tilt button
Before cab tilt, park the vehicle on the flat ground without
affecting the traffic demand of other vehicles (if required,
Front cover lock
please set warning sign at the periphery of the tilting site).
Initiate the parking braking function of the vehicle, and turn
the gear shift lever to the neutral gear, turn off the engine
and all working equipment, and close the door.
In front of the cab, flip down the cover to lock and close
Before tilting, fix or take out the substances not fixed in the
the front cover.
cab.
Before tilting, open the front cover and ensure that no
person stands in the front and rear tilting area of the cab.
Vehicle use
13.4.2 Operational process
101
13.4.3 Precautions for tilt
Make the key switch to ON position and switch on the rocker
switch for cab tilt;
Before tilting, take out or fix the substances not fixed in the
cab, and open the front cover.
When tilting, any person shall not stand in front of the cab.
After fully tilting the cab, the personnel can enter the part
under the cab for inspection and maintenance.
After the cab falls back, make sure that the tilting changeover switch is located at the lowering position.
To ensure normal operation of oil pump, open the oil pump
plug to check the liquid level of the oil pump every three
months. If insufficient, supplement the hydraulic oil timely.
Turn the change level of the tilt oil pump to the rising
Before filling, check whether the hydraulic oil is clean, and
position;
fill it only after the requirements are met.
13.4.4 Hydraulic oil filling
When the oil in the oil pump is insufficient in routine
inspection, fill hydraulic oil in the tilt system timely by the
method as below:
Open the oil pump plug, and slowly fill the specified
Change lever position when the cab rises
Continue to press the tilt button, and then the cab starts to
hydraulic oil until the liquid level reaches the bottom edge
of the fill hole.
Slowly lifted the cab, and meanwhile continue to fill oil.
rise until the cab is fully tilted. The cab must be lifted over
the dead center each time (the cab is tiled with the center of
gravity over the tilting point, then freely falls and keeps a
stationary state);
Put down the cab, and meanwhile make excessive oil spill.
Next, tilt the cab via an oil pump, and after the cab falls back
to the original position, check the oil level and replenish oil.
Turn the change level of the tilt oil pump to the falling
position, continue to press the tilt button to make the cab
Finally tighten down the oil pump plug.
fall until the axle sleeve of cab lock seat is locked. The tilt
indicator light on the cab instrument
is off, and then
the tilt lift switch in the cab is turned off.
13.4.5 Tilt system function checkout
Turn over the cab frontwards to the top dead center, and
check the falling condition of the cab after crossing the top
dead center. If the system works normally, the cab should
fall down slowly under damping condition without impact.
When the cab is tilted by about 30°, if the system works
normally, the cab should be kept at the position for 20 min
without falling down.
Change lever position when the cab falls
If the electric cab tilt device cannot be used, a crowbar or
manual tilt device can be used for tilting.
102
Vehicle use
13.5 Side tool kit opening and closing
Operation method:
The side tool kit shroud is locked with through the lock.
When opening the side tool kit, the manual switch on the
left floor of the main seat can be pulled. After the switch is
pulled, the shroud is disconnected from the lock, and then
Precautions:
In the opening process, the tool kit shroud should be
kept about 400mm away from the shroud to prevent the
shroud from being hit;
In the closing process, the tool kit shroud should be
pressed evenly. Don't press it excessively;
the shroud is upward lifted for some distance slightly from
When using the tool kit, please don't place heavy metal
the lower edge of the shroud and supported by the air
objects, and the total weight of objects shall not exceed
spring.
35 kg;
When the tool kit shroud is closed, press the shroud
Drive before confirming the tool kit shroud is fully closed
downward from the middle of the lower edge of the shroud
to avoid safety accidents.
by hand until the shroud is locked into the lock body, and
makes the impact sound.
13.6 Trailer connection and removal
13.6.1 Before connecting the trailer, it is
required to
① loosen the fastening device on the saddle
Manual switch position
② check whether the semi-trailer connection plate and
center pin are at least 50 mm lower than the tip of the
saddle. If necessary, adjust it to proper height
13.6.2 Connect the trailer as below
①The tractor slowly goes astern to the semi-trailer (saddle
connection will lock automatically)
②Fasten the handle or check the plug-in lock
③Connect the compressed air pipeline and cable
④Lift the support column of the semi-trailer to the driving
position
Note: After the tractor is connected with the semi-trailer,
be sure to check whether the lock handle of the hook or
the plug-in lock is correctly locked.
Opening state of side tool kit
Vehicle use
13.6.3 Pipeline and circuit connection
103
13.6.4 Before removing the trailer, it
is required to
The jumper hose joint of connection device of semi-trailer
towing vehicle is installed at the back of the cab. The hose is
used to transmit compressed air to the trailer. Looking
forward from the rear of the vehicle, red is the hose joint of
①prevent the semi-trailer from slipping
②check whether the pavement is solid
the air reservoir to supply air to the trailer, and yellow is the
③check whether the support column of the semi-trailer can
brake line joint of the trailer.
be loaded, and then stretch the support column until the
a.First connect the brake line joint of the trailer (yellow).
load is transferred from the tractor suspension to the
support column. The support column should not be
b.Then connect the air reservoir line (red).
stretched too much, or else the semi-trailer is pushed away
from the saddle. Be sure that the saddle may be wedged.
Air reservoir
line joint
Note:
Please be sure to follow the following sequence to
disconnect the connector. Otherwise, the semi-trailer
brake will be loosened, thus leading to the slipping of the
semi-trailer.
Brake line joint
of the trailer
First disconnect the air reservoir line (red), and then the
semi-trailer is braked.
Then disconnect the brake line joint (yellow).
1
3
4
2
5
The jumper cable is used to supply power to the trailer. The
jumper cable is divided into conventional power supply and
ABS power supply of trailers. When no trailer is connected,
the power connection can be fixed on the free socket.
①ABS power cable and free socket of trailers
②Conventional power cable and free socket of trailers
③Jumper air reservoir hose (red)
④Jumper trailer brake line (yellow)
⑤Rear work light
104
Vehicle use
13.6.5 Saddle lifting lock
Note:
There is a strict restriction on the distance between the
① Rotate the handle forward (→) ② Pull it out and fix it to
the groove of polar plate edge
semi-trailer and the tractor!
The mobility of a tractor trailer is limited!
② After the trailer is connected, check and ensure that the
When the driver leaves for a long time after parking the
lock ① has been in the locking position (falling position).
vehicle, he should check whether the operation handle is
Then, it is locked well. If the lock fails to be lowered to its
locked in place before driving again!
locking position, the saddle is not correctly connected.
Beware of accidents! Repeat this connection process.
When driving on puddles, slopes and muddy roads,
serious damage will be caused to the tractor and semitrailer.
The top surface of the saddle and lock hook should be
1
cleaned every 8,000 km or 4 weeks, and new lubricating
oil should be used. High pressure lubricating oil
containing MoS2 or graphite is recommended.
2
Vehicle use
13.7 Use of parallel fuel supply
system
105
The default state of the switch is fuel tank I, and the main
fuel tank of the parallel fuel tanks works at this time, and the
fuel value displayed by the fuel gauge is the current fuel
quantity of the main fuel tank; When this switch is closed,
Structure type
the fuel change-over valve works to switch the oil circuit
The parallel fuel supply system consists of a main fuel tank,
from the main fuel tank to the auxiliary fuel tank. Do not
an auxiliary fuel tank, a main fuel tank oil quantity sensor, an
deplete the fuel in the fuel tank, otherwise the air in the
auxiliary fuel tank oil quantity sensor, a fuel line, a fuel
supply line needs to be emptied.
supply reversing valve and a coarse fuel filter.
If the requirements of the grade of diesel oil (such as 0#
System function
diesel oil) in the main fuel tank are met in a high
The main and auxiliary fuel tanks in parallel can supply oil to
temperature environment, the main and auxiliary fuel tanks
the engine independently, and the main and auxiliary fuel
can contain the same grade of diesel oil, which can increase
tanks are independent of each other.
the capacity of the fuel tank. Under normal circumstances,
System principle
the main fuel tank is used). When the fuel gauge shows
the changeover switch should be set to I (that is, the fuel in
The main and auxiliary fuel tanks are independent of each
zero, it indicates that the fuel in the main fuel tank is
other, and can hold the same grade or different grades of
basically used up at this time. Then we can press the
diesel oil. The main and auxiliary fuel tanks are switched by
changeover switch to II to enable the standby fuel in the
the solenoid valve.
auxiliary fuel tank.
Operation mode
The parallel fuel tank changeover switch is located on the
instrument panel of the cab, as shown in the figure (Note:
The appearance of each vehicle type is different. The
changeover switch is in the state I of using the fuel of the
main fuel tank and in the state II of using the fuel of the
auxiliary fuel tank.);
If the temperature is low in winter or cold zone, the main
fuel tank can hold slightly higher grade of diesel oil, and the
auxiliary fuel tank can hold low-grade diesel oil matching
the use environment for low-temperature start-up. Before
starting the engine, set the changeover switch to II, start the
engine with diesel oil from the auxiliary fuel tank, and set
the changeover switch to I when the diesel oil in the main
fuel tank is heated by the heating system until the diesel oil
fluidity is acceptable, and use the diesel oil from the main
fuel tank for normal operation.
Note: If the engine cannot be started normally after the
main and auxiliary fuel tanks are switched, the air inside
the pipeline must be exhausted before the engine can be
started normally. During use, do not use up the fuel in the
fuel tank; otherwise, the air in the supply pipeline needs
to be emptied.
106
Vehicle use
13.8 Removal of overhaul cover plate
① Opening of relay overhaul cover plate
The overhaul cover plate of relay box is located above the
instrument platform of front passenger seat. When it is
1
opened, the overhaul cover plate is ejected upwards with
1
1
the thumb at the arrow indication place from two sides, and
1
then the whole overhaul cover plate is taken out.
② Opening of ECU overhaul cover plate
ECU overhaul cover plate is located under the instrument
platform of front passenger seat, and pulled out in the
horizontal direction at the hand clasping place indicated by
2
2
2
2
Relay and fuse box
Electronic control unit
arrow when it is opened, and then taken out entirely.
Use and Maintenance of Special Parts for Natural Gas Vehicles
IV. Use and Maintenance of Special
Parts for Natural Gas Vehicles
1 Overview of Natural Gas Engine
System
1.1 Difference between LNG and CNG
107
1.2 Overview of gas engine
① Engine power
The power ranges of gas engines commonly installed in
X5000 are as follows:
Engine model
Power range
WP8NG
294-338 kW(400-460Ps)
WP13NG
294-338 kW(400-460Ps)
X12N
250-322 kW(340-440Ps)
X15N
316-404 kW(430-550Ps)
They are both natural gases with the same composition, but
exist in different states.
CNG is compressed natural gas, which is pressurized (over
3,600 pounds per square inch) and stored in a container as a
gas.
② Main structural features
LNG is a liquefied natural gas. LNG is created by
cooling gaseous natural gases to -162 °C at normal
One cylinder and one cover, reliable operation and easy to
pressure, and condensed into a liquid state.
disassembly;
After liquefying natural gas, more storage space,
Frame-type main bearing structure, high rigidity of the
transportation space, and cost can be saved. And LNG has
whole machine making it more reliable and helping extend
the characteristics such as high energy density and superior
the service life;
performance.
Inline engines of the whole series, a high degree of
The main differences are as follows:
State of existence. When natural gases are cooled to about 162 °C at normal pressure, their state of existence changes
from gas to liquid. That's why it is called Liquefied Natural
Gas. (LNG) But Compressed Natural Gas (CNG) is created by
pressurization and stored in a container as a gas.
Safety hazards. The main way of storing and transporting
natural gas is through CNG. The high pressure of CNG may
lead to many potential safety hazards, such as the increased
risk of fire and other safety concerns
Compared to CNG, LNG has a higher ignition point. Its
autoignition temperature is about 590 °C. LNG has a
narrower explosion range of 5% to 15%. LNG is safer as it is
lighter than air and easy to diffuse.
Volumetric energy density. The volumetric energy density of
CNG is about 26% of the gasoline, while that of LNG is
about 72% of the gasoline. That means the volumetric
density of LNG is over 2 times greater than CNG.
Environmental protection. Natural gas must undergo strict
pre-purification before liquefaction, so the impurity content
of LNG is much lower than that of CNG, creating conditions
for exhaust emissions to meet more stringent standards
when used as fuel in vehicles.
universality, easy to match the vehicles.
108
Use and Maintenance of Special Parts for Natural Gas Vehicles
1.3 General technical characteristics of
the gas engine
In addition to enjoying the advantages of the original diesel
machine, the engine has the following features:
Adopt electronic throttle technology and improve the
driving performance of the engine;
The electronically controlled injection technology for the
fuel supply system is adopted to ensure that the engine is
powerful, economical with sound emission characteristics
under any working condition;
A water-cooled turbine supercharger suitable for the gas
engine is selected, in which the circulating water will cool
down the lubricating and cooling oil of the supercharger,
The two pairs of friction pairs of the inlet and exhaust valves
and valve seats are selected with materials suitable for the
working characteristics of the gas engine to ensure their
wear resistance and good self-lubrication at high
temperatures;
The maximum speed control function ensures driving safety;
The high-efficiency oxidation catalytic converter is adopted
to greatly reduce the emission of harmful gases and meet
the EURO V emission requirements;
The ECU is highly compatible and can offer SAE-compliant
load signals to the automatic transmission, with an air
conditioning idle control function.
1.4 Safety precautions
effectively preventing the oil from carbonizing at the
pressure bearing and making the supercharger more
Please refer to the engine instruction manual provided with
reliable;
the engine for safety precautions related to the engine, and
With anti-surge technology, negative pressure is formed in
when parking and repairing the vehicle according to the
the vacuum tank after the engine is started. When the pedal
characteristics of natural gas vehicles:
please pay attention to the following safety precautions
is suddenly released as its engine is under a heavy load and
the fuel supply is cut off, the ECU will enable the tee
The regular maintenance and repair of the fuel system
solenoid valve to work according to the deceleration trigger
should be carried out by professional repair shops (facilities)
signal. As the negative pressure is formed in the vacuum
that have obtained certification from the relevant
tank, the bleeder valve is opened, which can release part of
authorized departments.
the air in front of the throttle, eliminating the possibility of
the supercharger surge caused by throttle closing and
Only technicians with professional training and certification
making the engine more reliable and economical;
in fuel systems maintenance and repair are authorized to
perform such tasks. Unauthorized personnel are not allowed
The electronically controlled high-energy ignition system is
to conduct repairs;
adopted to provide the best ignition time according to the
engine speed, intake pressure, intake temperature, and
Smoking is strictly prohibited at the maintenance site, and
other signals. The ECU can also adjust the ignition advance
fire prevention and firefighting measures shall be equipped
angle o ensure the comprehensive performance of the
at the site. If the gas cylinders are pressurized, vehicles must
whole machine during acceleration and deceleration
maintain a minimum distance of 10 meters from any open
conditions;
flames in the vicinity.
A gas mixing system that meets the characteristics of gas
In the process of vehicle maintenance and troubleshooting,
fuel is designed, which can effectively organize lean and
if any operation involving the disassembly, assembly, and
stable combustion and improve thermal efficiency;
adjustment of the pipe joint, valve, instrument, and
pressure-reducing devices, the maintenance personnel shall
The acceleration and enrichment function enables the
first disconnect the battery power supply circuit, close the
engine to obtain a relatively large fuel supply in the
main gas valve and cylinder valve, and wait for
acceleration condition, ensuring strong power during the
depressurization before disassembling the faulty parts;
acceleration transient and good economical performance in
the steady-state condition;
Use and Maintenance of Special Parts for Natural Gas Vehicles
It is prohibited to strike, twist or move the entire vehicle gas
pipelines at will;
After maintenance, a gas detector or soapy water shall be
used for leakage inspection;
After dismantling and inspecting the pipes and various
connectors, the pipes must undergo a blowdown treatment
to prevent sand and dust from entering the gas pipelines;
When cleaning the vehicle, special attention should be paid
to avoiding the engine's electronic control system
components, such as spark plugs, ignition coils, fuel
injectors, etc. It is strictly prohibited to directly clean the
engine with water, and a clean damp cloth can be used for
cleaning;
When CNG vehicles need to be stored for a long time, the
pressure inside onboard gas cylinders should not exceed 2
MPa, but not lower than 0.2 MPa. Please close the cylinder
valve, turn off the whole vehicle's electrical circuit, and keep
the vehicle away from fire sources and flammable
substances. The enclosed space where the vehicle is stored
shall have an exhaust device installed at the top and regular
ventilation should be conducted;
When the CNG vehicle is transported by train, ship, or
flatbed truck, the air storage pressure inside the onboard
gas cylinder shall not exceed 5 MPa. During transportation,
the bottle valve shall be closed, the circuit of the whole
vehicle shall be turned off, and the vehicle shall be placed
firmly.
109
1.5 Control system installation and
precautions
① Gas pipeline
Before all pipes are connected, the dust and debris in the
pipe shall be blown off with compressed air;
The connecting pipes shall be free from any folds or
rubbing.
② Wiring harness
In order to avoid high temperatures, the wiring harness is
not allowed to be arranged near the exhaust pipe side;
The connection of each connector and wire shall be able to
withstand a tensile force of at least 20 N without looseness
or even falling off;
The temperature rating of the wiring harness shall not be
lower than 125 °C, and it shall have excellent oxidation
resistance capabilities;
The layout of the wiring harness shall be reasonable, which
is easy for future maintenance;
The grounding wire and the wire connected to the negative
electrode of the battery shall be connected separately
according to the electrical schematic diagram.
110
Use and Maintenance of Special Parts for Natural Gas Vehicles
1.6 Precautions for the use of gas
engines
Before using the new vehicle, a check shall be conducted on
the gas pipeline, gas supply device, and electrical parts to
identify any potential issues such as gas leaks, and
unreliable wire connections. They shall be resolved in time.
Pay special attention to loose connections in the electrical
circuit, especially at the plug-in terminals of solenoid valves,
and ensure that the ignition high-voltage wires are properly
inserted.
Check whether the battery voltage is sufficient because the
engine ignition and the electronic control system need
sufficient voltage. So special attention should be paid to the
voltage of the battery;
1.7 Precautions for the daily use of
gas engine
① To ensure driving safety, the driver must check the
vehicle every day before each trip. The following items shall
be checked before driving:
Before driving every day, the driver must check whether the
fixation between the gas cylinder and the bracket, the air
supply device and the girder is firm, whether the gas
equipment is in good condition, whether the joints of all air
pipes leak, and whether the connector of each sensor is
loose before starting the engine;
The driver must check the engine oil level, check if the oil
If the engine fails to start after 3 consecutive times, recheck
the gas and circuit carefully;
level falls between the upper and lower markings of the
dipstick (preferably around 3/4 of the marking), and check
the oil level after the engine has turned off for ten minutes;
New vehicles shall undergo the necessary running-in before
being put into use;
The driver must check the coolant level by looking at the
water level markings in the middle of the outer side of the
Pay attention to monitoring the level of gas and filling the
gas in time. The relevant provisions of the gas station shall
be followed and the filling shall be operated by the station
personnel during gas filling; the sealing of the gas system
shall be checked during gas filling;
expansion tank, and check the coolant level. (If there are no
water level markings on the expansion tank, the driver
should open the water tank cover. Do not open the water
tank and drain valve when the water temperature is high to
avoid scalding.) If the level is too low, add coolant until it
reaches 1/4-1/2 of the expansion tank volume; start the
Gas vehicle drivers should strengthen their learning efforts
and strive to become familiar with the principles and
relevant knowledge of gas engines;
For the fuel used in the gas engine, it is first required to use
the automobile CNG that meets the national standards;
Since the combustion byproducts of the CNG singlefuel engine are different from those of the diesel engine, it
is required that the CNG single-fuel engine uses
specialized engine oil designed for the CNG engine;
engine and run it at idle speed for 3-5 minutes to exhaust
the air in the cooling system, and if the coolant level drops
after running the engine, please add more coolant to
maintain the proper level;
The driver must check the tension of the engine belt, fan
belt, and compressor belt. If they are loose, please tension
them. If they are damaged, please identify the cause and
replace them with new ones;
The driver must check the level of fuel, and add more fuel if
Caution: When used in cold areas or in winter, all natural
gas products should use Shaanxi Heavy Truck Automobile
Import & Export Automobile Co., Ltd.'s natural gas heavy
truck winter (-50 °C) antifreeze solution.
necessary;
The driver must check the battery voltage;
② To ensure driving safety, please insert the ignition key
and turn it to the "ON" position when starting the vehicle,
a. It is allowed to replace low-quality lubricating oil with
high-quality lubricating oil;
allowing the instrument panel to perform a self-check, then
b. After the running-in period is over, replace the engine oil;
ensuring that the gas rail is filled with gas.
start the engine after confirming everything is fine and
c. Regardless of whether the vehicle is in use or not, the
engine lubricating oil should be replaced once a year.
Use and Maintenance of Special Parts for Natural Gas Vehicles
111
Under normal temperature conditions, it is unnecessary to
depress the accelerator pedal, but when the engine is
unable to start due to the cold weather or the engine's
cold-start state, the accelerator pedal should be slightly
depressed;
KEY: This position is where the starting key is inserted and
pulled out
OFF: The position is where the power supply is closed
ACC: In this position, the power supply of the instrument is
connected
In the case of the single-fuel gas engine, it is normal to
observe white smoke or water droplets coming out of the
exhaust pipe shortly after starting the engine under lower
ambient temperatures. The phenomenon occurs because
CNG has a higher content of hydrogen (H), resulting in a
higher amount of H2O in combustion byproducts. At low
temperatures, the water cannot vaporize and instead
forms white smoke or water droplets. As the exhaust
temperature increases, the white smoke and water
droplets will disappear.
③ Correct driving methods can extend the service life of
the vehicle, improve economic efficiency and have a
significant impact on safe driving. The following principles
should be followed when running the engine:
Due to the nature of its fuel, a gas engine may exhibit
slightly lower acceleration performance compared to a
diesel engine, which is considered a normal phenomenon;
ON: the normal driving position
START: Engine starting position. After the engine is started,
the key will automatically return to the "ON" position
Special attention:
When the engine is running, it is not allowed to switch the
key to the "START" position, otherwise, it will cause
damage to the starter. The engine can only be restarted
after it has completely stopped;
When the first start fails, please wait for 30 seconds
before the second start; and then check whether the
engine oil pressure and coolant temperature are normal.
When starting the engine, the oil pressure should meet
the requirements stated in the engine's user manual once
the coolant temperature reaches its normal operating
level. The oil pressure should not be lower than the idle
pressure: idle speed ≥0.1 Mpa, rated speed: 0.3~0.6 Mpa
During the acceleration of the vehicle, it is recommended
to step on the accelerator slowly and avoid stepping on
the accelerator suddenly! That is how gas engines can
have more air to generate more power.
④ When shutting down the engine, the following
precautions should be taken :
As the engine temperature is very high after the vehicle
has been in operation, it is advisable not to shut down the
engine immediately. Instead, let the engine run at idle
speed for 3-5 minutes to cool down various parts. Once
everything has cooled down to normal levels, shut down
the engine by turning the ignition key to the "OFF"
position;
Finally, cut off the main power supply switch.
Special attention: If the engine runs for a long time under
heavy loads, the engine should run at low speed for a
period of time before the shutdown. After cooling the water
After starting the engine, if the low oil pressure warning
lamp lights up, or the engine oil pressure remains below
the lower limit, it is necessary to stop the vehicle in time
for inspection, and the vehicle can only resume operation
after the fault is eliminated;
After starting the engine, it is prohibited to slam the
accelerator pedal to start rapidly. Stop the vehicle
immediately for inspection when a malfunction is found.
The idle speed of the engine shall not exceed 10 minutes;
temperature of the engine to normal levels, the engine can
be shut down. Our engine is equipped with an exhaust gas
supercharger. As the supercharger rotor is a high-speed
rotating part, the sudden shutdown will cause ablation
damage to the rotor bearing due to a short-term lack of oil
and poor cooling.
112
Use and Maintenance of Special Parts for Natural Gas Vehicles
1.8 Instrument of gas engine
④ Water thermometer: The water thermometer indicates
the temperature of the engine coolant. When the ignition
switch is set to the "ON" position, the temperature of the
engine coolant is displayed. The temperature of cooling
5
water must be between 80 °C and 100 °C when the engine
is running.
Caution: If the water temperature is higher than 103°C (the
water temperature of China VI gas vehicles is greater than
3
1
4
2
or equal to 110°C), the warning light will illuminate and the
buzzer will sound.
⑤ Voltmeter: The voltmeter indicates the charging and
1
Tachometer
2
Odometer
3
Oil pressure gauge
4
Water temperature gauge
5
Voltmeter
① Tachometer: the engine tachometer is used to monitor
the operation of the engine. Unit: r/min. When the engine is
under medium and small loads and the rotating speed of
the engine is higher than the specified value, it will activate
self-protection. When the engine is under heavy loads and
the rotating speed is higher than 2400 r/min, it will activate
self-protection as well. At this point, the engine ECU will
send commands to reduce the throttle opening and reduce
the output power of the engine. This is reflected in the
vehicle's performance as the vehicle instability during
operation.
② Odometer: It is used to measure the speed and
accumulate the mileage of the vehicle.
③ Oil pressure gauge: It is used to indicate the oil pressure
value. If the oil pressure is below the normal range, the
engine oil pressure warning light will be on. In such cases,
the vehicle cannot be started until the warning light goes
off.
Notes: During normal operation, if the oil pressure indicator
is on, it means that the oil pressure of the lubrication
system is insufficient. It is important to stop the vehicle
immediately for inspection and drive it to the maintenance
shop for inspection and troubleshooting if necessary.
discharging state of the battery. When the engine stops
running, the pointer reading on the voltmeter displays the
battery voltage. When the engine is running, the pointer
reading displays the voltage of the generator output.
Use and Maintenance of Special Parts for Natural Gas Vehicles
1.9 Maintenance of gas engine
1.9.1 Routine maintenance instructions
Project
Maintenance
interval
Maintenance Items
Check the completeness and tightness of mounting brackets for gas cylinders,
solenoid valves, and pressure regulators, and tighten any loose fasteners.
Check the gas volume, switch on the power supply of the whole vehicle,
turn on the ignition switch (do not start the engine), and check the gas
volume shown in the gas volume indicator.
Daily
maintenance
Daily
Check whether there is leakage in the pipes and joint components of the gas
supply system (it can be judged by detecting any unusual gas odor in the
surrounding environment); For articulated vehicles, pay special attention to
checking the high-pressure hose at the articulated points for signs of abrasion
or any visible cracks or aging. If there is leakage in the system, the driver should
not disassemble it and should promptly notify the professional maintenance
manufacturer to send technicians for repair.
Check the ignition system and generator for electrical leakage and flashover. If any issues
are found, they should be repaired promptly. Check the wiring harness and connections
of various sensors to ensure they are securely fastened and free from looseness.
Inspection and fastening of CNG gas cylinder fixing device: check whether the CNG
gas cylinder fixing device is deformed or damaged; tighten the fixing device.
Inspection of CNG gas cylinder valve:
1. Check the multi-function valve and inflation valve for any leakage with an
air leakage detector
or detection fluid, and if any issues are found, Handle them in time.
2. Check the manual exhaust valve to ensure it operates smoothly and the
pipe fittings are free from any leaks.
3. Check the inflation valve , pipe fitting , and pipe clamps to ensure they are
securely tightened and free from any leaks.
Inspection of the pipes and connectors of the system:
1. The pipe body shall be free of damage and crack ; check with a detector or detection
fluid for leakage.
2. The pipe fitting and the valve shall be firmly connected without looseness and leakage.
Level I
maintenance
5000-6000km
Inspection and fastening of pressure reducer:
1. Check the pressure reducer body and the connector for leakage with a tester or
detection fluid.
2. Check the bracket of the device for any looseness and tighten them as necessary.
Check the circulating water pipes and connectors of the pressure reducer:
1. Check whether the warm water pipe is blocked by dirt, and if any are found,
they should be cleared.
2. Check whether the water pipes are aging , cracked , damaged , or leaking ,
and replace them if necessary.
3. Check the fastening condition of the pipe fitting and tighten it if necessary.
Solenoid valve operation and safety check:
1. Check whether each solenoid valve is operating properly, smoothly,
and reliably, and whether there is leakage.
2. Check whether the power plugs are secure and have good contact.
3. Check and tighten the solenoid valve bracket.
113
114
Use and Maintenance of Special Parts for Natural Gas Vehicles
1.9.1 Routine maintenance instructions
Project
Level I
maintenance
Maintenance
interval
5000-6000km
Maintenance Items
Power supply system: reliable connection of low-voltage circuit, no damage
to insulation, good contact, no short circuit and open circuit; complete and
reliable fuse that meets the requirements in the fuse box, no additional
unauthorized electrical connections
Clean, check the spark plug, and check the high-voltage line.
All Level I maintenance items
Cleaning of CNG filter:
1. Check the filter, and clean the filter and filter element.
2. Check for leakage in the reassembled filter and connector.
Level II
maintenance
Every 15,000 Km
Ignition system:
1. The ignition coil insulation shall be free from damage , electric leakage ,
and flashover, and its mounting is secure and reliable.
2. The gaps between spark plugs shall meet the requirements; replace the
spark plug with a service mileage of 15,000 km (before replacing the longlife spark plug).
Cleaning of the mixer
Keep the air holes in the mixer throat pipes clear.
115
Use and Maintenance of Special Parts for Natural Gas Vehicles
1.10 Brand and quantity of lubricating oil filled in the assembly
No.SN
Assembly
Assembly
Lubricant
Lubricanting oil
Brand Lubricating oil brand
Quantity
Quantity(L)
1
WP6NG
engine series
Lubricating oil for natural
gas vehicle
15W-40(China V emission standard)
2
WP6HNG
engine series
Lubricating oil for natural
gas vehicle
15W-40(China VI emission standard)
3
WP10NG
engine series
Lubricating oil for natural
gas vehicle
15W-40(China V emission standard)
4
WP12NG
engine series
Lubricating oil for natural
gas vehicle
15W-40(China V emission standard)
5
WP13NG
engine series
Lubricating oil for natural
gas vehicle
15W-40(China V emission standard)
6
ISG12
engine series
Lubricating oil for natural
gas vehicle
15W-40(China V emission standard)
7
WP8NG
engine series
Lubricating oil for natural
gas vehicle
15W-40(China VI emission standard)
WP10HNG series
Lubricating oil for natural
gas vehicle
15W-40(China VI emission standard)
9
WP10.5HNG
engine series
Lubricating oil for natural
gas vehicle
15W-40(China VI emission standard)
10
WP13NG engine
series
Lubricating oil for natural
gas vehicle
15W-40(China VI emission standard)
38
11
WP15HNG
engine series
Lubricating oil for natural
vehicle
15W-40(China VI emission standard)
38
12
WP12NGHPDI
engine series
Lubricating oil for natural
gas vehicle
15W-40(China VI emission standard)
13
X14N engine
series
Lubricating oil for natural
gas vehicle
15W-40(China VI emission standard)
14
YCK11N
ngine series
Lubricating oil for natural
gas vehicle
15W-40(China VI emission standard) 1
15
YCK13N engine
series
Lubricating oil for natural
gas vehicle
15W-40(China VI emission standard)
8
16
18
24
27
27
30
22
30
30
34
38
30
36
116
Use and Maintenance of Special Parts for Natural Gas Vehicles
1.11 Precautions for gas system
maintenance
2. CNG gas supply
2.1 Overview of CNG Vehicle Safety
The regular maintenance and repair of the fuel system
should be carried out by professional repair shops
(facilities) that have obtained certification from the relevant
In the process of compression, storage, transportation,
authorized departments.
decompression, and combustion, the natural gas is sealed
strictly, which minimizes the likelihood of leakage;
Only technicians with professional training and certification
in fuel systems maintenance and repair are authorized to
Natural gas is lighter than air (its density is 55% of the air
perform such tasks. Unauthorized personnel are not
density); and if there is leakage, it will dissipate quickly
allowed to conduct repairs;
under high pressure and is less likely to ignite;
Smoking is strictly prohibited at the maintenance site, and
The gas cylinder of natural gas has undergone physical
fire prevention and firefighting measures shall be equipped
experiments, water pressure experiments, impact
at the site. If the gas cylinders are pressurized, vehicles must
experiments, blasting experiments, falling experiments, fire
maintain a minimum distance of 10 meters from any open
experiments, gunshot experiments, penetration
flames in the vicinity.
experiments, and pressure cycling experiments. It is
equipped with explosion-proof devices to ensure safety;
When repairing the vehicle, it is strictly prohibited to strike
or impact the gas cylinders, pipelines, and various valve
bodies;
The components and modifications of CNG vehicles comply
with the relevant national standards, which can ensure
safety and the availability of spare parts.;
In the process of vehicle maintenance and troubleshooting,
if the dismantling and adjustment of the gas device's pipe
Odorants are typically added to automotive natural gas to
joints, valves, Instruments, and pressure reducers are
enhance the early detection of natural gas leakage and take
involved, the maintenance personnel should first disconnect
preventive measures.
the battery power supply circuit, close the main gas valve
and cylinder valve, and dismantle the faulty part after the
pressure is relieved. If it is difficult to accurately diagnose
the leakage or faulty part, it is allowed to open the main
gas valve for pressurized inspection on the premise that has
no open flame within a 10-meter radius of the vehicle. After
the leakage part is identified, the main gas valve and all
cylinder valves should be closed immediately, and the
pressure should be relieved before dismantling and
repairing.
When troubleshooting the gas supply system, the main gas
valve and all gas valves of steel cylinders must be closed for
pipe pressure relief. It is strictly forbidden to perform repair
work while the system is pressurized;
A strict inspection should be carried out to check whether
the ferrule is intact and undamaged. The high-pressure
pipelines, clamps, and connectors should only be replaced
with new ones and should not be reused. After
maintenance, a gas detector or soapy water should be used
for leakage inspection;
Blowdown treatment: After dismantling and inspecting the
pipes and various connectors, it is necessary to perform
blowdown treatment on the pipes;
Use and Maintenance of Special Parts for Natural Gas Vehicles
117
The panel assembly integrates the inflation valve (V3), gas-
2.2 Schematic diagram of the CNG
vehicle supply system
filling cut-off valve (V1), exhaust valve (V2), and pressure
gauge on one panel to realize the integration of functions
such as filling, cutting off, and venting natural gas.
В верхней части
газовый баллон
8×120л
Фильтр тонкой
очистки низкого
давления
running. During vehicle maintenance, close the gas cylinder
Редукционный
клапан высокого
давления
Фильтр тонкой
очистки высокого
давления
Open the V1 globe valve when refueling, close it after
refueling; close the V1 globe valve when the vehicle is
valve and open V2 to release the remaining high-pressure
gas in the pipeline.
Двигатель с собой.
Выпускной
клапан
Note: The technical parameters and installation methods of
the panel assembly will vary depending on the model, place
Боковой газовый
баллон 4×80л
of use, etc., and the operation instructions on the panel shall
Панель в
сборе
Обратный клапан
Фильтр
грубой
очистки
высокого
давления
Датчик
давления
Двигатель
prevail.
Теплообменник
Note:
The schematic diagram of the CNG system will vary
depending on the model. Users are advised to refer to the
actual vehicle model for accurate information
2.3 Composition of natural gas
supply system
a. Manual cut-off valve:
Function description:
Rotate the handle clockwise to close, and counterclockwise
to open. The maximum angle of rotation of the handle is
180° when fully open;
When the handle is in the closed position, it blocks the
passage below the "T"-shaped channel, while the left and
right ends remain open;
The CNG gas supply system consists of gas cylinders, high-
When the handle is in the open position, all the three
pressure pipelines, connectors, CNG integrated control
channels are open;
panel assembly, pressure gauges, gas volume display,
manual cut-off valves, exhaust valves, high-pressure
When it is used as an exhaust valve, the valve remains
solenoid valves, filters, check valves, overcurrent protection
closed. It only opens when the maintenance system needs
valves, pressure reducers, high-pressure hoses, circulating
to release the gas in the pipeline. After maintenance, the
water pipes, etc. (The specific vehicle configuration and
valve should be closed.
schematic diagram may be slightly different from this
manual due to design requirements, so the actual product
shall prevail.)
118
Use and Maintenance of Special Parts for Natural Gas Vehicles
b. Inflation valve:
Pin-type inflation valve
② High-pressure coarse filter
NGV1 inflation valve
Function Description:
It is used to filter solid impurities in natural gas. The
filtration accuracy is 10-50 μm.
Notes:
The filter element should be cleaned every 30,000 km and
replaced every 100,000 km or 12 months (whichever comes
first), or the replacement cycle shall be determined
Pin-type inflation valve
NGV2 inflation valve
according to the local gas quality.
③ High pressure fine filter
Function description: It enables safe and quick inflation of
the vehicle, with a built-in check valve that is detachable. It
comes with a dust cap to prevent dust, mud, and other solid
particles from entering the inflation valve and affecting the
service life of the inflation valve and CNG pipeline system.
c. Pressure gauge:
Function Description:
It is used to filter impurities and oil and water in natural gas.
The filtration accuracy of the outer filter layer is 10 μm, and
the filtration accuracy of the inner filter layer is 0.3~0.6 μm.
Notes:
The vehicle should undergo a drainage process every 15-30
Function Description:
The pressure display range is 0-40 MPa, used for indicating
the residual gas pressure in the gas cylinder.
days of operation or as needed, to completely remove the
oil-water mixture from the oil cup.
The filter element should be replaced every 50,000 km or 6
months of vehicle operation, whichever comes first.
Additionally, the rubber sealing ring of the housing should
be replaced at the same time.
Use and Maintenance of Special Parts for Natural Gas Vehicles
④ overcurrent protection valve
⑤ Check valve
A. Manual resetting overcurrent protection valve
Function description: When the pipeline system is inflated
(standard)
119
with double pipes, it is used in conjunction with the
overcurrent protection valve. The valve core automatically
Function description: During normal operation, the reset
opens when filling gas, and automatically returns to close
valve core is normally closed. When the flow through the
after filling gas. It can prevent the gas in the gas cylinder
overcurrent protection valve is greater than its set value
from flowing back to the filling port through the check
(about 1.2 MPa), the overcurrent protection valve will cut off
valve.
the air flow to prevent a large amount of continuous
leakage of natural gas in the pipes. After troubleshooting,
open the handle of the overcurrent protection valve,
overcurrent protection valve the pressure at both ends
reaches balance, close the overcurrent protection valve.
⑥ Flare connector/gas cylinder valve adapter fitting
Function description: It is installed on the gas cylinder valve
and used to connect the pipes between the gas cylinders
and between the gas cylinders and the panel assembly
b. Electromagnetic resetting overcurrent protection
Cone connector
Gas cylinder valve adapter fitting
Function description: The working voltage is DC24V and
the power supply remains closed during normal operation.
⑦ Tee fitting
When the flow through the overcurrent protection valve
exceeds its set value (about 1.2 MPa), the overcurrent
protection valve will cut off the airflow to prevent a large
amount of continuous leakage of natural gas in the pipes.
After troubleshooting, the power supply should be turned
on to balance the pressure at both ends of the overcurrent
protection valve and then the power supply is turned off.
3-∅8tee fitting
3-∅12 tee fitting
2-∅10-∅12 tee fitting
⑧ Equal-diameter straight-through connector
Function description: When the length of the steel pipes
between the two components is insufficient, this component
is used for the transitional connection.
120
Use and Maintenance of Special Parts for Natural Gas Vehicles
⑨ High pressure solenoid valve (optional)
Function description: The working voltage is DC24V. It is
2.4 Operational guidelines for gas
supply system of CNG vehicles
used to cut off and open the high-pressure gas normallyclosed valves in the pipes. It will open when power is
applied.
① When the vehicle is inflated
Warning: During vehicle refueling, it is essential to fill the
vehicle with CNG that meets the requirements of GB 180472017. Failure to do so may result in inadequate vehicle
power, shortened engine lifespan, and, more critically,
potential damage to the CNG cylinder, leading to a reduced
cylinder lifespan or even unsafe incidents such as cylinder
explosions.
Operational guidelines for vehicle refueling
When the CNG vehicle is in place, the power supply of the
vehicle should be turned off after the driver and passengers
get off the vehicle;
When filling gas, remove the dust cap on the inflation valve
V3, insert the pneumatic gun, and open the gas-filling cutoff valve V1 for filling gas;
⑩ High pressure pressure reducer
Start to fill gas up to 20 MPa, and then stop filling;
After the inflation, pull out the pneumatic gun, close
Function description: The lever diaphragm decompression
the gas-filling cut-off valve V1, insert the dust cap;
mechanism is adopted, which employs a two-stage pressure
The vehicle drives away from the gas station area;
reduction process to reduce high-pressure gas to lowpressure natural gas in the range of 8 bar to 9 bar. It is
equipped with a high-pressure solenoid valve that operates
at a voltage of DC24V.
Notes:
During the inflation process, the temperature of the gas
cylinder will rise, and it may feel noticeably warm to the
touch, but it should not be hot. This is because the gas is
being compressed and releasing heat during inflation,
which is a normal phenomenon;
After the vehicle is inflated (up to 20 Mpa), it is normal
for the pressure to drop to 17~18 MPa after being left
for 6 hours. This decrease in pressure is due to the
decrease in system temperature.
During refueling, the operating procedures of the CNG
gas station shall be strictly implemented, and the
inflation pressure of CNG shall not be higher than 20
MPa. If the pressure of the gas cylinder group is zero, the
CNG residual gas in the gas storage system must be
replaced by filling nitrogen before CNG can be filled
again;
In the process of vehicle inflation, the main power supply
of the vehicle must be turned off, and smoking or the use
of open flames is strictly prohibited in the surrounding
area.
Use and Maintenance of Special Parts for Natural Gas Vehicles
② When the vehicle is started
121
c. Precautions for operation during driving:
Before starting the CNG vehicle, the driver only needs to
open the manual cut-off valve on the pipes at the front end
It is important to monitor the natural gas level during the
of the gas cylinder group of the truck(generally on the right
vehicle's operation. If you notice a rapid or unexpected
side of the vehicle) to start the vehicle according to the
decrease in the gas level that doesn't align with the distance
driving operation procedures of the gasoline or diesel
traveled, it is advisable to stop the vehicle and check for any
vehicles.
potential gas leaks;
③ When the vehicle is running
If the vehicle suddenly stops during operation or after
Drivers of natural gas vehicles must receive technical
refueling, resulting in the inability to drive normally, it could
training on the use of natural gas vehicles, master the
be due to the activation of the overcurrent protection valve.
knowledge of daily safety inspection of natural gas vehicles
The driver should immediately turn on the emergency lights,
and key points of safe driving techniques, and obtain the
open the manual reset handle(or press the reset power
training certificate before driving the natural gas vehicle.
switch for vehicles equipped with an electromagnetic reset
a. Inspection prior to driving:
Check whether the gas cylinder is firmly fixed with the
bracket, and whether the gas pipeline is fixed with the
bracket;
Check whether the sensor connector is loose, whether the
wiring harness falls off, and whether there is rubbing or
pulling;
Check if the gas pipeline is worn or cracked
Check if the rubber water pipes are aged, cracked or
crushed;
Check the storage capacity of the natural gas, check
whether the gas volume display is basically consistent with
the indication value of gas volume observed before parking,
and confirm whether the CNG pipe joint has a slight leakage
hazard;
Check whether there is leakage on the gas cylinders and
high and low pressure pipes, open the refueling
compartment and gas cylinder compartment, and smell by
the nose; if necessary, use neutral detergent (or soapy) foam
water to check whether there is leakage on all pipe joint. If
there is a peculiar smell and air leakage, close the manual
cut-off valve on the gas cylinder, and notify the natural gas
v e h i c l e p rof e s s i o n a l m a i n t e n a n c e p e r s o n n e l f o r
maintenance;
b. Selection of the gears during driving:
When driving natural gas vehicles, attention should be paid
to the selection of gears, and low-speed driving in high gear
should be avoided. During long-term operation, the water
temperature of the engine should be kept within the range
required by the engine the operation manual. Low water
temperature is likely to cause ice blockage in the highpressure reducer, damage to the seal valve plate, and an
increase in gas consumption.
overcurrent protection valve) for approximately 10 seconds,
wait for the pressure to balance on both ends of the
overcurrent protection valve, turn off the manual reset
handle(or the power) once the pressure has balanced. At this
point, the gas system should return to normal operation.
In winter, when the temperature drops below 10 °C, for
natural gas vehicles parked outdoors, it is recommended to
start the engine and allow it to operate at medium to low
speeds. Once the engine reaches the specified operating
temperature, it is safe to start driving.
During the journey, if you feel a lack of power in your
vehicle, you should check if the inlet and outlet ports of the
pressure reducer and the gas supply pipe connections are
frozen. If they are frozen, you can use warm water to thaw
them, but be sure not to use fire or open flames.
In summer, when the weather is hot, the driver must pay
attention to the reading of the water thermometer. If the
water temperature is close to or reaches the upper limit
specified in the engine instructions, the driver should check
whether the engine cooling system works normally. If it is
abnormal, the driver should first eliminate the cooling
system failure.
122
Use and Maintenance of Special Parts for Natural Gas Vehicles
④ When the vehicle stops
2.5 Repair and maintenance
a. Precautions for temporary parking: For temporary
① Technical conditions that maintenance enterprises
parking, it is recommended to choose a ventilated and cool
should possess:
place away from fire and heat sources, and set up parking
warning signs. When parking, the engine and the main
Operators performing CNG vehicle maintenance shall
power supply switch should be turned off. If the vehicle is
receive professional training and pass the examination.
parked for more than 3 hours, the driver needs to turn off
the manual cut-off valve fixed on the pipes at the front end
The maintenance, testing and diagnostic instruments and
of the right gas cylinder group when leaving the vehicle. If
equipment required for the special requirements of the
the vehicle is parked for more than 24 hours, the driver
maintenance of CNG vehicle special devices are possessed,
needs not only to turn off the manual cut-off valve fixed on
including air tightness and pressure inspection;
the pipes at the front end of the gas cylinder group but also
to turn off all gas cylinder valves to ensure safety.
A special site for air tightness inspection and pressure relief
b. Precautions for night parking: When parking at night, it is
provided;
operation and a warehouse for storing special devices are
recommended to choose a ventilated and cool place away
from fire and heat sources. Before parking at night, an
The CNG vehicle maintenance workshop shall be well
inspection needs to be carried out to check if the system is
ventilated, and anti-open flame and anti-static signs shall
normal, if there is any air leakage, and if the fixing device of
be clearly indicated in places where there is a possibility of
the gas cylinder is loose. After the vehicle is parked steadily,
leakage;
the engine, electrical switch, and gas circuit globe valve
should be turned off. The pressure gauge pressure reading
Feasible and effective fire safety management measures
or gas volume indicator value should be checked and
and necessary equipment, firefighters, etc. are available;
recorded. (Before driving the next day, the driver needs to
observe the pressure gauge reading or gas volume
The CNG special equipment involved in the maintenance
indicator value again to evaluate whether there is a slight air
o p e r a t i o n s h a l l c o m p l y w i t h t h e s t a n d a rd s ; t h e
leakage risk in the pipe joint).
transportation, storage, distribution, and use of gas
c. Precautions for long-term parking: When the vehicle is
departments;
cylinders shall comply with the provisions of relevant
parked for a long time, in addition to following vehicle
parking regulations, the natural gas should be depleted as
② Safety requirements for maintenance operations:
much as possible. Generally, when the pressure drops to
around 0.2-0.4 MPa, the gas cylinder valve should be closed
Before the maintenance of CNG vehicles, the air tightness
immediately. The power supply and the battery cables
inspection of the CNG special device shall be carried out
should be disconnected. The vehicle should be placed in a
first. If there is leakage, the fault shall be eliminated first,
ventilated, moisture-proof, fireproof, and sun-proof place.
and the maintenance operation shall be carried out after
Before using the vehicle again, it is recommended to
confirming that the system seals well;
confirm that the high-pressure pipeline is in good condition
and that the connection parts are not loose or leak. If
During the maintenance, the inspection and maintenance
necessary, it is advisable to perform a gas replacement
related to the use of CNG shall be carried out first, and then
procedure for the storage cylinder before refueling and
the gas cylinder cut-off valve shall be closed and the CNG in
using the vehicle again.
the pipes shall be exhausted, and then the maintenance of
other items shall be carried out;
When open flame operations such as welding and cutting
are required, the batter y and the electric control
components of important assembly shall be removed. The
gas cylinder shall be safely removed and placed in a special
warehouse for safekeeping; or the CNG gas supply system
(including gas cylinder) shall be depressurized in a special
site that meets the safety protection requirements to ensure
that there is no CNG in the gas supply system;
Use and Maintenance of Special Parts for Natural Gas Vehicles
If it is necessary to grind or cut near the gas cylinder, it
123
b. Regular maintenance:
should be removed or effectively isolated. The gas cylinder
should be maintained and tested by qualified units and
The gas supply system requires regular maintenance every
personnel, and it is not allowed to carry out excavation,
month;
welding, and cutting operations on the gas cylinders;
CNG steel cylinders should undergo a gas tightness and
In case of gas leakage in CNG vehicles, the power supply
strength test every three years. Composite cylinders (steel
and gas cylinder cut-off valve shall be closed immediately,
liner with glass fiber wrapped cylinders) should be tested
and then the treatment shall be carried out at the special
every three years. If the cylinder exceeds six years of service,
site. If the high-pressure pipeline is broken or falls off,
it should be tested every two years;
causing a large amount of gas leakage, and failure to close
the gas cylinder cut-off valve, the site shall be isolated
The high presure CNG pressure gauge shall be calibrated
immediately. People and vehicles are not allowed to enter.
once every year;
The fire sources shall be isolated, and the treatment shall be
carried out after the natural gas is dispersed;
Please refer to the relevant provisions in the routine
maintenance of the system for the regular inspection of
In case of fire, in addition to closing the power supply and
gas cylinder cut-off valves immediately, the site shall be
isolated, and effective fire extinguishing and rescue
measures shall be taken immediately.
③ Maintenance work content and technical requirements
a. Routine maintenance:
The driver should focus on observing whether the CNG
special device has leakage and abnormal conditions before
driving, during driving and after stopping the vehicle;
The driver should inspect the working status, connection,
and seal of various functional components and systems of
the CNG special device, and ensure that they are in normal
condition and free from looseness, leakage, or damage. The
gas cylinder and fixed bracket are fixed firmly and
undamaged, and replaced if necessary; The CNG pipelines
should not collide with other components;
The driver should check the CNG storage gas level, and
immediately add CNG when it drops below the specified
value;
During driving, the driver should observe the working
conditions of all systems of the vehicle at any time. When
abnormal phenomena such as overheating, overcooling,
and peculiar smell are found in the CNG special device, the
driver should turn off the CNG gas cylinder cut-off valves
immediately and send it to the CNG vehicle maintenance
enterprise for maintenance in time;
other parts;
Use and Maintenance of Special Parts for Natural Gas Vehicles
124
c. Items, contents and technical requirements for routine maintenance of the system
SN
1
Project
Gas storage device
Operation Content
CNG gas cylinder and
fixed bracket
1) Check and fasten the
pipeline and connector;
2
CNG pipes and clamps
2) Check each connection
part for leakage.
3
4
Globe valve, inflation
valve, combination valve,
and other various control
valves, as well as the
related instruments, etc.
Filling port
Check the seal and working
performance
1) Check the installation
and fastening of the
filling port;
2) Check the check valve.
Technical Requirement
1) The inspection and verification of the gas cylinder are valid.
2) The surface of the gas cylinder shall be free of defects such
as serious scratches, bumps, and cracks.
3) The fixed bracket and cable ties shall be intact firmly without
cracks, and the padding shall be intact and undamaged, and
the gas cylinder shall be fixed reliably without tampering and
rotation.
4) The frame is inspected to recalibrate the tightening torque of
the bolt fasteners with the following cycle:
When the total mileage of the vehicle is 3000 km, a
maintenance check is performed on the gas cylinder frame with
the following maintenance items:
1 Inspection of the frame itself for obvious defects, cracks;
2 Calibrate the tightening torque of each bolt fastener. When
the total mileage of the vehicle is 8,000 km, the second
maintenance shall be carried out. When the total mileage of the
vehicle is 18,000 km, the third maintenance check shall be
carried out. After that, the maintenance check shall be carried
out once every 10,000 km. See the following table for the
specific calibration torque.
1) The high pressure pipeline and connector shall be
free of scratches and other damages.
2) The connector shall be well fastened and there is
no air leakage. After holding pressure for 5minutes,
apply leak detection liquid and observe for at least 1
minute, no bubbles appear.
3) The hose shall be free of aging, oil dirt and cracks,
and shall be connected reliably without friction with
other components.
1) All kinds of valves shall have good seal, flexible and
effective opening and closing performance, and the
relevant instruments shall work normally and be installed
firmly and reliably.
1) The filling port shall be fixed firmly and clean.
2) The filling port and check valve shall work reliably
without air leakage, and the dust cover/plug shall be
reliable and effective.
Pressure transducer,
pressure gauge
Performance inspection
1) Correct display.
2) There is no leakage at the connection of the air inlet
seat/pressure gauge connector.
6
High-pressure
coarse filter
Clean or replace the
filter element
1) Soak and clean the filter element with gasoline and
blow dry with compressed air at 30,000 km; replace
every 100,000 km or 12 months (whichever comes first).
7
High pressure fine filter
Drain, clean, or replace
the filter element
1) 15-30 days for drainage and 50,000 km
or 6 months for filter element replacement;
2) Clean and works well.
8
Metal braided hoses
Regular replacement
Replacement cycle of two years (depending on the use of
different working conditions vary slightly)
5
Use and Maintenance of Special Parts for Natural Gas Vehicles
Contents
Gas Cylinder Framework
Nut Type
Tightening Torque (N·m)
M6-8.8
10±1
M8×1-8.8
23±2.5
M10×1-8.8
45±4.5
M12×1.5-8.8
75±7.5
M14×1.5-8.8
135±13.5
M16×1.5-8.8
200±20
Spiralock Nut M14-10
150±15
Spiralock Nut M16-10
220±20
Spiralock Nut M18-10
300±30
M6
6±0.5
M8
12±1
3/4"-16UNF
18±1.5
7/8"-16UNF
22±2
Gas Cylinder Pipes
125
126
Use and Maintenance of Special Parts for Natural Gas Vehicles
2.6 CNG Supply System Failure and
Troubleshooting Methods
① The engine does not start.
3. LNG Gas Supply Section
3.1 Characteristics of LNG
① Basic knowledge of LNG:
Check the pressure gauge on the CNG control panel to
LNG is the abbreviation of Liquefied Natural Gas (Liquefied
confirm whether there is any gas in the gas cylinder;
naturalgas), which has a very low temperature, its boiling
If the above method does not solve the problem, please
point is about -162 ℃ at standard atmospheric pressure,
turn on the power supply switch first, then slowly and
and the gradient of boiling temperature with steam
gradually open the CNG high-pressure filter drain port to
pressure is about 1.25×10-4 ℃/Pa, natural gas cannot be
check the CNG outlet pressure;
liquefied by pressurization at room temperature, and the
If no hissing sound is heard, the CNG gas supply system is
temperature must be lowered below about -80 ℃ to be
faulty, and it is necessary to clean the filter element or
liquefied at a certain pressure. It is necessary to lower the
report to the service station of Shaanxi Heavy Duty
temperature below about -80 °C in order to liquefy at a
Automobile or the gas pipeline supplier for repair;
certain pressure. Normally 1 volume of LNG (liquid) will
If a strong hissing sound can be heard, please check the
yield 625 volumes of gas (standard state), which is
engine engine unit, and report to the service station of the
combustible in atmospheric conditions when mixed with air
CNG engine manufacturer for maintenance.
at about 5 %-15 % of its volume. LNG vapor is odorless.
② The engine stalls easily
natural gas in the air can cause nausea and dizziness due to
Natural gas is an asphyxiant, and high concentrations of
lack of oxygen.
Check the gas supply system for blockages or report to the gas
pipeline supplier for repair.
③ The vehicle can not be filled with gas
Check whether the gas-filling cut-off valve V1 is turned on;
Check whether the dust cap on the inflation valve V3 is
turned on and removed;
If the above methods do not eliminate the problem, the
inflation valve, gas-filling cut-off valve or pressure gauge is
generally not working, and needs to be replaced or
reported to the gas pipeline supplier.
② Handling of LNG Hazards:
Extremely low temperature. The boiling point is about -162
°C at standard atmospheric pressure;
Only a small amount of liquid can be converted into a large
number of gases. 1 volume of LNG can be roughly
converted into 600 ~ 625 volume of gas;
The natural gas is flammable. Under normal environmental
conditions, 5~15% (by volume, similarly hereinafter) of
natural gas mixed with air is flammable. This means that
when the volume fraction of natural gas in the air is < 5%,
or > 15%, it will not burn and certainly will not explode.
Use and Maintenance of Special Parts for Natural Gas Vehicles
Safety Protection
3.2 Safety Summary and Protective
Measures
① Safety Protection Equipment and Measures
The following general safety knowledge is required when
working on sites where natural gas or LNG is present:
Safety Summary
Keep LNG equipment away from flames and electric sparks,
When repairing or replacing components on the gas
and there shall be no flammable or combustible objects in
cylinder body, the liquid and gas in the container shall be
the vicinity;
drained in a safe way;
No pyrotechnics are allowed in places where LNG
When filling or using LNG, the liquid shall be prevented
equipment is maintained, filled and stored;
from splashing or overflowing, and anti-freezing measures
Goggles, face shields, insulated gloves and protective
shall be taken during operation, and the vehicle shall be
clothing are required when working in areas where LNG is
powered off when filling;
present. Protective clothing shall be made of cotton, and
In the process of filling or use, the valve will not be easy to
long trousers shall be worn, no skirts and shorts shall be
open and close due to frosting, the user can not be forced
worn and no nails shall be driven into the soles of shoes.
to twist, and it can be thawed with warm water before
The trouser legs shall not be rolled up and shall cover the
opening and closing.
opening of the shoe. Gloves should be made of cotton or
leather and should be long and wide enogh to take off
Warning: Forced screwing may cause damage to the valve,
quickly; they shall be intact, dry, not torn and wet;
resulting in personal injury
It is necessary to evacuate and relieve the pressure of LNG
The gas cylinder stored for more than 5 days must be
A suitable number of dry powder fire extinguishers shall be
cylinders during the disassembly of parts for maintenance;
drained of liquid and the pressure released to 0 MPa, with
provided;
all valve closed, and it should be placed in an open or
There shall be an adequate water source around. The
ventilated space. The gas cylinder liquefied natural gas must
purpose of the water source is for cooling, not fire
not be placed in a confined space;
suppression;
It is prohibited to install a plug at the outlet of the gas
The oxygen concentration and natural gas concentration in
cylinder safety valve.
the area shall be measured before entering the natural gas
area;
Warning: Adding a plug at the outlet of the gas cylinder
safety valve will seriously affect its safety performance and
Warning: Keep the area where the equipment is located
lead to serious expansion and deformation of the inner
well ventilated and make sure the system is depressurized
container, causing great safety hazards.
and kept away from flammable materials, electric sparks and
ignition sources when servicing or maintaining the
Welding on the cylinder body is prohibited.
Warning: Welding on the cylinder body will lead to loss of
vacuum, serious expansion and deformation of the inner
container, causing great safety hazards.
equipment.
127
128
Use and Maintenance of Special Parts for Natural Gas Vehicles
② Treatment in case of cold burns
③ Handling method of leakage
When the skin is bonded to a low-temperature surface, the
Ventilation requirements for spaces with protential leakage
skin and flesh can be thawed by heating with hot water, and
shall meet a ventilation rate of not less than 1/12 of the
then the frozen part can be removed and the injured can be
volume of the confined space per minute (equivalent to not
moved to a warm place (about 20 °C);
less than 5 replacements per hour);
Remove all clothing that interferes with the blood flow in
Confined space shall be equipped with combustible gas
the frostbite area;
alarms. The minimum lower limit of the alarm is when the
content of natural gas in the air of the space reaches 1% of
Immediately bath the frostbitten area in water at a
the volume content, an alarm shall be issued. The alarm
temperature of 40~45 °C, no drying or direct heating
signal shall be audible and visual and the driver can see the
methods are allowed. If the water temperature exceeds 45
alarm display;
°C, it will aggravate the damage to the body tissues in the
frostbite area;
Equipped with the necessary fire extinguishers.
Immediately transport the injured to the hospital for further
Warning: Do not use water to spray the liquefied natural
treatment;
gas liquid, which will cause a large amount of evaporation
of LNG and increase the fire intensity.
If the injured has entensive frostbite and the body
temperature has dropped, the injured needs to be
④ Treatment of Asphyxiation
immersed in water of 40~45 °C and taken to the hospital as
soon as possible;
Excessive accumulation of natural gas may thin the
concentration of oxygen in the air, which may lead to
The frostbitten body part starts to hurt and swell after
unconsciousness, injury, or even asphyxiation when a
heating, if the injury is not serious, the frostbitten part shall
person is exposed to this environment;
be heated slowly and continuously until the skin changes
from gray to pink or red.
When the operator loses consciousness due to lack of
oxygen, he shall be evacuated from the scene immediately
The wounded are not allowed to smoke or drink alcohol,
and artificial respiration shall be carried out. If the operator
which will reduce the liquid level of blood flowing to the
stops breathing, he shall immediately carry out artificial
frostbite tissues, and are given tetanus shots to prevent
respiration and be sent to the hospital immediately for
infection.
treatment;
When the oxygen concentration in the environment is less
than 19%, use air purge to natural gas the high
concentration area, keep the oxygen concentration >19%,
but pay attention to controlling the concentration of the
natural gas <1%,
Warning: When the oxygen concentration in the air is less
than 10% or the natural gas concentration is more than
50%, the staff cannot enter the LNG area.
129
Use and Maintenance of Special Parts for Natural Gas Vehicles
3.3 Introduction to LNG Vehicle Gas
Supply System
3.3.1 LNG Vehicle Gas Cylinder
LNG vehicle gas cylinder is a kind of cryogenic insulation
pressure vessel, designed with a double-layer (vacuum)
structure. The inner container is used to store cryogenic
liquid LNG, and its outer wall is wrapped with multi-layer
insulation material, which has super heat insulation
performance. At the same time, the jacket (the space
between the two layers of containers) is pumped into a high
Warning:
vacuum, forming a good insulation system. The shell and
support system are designed to withstand the relevant
Do not touch the vacuum plug by the user!
external forces generated by the transport vehicle during
driving.
The inner container is designed with a two-stage safety
valve to provide protection against overpressure. In case of
overpressure, first open the main safety valve with an
All pipes and valves are set at one end of the gas
cylinder, as shown in the figure below, and are protected
by retaining rings or protective covers
opening pressure of 1.9 MPa (281 psi) and the secondary
safety valve with an opening pressure of 2.41 MPa (357 psi).
The set pressure is higher than the main safety valve. In the
event of failure or malfunction of the main safety valve, the
11
1
secondary safety valve will operate, ensuring safe and
10
secure use of the gas cylinder.
2
9
The protection of the shell under internal overpressure is
3
achieved by an annular vacuum plug. If leakage occurs in
8
the inner container (causing the jacket pressure to be too
high), the vacuum plug will automatically open for pressure
relief when the interlayer pressure reaches 0.1~0.2 MPa.
4
5
6
7
When leakage or vacuum damage occurs to the vacuum
plug, the insulation capacity will decrease or fail. At this
time, the shell may "sweat" or frosting. Of course, it is
1
Main safety valve
the pipe connected to the gas cylinder. A fixed support with
2
Secondary safety valve
a rubber lining is provided inside the weld at both ends of
3
Venting valve
4
Pressure regulating boost valve
5
Economic valve
6
Pressurized globe valve
7
Vacuum clogging (do not move)
8
Check valve
9
Outlet valve
10
Needle Valves (Connect the panel pressure gauge)
11
Overflow valve
normal for frosting or condensation to occur at the end of
the gas cylinder, and the fastening strap of the gas cylinder
shall be able to withstand a force 8 times the total weight.
130
Use and Maintenance of Special Parts for Natural Gas Vehicles
3.3.2 Introduction to LNG Vehicle
Supply System Process
Gas State Газовое состояние
The LNG Vehicle Supply System consists of gas cylinder,
Liquid State
жидкое
состояние
vaporizer, buffer tank, solenoid valve, voltage stabilizer, filter,
etc. The vaporizer mainly uses the engine circulating cooling
water to heat and vaporize the liquefied natural gas, so that
the natural gas can meet the operating temperature and
Выход охлаждающей воды
flow requirements of the engine. It shall be installed as close
as possible to the gas cylinder, and the flow direction of the
heating water should be the same as that of the LNG, and
the vaporizer will not increase the internal pressure of the
cylinder.
The function of the buffer tank is to reserve a certain
amount of gas for emergency needs. When the vehicle
power is large and more natural gas is required for starting,
a buffer tank can be equipped after the vaporizer. If the
vehicle power is not large and the length of the air supply
pipeline (its role is equivalent to the buffer tank) meets the
needs due to the limitation of the installation space of the
vehicle, this container can be omitted,
The main function of the voltage stabilizer is to reduce the
pressure of the natural gas after the vaporization of the
vaporizer, so that it can meet the pressure requirements of
the engine and maintain the pressure stability.
The function of the solenoid valve is that when the ignition
switch of the engine is closed or in the secondary position,
and the engine the flameout ignition switch is still on, the
valve is in closed state, which can prevent the natural gas
from flowing to the engine and prevent the natural gas
leakage.
The specific flow chart is shown in the figure. (Note: For the
specific working principle, the schematic diagram of each
zero and component and the maintenance method, please
refer to the "LNG System Operation Manual" attached to the
vehicle.)
Вход охлаждающей воды
Отверстие подачи воздуха
автомобильного двигателя
Отверстие подачи
воздуха автомобильного
двигателя
Schematic Diagram of LNG Vehicle Supply System
Use and Maintenance of Special Parts for Natural Gas Vehicles
3.3.3 Sign Description:
Sign
Name
Functions
C1
Low temperature filling port
Used for connecting the dispenser to the gas cylinder
C2
Low temperature blowdown port
Used for connecting the blowdown gun to the gas cylinder
Vv
Venting valve (manual)
Used for storage pressure relief of gas cylinders
Vu
Outlet valve (manual)
Used for controlling the fuel supply
Va
Vaporizer
Converting LNG into CNG
FCv
Inlet check valve
Used for preventing backflow of liquid in the gas cylinder
Dcv
Outlet check valve
Used for preventing backflow of liquid supply pipes
Er
Overflow valve
Prevent a large amount of fuel leakage when the supply pipes is broken
Ef
Overflow valve
Prevent a large amount of fuel leakage when the supply pipes is broken
P1
Pressure gauge for gas cylinder
Display the storage pressure
P2
Buffer tank pressure gauge
Display of buffer tank pressure
PBr
Pressure regulating valve
Automatic supercharging when the storage pressure is too low
Pr
Supercharger
Conversion of LNG to CNG by heat exchange with air +
Pv
Boost pressure valve
Pressurize the gas cylinder in case of insufficient storage pressure.
LG
Display of liquid level gauge
Display the fuel level inside the gas cylinder
PRv
Main safety valve
Pressure relief to protect gas cylinders
SRv
Secondary safety valve
Pressure relief to protect gas cylinders
Bc
Buffer tank
Store natural gas to ensure gas supply
LRe
Voltage stabilizer
Ensure constant pressure in the engine
Cb
Transmitter
Convert a capacitive signal into an electrical signal
SV
Solenoid valve
Stop the flow of natural gas to the engine and prevent natural gas leakage
131
132
Use and Maintenance of Special Parts for Natural Gas Vehicles
When the vehicle is equipped with only one gas cylinder,
3.3.4 Operating Specifications for
LNG Vehicle Gas Supply Systems:
level indicator light is on, and the buzzer alarms for 5
① Routine inspection before each trip
seconds until the liquid level is ≥ 23 %, and the liquid level
Check the storage pressure and fuel. If the cylinder pressure
%, the liquid level indicator light is on, and the buzzer
is lower than 0.8 MPa, the gas cylinder shall be pressurized,
alarms for 5 seconds.
the liquid level value is between 10 % and 20 %, the liquid
indicator light goes out; when the liquid level value is < 10
and the boost pressure valve and venting valve shall be
opened; otherwise, it is unnecessary.
When filling multiple gas cylinders, this gauge head displays
the liquid level of each gas cylinder. When the liquid level
value of one of the gas cylinders is ≤20%, the liquid
Indicator flashes for 5 s and the buzzer alarms for 5 s; when
it is <10%, the liquid level indicator flashes for 5 s, and the
buzzer alarms for 5 s. When 10% ≤ total cylinder volume ≤
20%, the liquid volume indicator light is on and the buzzer
alarm is on for 5 s until the total volume ≥ 23%, then the
Open the outlet valve and check the pipeline system for
indicator light is off. If the calculated LNG volume ratio is
leakage at the same time.
>100%, the gas volume indicator pointer on the instrument
Tip: When opening each globe valve, screw it until it can't
instrument does not receive any gas cylinder liquid level
will indicate the previous position. In "LNG" mode, if the
be screwed, and then screw it back for 1/4 turn to protect
signal for 5 s, the liquid level pointer will indicate zero, and
the valve.
the liquid level indicator will be on and the buzzer will alarm
for 5 s.
Sign Description:
Note:
Turn on the master switch of gas cylinder gas
volume engagement power, turn on the power
When the LNG liquid level is less than 15% of
key switch in the cab, and check the gas from
the rated volume, the refilling is required.
the gas gauge.
The gas volume gauge needs to be checked if it
does not indicate correctly, and the sensor
needs to be checked by a professional.
Use and Maintenance of Special Parts for Natural Gas Vehicles
② Filling of LNG Gas Cylinder
Conventional filling of the LNG gas cylinder
133
Notes:
Before filling, it shall be inspected whether there
is frosting or sweating on the surface of the gas cylinder. It is
In general, refilling shall be prepared when the liquid level of
recommended that the gas cylinder with this phenomenon
the gas cylinder is less than 20%, and refilling when it is not
shall not be filling and shall be sent back to the
allowed to be less than 15%.
manufacturer for repair;
Cylinders that have been filled for the first time, stopped
working for two weeks, and repaired are usually referred to
Check if there is pressure in the gas cylinder. If the pressure
as "hot cylinders". The hot cylinder must be filled in such a
is zero, the gas cylinder shall be purged and tested for
way that the temperature of inner container is cooled to the
airtightness. After passing the test, it can be filled.
LNG temperature. It shall be carried out according to the
following procedures: Open the protective caps of low
Note:
temperature filling port and low temperature blowdown
port, purge (or wipe with dry and clean veil) the low-
Before filling, check if there is moisture or impurities in the
temperature liquid filling port and low-temperature
low temperature filling port, and ensure that the moisture
blowdown port with dry nitrogen to ensure that there is no
and impurities are completely removed during the filling
moisture and impurities; and connect the blowdown gun
process;
and the low-temperature blowdown port, and screw the air
return gun by 90°; and connect the pneumatic gun and the
If there is moisture, it will quickly condense into ice cubes
low-pressure liquid filling port; and open the pump of the
when filled with liquid. Ice can clog inlet check valves, low
gas station to fill the gas cylinder with liquid. When the air
temperature filling port, or even enter bottles. Blockage
filling gun displays about 30 L, stop refilling; and open the
causes low temperature filling port, inlet check valve is not
gas cylinder air release valve to reduce the pressure to 0.3
tightly closed, resulting in leakage, and even damage to the
MPa, and then close the vent stop valve.
sealing surface. If the ice cube enters the inside of the gas
Allow the gas cylinder to cool down for about 10 minutes,
cylinder, it will be blocked at the outlet check valve during
during which the pressure of the gas cylinder will rise;
the liquid discharge process, resulting in poor liquid supply,
observe the storage pressure gauge. If the storage pressure
making the engine power insufficient or even unable to
is high, it may be necessary to vent the filling, and restart
start;
the gas station pump for filling until the dispenser stops
automatically; confirm that the air release valve has been
If there are impurities, during liquid filling process, they may
closed, remove the pneumatic gun and blowdown gun;
cause the inlet check valve and low temperature filling port
cover the protective caps of low temperature filling port and
not to close tightly, and even damage the seal surface.
low temperature blowdown port.
Furthermore, if the front end of the engine is not equipped
Conventional filling: It refers to the normal use of gas
with a filter, the impurities may damage the engine,
cylinder, in the filling gas cylinder inner container in a low
temperature state and a part of the liquid. Open the
Notes:
protective cap of the low temperature filling port and the
low temperature blowdown port, purge (or wipe with a dry,
During the filling process, you will find that the tank
clean veil) the low temperature filling port and low
pressure rises first, and then drops to a pressure close to the
temperature return port with a dry nitrogen to ensure that
gas station. If the pressure remains high and does not fall
there is no moisture and impurities; connect the return gun
back, it indicates that the filling has failed. If the filling fails,
and low temperature return port, screw the return gun by 90
stop filling immediately and vent the tank pressure, and
°; connect the pneumatic gun and the low temperature
restart filling after the pressure drops;
filling port; open the gas station pump for filling until the
A fully filled gas cylinder has a very rapid increase in
filling machine stops automatically; confirm that the air
pressure, which may cause the safety valve to open;
release valve has been closed, remove the pneumatic gun
Therefore, fully filled gas cylinders shall be used as soon as
and the blowdown gun; cover the protective caps of the low
possible and long-term storage is prohibited.
temperature filler and the low temperature return port.
Warning: When venting to the atmosphere, the vented gas
Tip: Try to reduce the pressure of the bottle when refilling
shall be led to a safe place, otherwise it will cause the risk of
fire and explosion.
134
Use and Maintenance of Special Parts for Natural Gas Vehicles
③ Supercharging
④ Air Bleeding
The following conditions require pressurization of the
During the use or maintenance of the gas cylinder, the gas
gas cylinder:
cylinder shall be emptied as following steps if necessary.
Remove the connector, open the vent stop valve, reinstall
the connector after it is completely emptied, and close the
venting valve.
When the gas cylinder is used for the first time and the
pressure is lower than the need of the engine;
After the validation of safety valve and pressure gauge of
the gas cylinder;
The gas cylinder is repaired after venting;
The gas cylinder that the boost regulator is set at a pressure
that is lower than the required pressure for the engine.
The specific pressurization method is:
open the boost pressure valve and open the venting valve
at the same time. After the storage pressure meets the
requirements of the engine, close the boost pressure valve
and the venting valve.
Use and Maintenance of Special Parts for Natural Gas Vehicles
135
⑤ Liquid Outlet
⑥ Air Supply Pipeline
When the gas is supplied to the vehicle, the outlet globe
The air supply pipeline is mainly composed of a vaporizer, a
buffer tank, a buffer tank pressure gauge, a combination valve
and each connecting pipes.
valve is opened, and the liquefied natural gas passes
through the outlet check valve, then flows through the
outlet valve and the overflow valve and enters the gas
supply system.
When the pressure difference between the inlet pressure
and the outlet pressure of the overflow valve is greater than
the set value, the overflow valve will be quickly closed to
stop the external liquid supply. Close the outlet globe valve,
and the overflow valve will quickly return to the open state,
Vaporizer
Buffer tank
Buffer tank pressure gauge
Combination valve
⑦ Security systems
The safety system is mainly composed of main safety valve,
secondary safety valve, storage pressure gauge, liquid level
gauge and air release valve. In use, it is necessary to observe
whether the secondary safety valve plug cap falls off before
each trip and after parking. If it falls off, it indicates that the
main safety valve is invalid and needs to be replaced.
Note:
The storage pressure is too high or the outlet valve is
opened too fast at the beginning, which may cause the
overflow valve to close and cause the engine to stall;
For the on-line adjustment of each valve, please refer to the
LNG System Operation Manual attached to the vehicle.
136
Use and Maintenance of Special Parts for Natural Gas Vehicles
3.4 Repair and Maintenance of LNG
3.4.1 Routine Maintenance Requirements
Maintenance items
Maintenance interval
Maintenance method
Fastening strap for gas cylinder
Maintenance of new vehicle
2500-3000 km,
Post-maintenance
2500-3000 km
Pre-tightening, tightening torque
Coupling nut of gas
cylinder and bracket
15 days
Tighten the nut
Coupling nut on the
gas cylinder pipe
Before each trip
Visually observe for leakage.
Vaporizer
6 months
Clean the scale on the coil
Valve
Frequent
Check whether it is not closed
tightly and leakage
Safety valve
12 months.
Send it to the local technical supervision
department for verification
Pressure gauge
12 months.
Send it to the local technical supervision
department for verification
Vacuum level of the gas cylinder
12 months.
Pressure test
Leak detection
Frequent
Gas-tight test or leak detection
Metal braided gas hose
2 years (slightly different depending
on different service conditions)
Replacement of metal
braided gas hose
Polyurethane gas hose
2 years (slightly different depending
on different service conditions)
Replacement of polyurethane
gas hose
Leak detection operation instructions: Portable methane detector can be used to check the gas system natural gas leakage
points of the vehicle (shall follow the detector manufacturer's instructions for correct use). To ensure the normal operation of the
vehicle, regular system leak detection shall be carried out, if the leak is found, it shall be repaired immediately. In some special
conditions, it is difficult to accurately determine the leakage point with the detector, you can use soap solution to check the leak.
Any fuel leakage, once found, it must be repaired .
Use and Maintenance of Special Parts for Natural Gas Vehicles
3.4.2 Basic Faults and Troubleshooting Methods of LNG Vehicle Gas Part:
Phenomenon
Apparent Phenomenon of Gas
Cylinder System
The storage pressure
continues to drop and the
booster coil does not frosting.
Insufficient power
of engine
The storage pressure
continues to decrease and
the booster coil is frosting
The storage pressure drops to
a certain value (lower than the
required pressure of the engine),
and the booster coil is frosting
Insufficient power
of engine
Examination content
Treatment method
Failure of booster regulating valve
Replace the wearing parts
Blockage of booster pipes
Drain off the liquid in the
cylinder, replace the gas
cylinder with dry nitrogen, and
then purge the gas cylinder
with 0.3~0.4 MPa nitrogen.
The setting of the economy
regulator valve is lower than
the setting of the boost
regulator valve and lower
than the engine pressure needs.
Adjustment of the
economic valve
The setting of the boost
regulating valve does
not meet the requirements.
Adjustment of the pressure
regulating valve
The pressurization coil is
covered with dirt
Rinse it off with water
The storage pressure is normal,
and the booster coil does not
frosting, and the pressure behind
the pressure stabilizing valve is
lower than the engine pressure.
The set value of pipes pressure
stabilizing valve is lower than the
engine needs
Gauge P1 is stable,
gauge P2 is jumping
Failure of pressure
stabilizing valve
Gauge P1 is jumping
Failure of gas cylinder
pressure regulating valve
Adjustment of the pressure
regulating valve
The set pressure of economic
valve is lower than the
pressure regulating valve
Adjust or change the
economic valve and
pressure regulating valve
The outlet valve is opened too
fast when starting the vehicle
Slowly open the outlet valve
Pressure regulating valve of
gas cylinder malfunction
or incorrect setting
Adjustment or replacement of
pressure regulating valve
Regulating the pressure
stabilizing valve
Unstable engine
power
The engine fails to
start or suddenly
Flameout
The overflow valve is blocked
The display value of P1 pressure
is too low
137
138
Use and Maintenance of Special Parts for Natural Gas Vehicles
3.4.2 Basic Faults and Troubleshooting Methods of LNG Vehicle Gas Part:
Apparent Phenomenon
of Gas Cylinder System
Examination content
Treatment method
Condensation and
frosting on
the surface of
gas cylinder
Deterioration of vacuum
Return to the supplier
for repair
The small check
valve does not work
Change
Economic valve is set too high
Adjustment of the
economic valve
Excess filling
Filling according to
the rated amount
Filling of thermos
Normal phenomenon,
increase the gas volume
The safety valve fails.
Change
Drain gas cylinder
when filling
Pneumatic gun hose is
not a vacuum tube
The gas station issues
Low temperature
valve frozen
Valve Leakage
Maintenance
Phenomenon
The storage pressure rises
too fast or continuously
The gas cylinder
surface is normal
The safety valve does not
seal after being opened
The internal pressure
The set pressure of the filling
equipment is too high
of the cylinder is
too high during filling
The pressure in the cylinder
is too high when using gas
Regulate the gas filling
equipment to the
appropriate pressure
Filling of thermos
Normal phenomenon, press
the air return pipe to vent
Improper adjustment of
the economic valve
Adjust the economic valve
to the proper pressure
The economic valve
fails or is damaged.
Repair or replace the
economic valve
Use and Maintenance of Special Parts for Natural Gas Vehicles
3.5 Introduction to HPDI
Supply System
The HPDI system is a fuel feed system that allows diesel
engine to use natural gas as the primary engine fuel. By
replacing up to 95 % of the diesel with clean-burning natural
gas, trucks with the HPDI system can maintain the same
power and performance as equivalent trucks that use only
diesel .
3.5.1 Working Principle of HPDI System
The low temperature pump mounted on the gas cylinder
extracts and pressurizes the LNG from the LNG gas cylinder. A
vaporizer (heat exchanger) uses hot engine coolant to heat
high pressure LNG to high pressure natural gas. This high
pressure gas is the main fuel for the engine. CNG is supplied
to the gas control module (GCM), and then the pressure is
regulated and delivered to the fuel injector.At the same time,
Hydraulic oil tank
a high-pressure diesel pump mounted on the engine draws
diesel fuel from the diesel tank. The high-pressure diesel fuel
is supplied to the fuel control module (DCM), which then
regulates the pressure and delivers it to the injectors. In the
engine combustion chamber, each cycle, the HPDI injector
injects a small amount of diesel fuel for compression ignition,
followed by a large amount of CNG to be ignited by the
burned diesel fuel, thus making the engine work continuously.
3.5.2 Componnents of HPDI System
① Hydraulic pump: It is assembled at the power take-off port
above the flywheel housing of the engine to provide high
pressure hydraulic oil for driving the low temperature pump;
② Hydraulic oil storage tank: It is installed on the LNG gas
cylinder bracket to provide hydraulic oil to the low
temperature pump;
③ Hydraulic oil cooler: It is installed on the LNG gas cylinder
bracket, used for coolant pressure oil;
Hydraulic oil cooler
139
140
Use and Maintenance of Special Parts for Natural Gas Vehicles
④ LNG gas cylinder: One or more stainless steel LNG gas
⑩ Exhaust valve (atmosphere/blue): This valve is located on
cylinder are installed on the gas cylinder bracket. Because
the right side of the gas cylinder protective cover. When it
the gas cylinder is used to contain LNG with extremely low
cannot be exhausted to the gas station, it controls the
temperature, it adopts a double-layer container design. The
excess gas cylinder compressed natural gas to be safely
inner container and the outer bladder are separated by a
discharged to the atmosphere through the vehicle vent
thermal insulation layer and a vacuum to avoid the influence
pipe;
of the external environment. This thermal insulation layer
can keep the LNG cold for a long time;
11
⑤ Low temperature pump: It is installed inside the gas
of this valve requires the use of special maintenance tools,
cylinder, the pump pumps and pressurizes liquefied natural
which can only be carried out by professional personnel;
Drain valve: Maintenance or repair of gas cylinder or
pump before emptying the gas cylinder of LNG. Operation
gas, which is vaporized into compressed natural gas with the
help of hot engine coolant and transported to a high
12
pressure buffer tank;
valve is located near the buffer tank, used to isolate the
⑥ Primary pressure relief valve: The valve is designed to
maintenance of the downstream gas system. This valve can
Buffer tank high-pressure natural gas shut-off valve: This
high pressure natural gas in the buffer tank during the
open when the storage pressure exceeds 16 bar. When the
only be operated by professional maintenance personnel
storage pressure drops below 16 bar, this valve is
during maintenance or repair;
automatically closed;
Buffer tank high pressure
natural gas shut-off valve
⑦ Secondary pressure relief valve: The valve is designed to
open when the storage pressure exceeds 22 bar and the
primary pressure relief valve fails. It is equipped with a
safety cover, which acts as a visual indicator of the failure of
the primary pressure relief valve and at the same time
prevents impurities and moisture from entering the valve,
⑧ Automatic shut-off valve: This valve is located outside the
protective ring of the LNG gas cylinder, gas cylinder CNG
outlet. When the low temperature pump does not work, if
the downstream pressure drops below 26 bar, the shut-off
Buffer tank pressure
relief device
valve prevents CNG from flowing out of the LNG gas
Buffer tank of high
pressure assembly
cylinder;
⑨ Check valve (gas station/green): This valve is located on
the left side of the protective cover of the gas cylinder to
control the return of excess compressed natural gas to the
gas station. Before refilling, the excess compressed natural
gas is safely returned to the gas station through the refilling
pipe or the special vent pipe of the gas station;
13
High pressure buffer tank assembly: The high pressure
contains CNG in the buffer tank, usually installed on the gas
cylinder bracket or behind the cab. It is used to reduce the
natural gas pressure pulse of the low temperature pump
introduced into the system. The high pressure gas (CNG) is
delivered from the buffer tank to the engine for
combustion.
14
High pressure gas filter: the high pressure gas filter
provides filtration for CNG entering the engine;
Use and Maintenance of Special Parts for Natural Gas Vehicles
15
Buffer tank pressure relief device: temperature actuation
device to protect the buffer tank from excessive pressure. In
case of fire/temperature exceeds 109 °C (228 °F), vent to the
141
3.5.3 Operating Specifications for
LNG Vehicle Gas Supply Systems:
ground;
① Gas cylinder of HPDI system does not need manual
16
Buffer tank relief valve: pressure-driven valve to protect
the buffer tank and avoid excessive pressure, and the relief
operation for the liquid discharge and is automatically
controlled by the system.
pressure is set at 400 bar;
② The gas cylinder has two manual valves, venting valve
17 Purge filter: filtering the discharged gas;
and check valve. When the gas cylinder needs to be
emptied, open the venting valve and the gas is directly
discharged into the atmosphere; when the refilling station
needs to refilling gas, open the check valve after firmly
connecting the return hose or special vent pipe. Before and
after adding liquid, the check valve must be closed; during
normal operation, close the vent valve and the check valve
at the same time.
③ Filling and returning air operation:
When filling, first close valve 1 and valve 2 to fill cylinder 1
(lower), then open valve 1 to fill cylinder 2 (upper) after
filling is completed, and then close valve 1 after that.
High pressure filter
Purge filter
Close valve 1, open the green gas return globe valve at the
head of cylinder 1, and then open valve 2 when the return
operation of cylinder 1 is completed; close cylinder 1 (lower)
head green return air globe valve after return air is
completed, close valve 2.
Close the green gas return globe valve at the head of
cylinder 1 (lower), open the green gas return globe valve at
the head of cylinder 2 (upper), and then open valves 1 and
2; after the end of the return, close the green gas return
globe valve on the head of cylinder 2 (upper), and then
close the valve 1, valve 2.
Buffer tank pressure relief Valve
18
Vent pipe: The vent pipe is a small-diameter pipe, usually
arranged upward along the rear of the cab. Excess gas can
be safely discharged upward from the truck through the
vent pipe as a path. There are two vent pipe: the first is used
Valve 1
to drain the LNG gas cylinder, and the second is used to
drain the engine gas rail, GCM and buffer tank pressure. The
second is equipped with a filter.
Valve 2
142
Use and Maintenance of Special Parts for Natural Gas Vehicles
3.5.4 HPDI Systems Safety Precautions:
Daily Inspection Items
Warming! The HPDI system contains high pressure gases,
Check Driver Report
liquids, and cryogenic fluids, even when the truck is turned
service or repair a truck equipped with an HPDI system.
Drain all water in the diesel
oil-water separator
Never turn an unfamiliar valve, or serious high pressure
Drain all air and fluid reservoirs
off. No unauthorized or untrained person should attempt to
explosions or cryogenic frostbite may occur;
Drain the diesel from the purge filter
The HPDI system operates at a maximum pressure of 33
Engine
Check the intake and
supercharging pipes
MPa. Even after the engine is turned off, high pressure can
be present in the LNG gas cylinder and most CNG pipes.
Check the crankcase breather pipe
The system is designed to safely withstand these high
pressure and is equipped with pressure safety devices;
Check the fan and cooling system
The vehicle must be parked outdoors and must not be
Check the engine oil, engine coolant
and hydraulic oil oil level
allowed to vent or leak in a confined space. The natural gas
may rise and collect in areas with possible ignition sources,
Check the vehicle for diesel fuel,
hydraulic oil and coolant leaks
Oil fluids
which may cause explosions, so outdoor parking is
Check the hydraulic oil cooler for
impurities or damage
mandatory. The gas cylinder pressure relief valve is opened
at a pressure of approximately 16 bar. It is normal for the
Check the LNG system for loose
or damaged component
LNG storage pressure to rise and vent regularly through the
vent pipe;
LNG is cryogenic (extremely cold) liquid. Avoid contact with
liquid and pipeline, otherwise frostbite and freezing crack
Check the LNG system for gas
or diesel leakage
Check the LNG
system
Check for excessive frosting
in the LNG system
may occur. Wear appropriate PPE when working around
Check the natural gas leakage
alarm - alarm and indicator
LNG gas cylinders or pipes.
Check the LNG level, storage pressure
and gas cylinder valve position
3.5.5 Maintenance of HPDI System:
① The following routine maintenance work is required to
② The LNG delivered to the LNG gas cylinder shall be
ensure reliable performance of the HPDI system. See the
filtered with a nominal 5 micron and an absolute value of 10
following table
micron accuracy. Before refilling, the LNG gas cylinder filler
must be dried with compressed air to avoid system freezing
and contamination;
③ Low temperature pump hydraulic oil specifications: LHV32 is used in general environment temperature
conditions, according to the national standard GB 11118.12011 hydraulic oil. Aviation-10 ground use is used in cold
areas in northern winter temperature conditions, according
to the standard Q/SY YM 0024-2000, this oil can not be
used in summer. In addition to the basic engine oil capacity,
LNG fuel systems requires the following additional number
of hydraulic oil (for reference only): 450 L single bottle
system 14 L/450 L double gas cylinder system 16 L/1000 L
single bottle 16 L.
Use and Maintenance of Special Parts for Natural Gas Vehicles
3.5.6 Fault Diagnosis of Gas Cylinder
143
4. LNG Vehicle Transportation and
Storage Requirements
① Valve Freezing
Due to the extremely low temperature of LNG, the pipes are
prone to the frosting formation. Frosting can sometimes
make it difficult for the manual valve to rotate or freeze. The
following measures can be tried:
Allow the valve to thaw naturally under the temperature of
ambient air
Before refilling, use compressed air (available at LNG gas
stations) to dry the valves
If feasible, pour water directly onto the valve body (cold or
4.1 Transportation of LNG Vehicles
If the vehicle is towed by train, ship or pallet truck and the
vehicle is placed in a confined space, the gas in the special
device of LNG vehicle shall be emptied; If the lifting method
is used for loading and unloading, special slings shall be
used for loading and unloaded, and the special device of
LPG vehicle shall be free of bumps and scratches;
During transportation, the vehicle shall be placed firmly, and
the operation valve of the special device for LNG vehicle
shall be turned off and the power supply shall be cut off.
hot water is fine)
4.2 Storage of LNG Vehicles
Do not:
Use any open flame or heat gun to heat the valve
The LNG vehicle shall be parked in a ventilated, moisture-
Strike the valve with an object such as a hammer
proof place with fire-fighting facilities, far away from fire
Forced opening or closing the valve - the valve may break
sources and flammable substances, and shall ensure that the
natural gas discharged gas cylinder overpressure does not
② LNG gas cylinder fogging or frosting/low fuel
efficiency
accumulate. After parking, all operating valve of special
devices for LNG vehicles shall be turned off and the power
supply shall be cut off;
If excessive frosting or condensation (sweating) is
continuously found on the LNG gas cylinder, the vacuum
If the storage time of the vehicle is less than two weeks, at
level of the gas cylinder may decrease;
least the LNG fuel of "gas cylinder volume × 20%" shall be
kept in the gas cylinder; if it exceeds two weeks, the liquid
Poor LNG vacuum level of the gas cylinder can also be
and gas in the gas cylinder shall be emptied, and the LNG
indicated by fuel efficiency loss or rapid formation of LNG
gas cylinder shall be refilled when the vehicle is used again.
storage pressure;
It is also important to record storage pressure and the
condition of LNG gas cylinders as part of the before-andafter inspection. These checks help to understand the
normal cylinder pressure and condition of the vehicle. If you
suspect that the vacuum of the LNG cylinder is defective,
contact your local authorized repair station.
144
Use and Maintenance of Special Parts for Natural Gas Vehicles
5. Instructions for Use of Natural Gas
China VI Aftertreatment System
5.2 Key Components Precautions
① Aftertreatment system assembly: after the engine works
5.1 Introduction of Aftertreatment
System:
Three-way catalytic converter (TWC): a redox catalytic
converter coated with a noble metal catalyst on a
honeycomb ceramic carrier (or metal carrier),
The engine exhaust gas enters the three-way catalytic
converter through the exhaust pipe, and the gas uniformity
meets certain requirements (VI≥0.95) and enters the
for a period of time, the surface of the aftertreatment
system will reach more than 100℃. Please do not touch it to
avoid burns;
② Maintenance of exhaust system: to avoid the impact of
loose bolts on the exhaust system, it is necessary to check
whether the bolts of the exhaust system are loose regularly.
It is recommended to check once every 5,000 km or
maintain the exhaust together with each routine
maintenance of the air filter.
catalytic conversion component. After catalysis, the CH4,
CO and NOx in the exhaust gas will be converted by more
than 90%, engine the exhaust gas is discharged into the
atmosphere.
Reaction principle in three-way catalytic converter:
NOx reduction reaction: NO + CO → N2 + CO2 CO
Oxidation reaction: CO + O2 → CO2
HC oxidation reaction: HC + O2 → CO2 + H2O
The three-way catalytic converter is divided into two types:
cylinder structure and box structure, the schematic diagram
of the cylinder structure of the three-way catalytic converter
is shown in Figure 1, and the schematic diagram of the box
structure is shown in Figure 2.
5.3 Emission Control Precautions
When the vehicle exhaust aftertreatment system does not
work properly, the driver alarm system will give a prompt ,
and when the alarm is continuously ignored, the driving
performance limit will be activated and the vehicle will not
work normally . The alarm system and driveability limits are
designed to allow the user to resolve aftertreatment
malfunction errors in time. Ignoring the driver alarm system
and failing to correct errors in time, serious consequences
will be caused to the vehicle performance. Driver Alert
System: When a fault is detected, the driver performances
limitations system will be activated if it is not corrected in
time . The driver alarm system will notify the driver with a
visual alarm. Driving performance limit system :
① Primary drivability limiting system: after the primary
drivability limiting system is activated, the maximum output
torque at the speed point from the maximum torque speed
of the engine to the speed point where the governor fuel
cutoff starts is reduced to 75% of the exterior characteristic
torque.
② Severe driving performance limitation system: after the
Fig. 1 - Schematic diagram of barrel-type
three-way catalytic converter
severe driving performance limitation system is activated,
the vehicle running speed will be limited to 20 km/h (limp
mode),
Fig. 2 - Schematic diagram of box-type
three-way catalytic converter
Use and Maintenance of Special Parts for Natural Gas Vehicles
145
5.4 Instructions for Use of Natural Gas China VI Aftertreatment System
The list of components related to emission warranties shall be consistent with the information disclosure of engine, and the
minimum emission quality assurance period shall not be less than 5 years or 160,000 km
SN
List of Emission Key Components of China VI Natural Gas
1
Exhaust After
-processor
Assembly of Three
-way Catalytic
Converter
Aftertreatment
System
160,000 km / 5 years
(whichever comes first)
Exhaust-related
sensors
2
Minimum Warranty Period
Front and rear
oxygen sensor
5.5 Common Problems and Troubleshooting Methods
Fault Category
Description of Failure
Workaround
Communication failure of oxygen sensor
Check whether the oxygen sensor
pins are connected correctly.
Open circuit, short circuit or wrong
power supply of the oxygen sensor
Check the connection of
oxygen sensor line.
Failure of oxygen sensor
146
Maintenance of vehicle
V. Maintenance of vehicle
1 Inspection and replacement of working fluid
1.1 Engine oil change cycle and filling amount
① Weichai engine
First maintenance: 3,000-5,000 km
Regular maintenance:
Truck and tractor: 15,000~18,000 km or within 12 months from the date of last maintenance (whichever comes first).
Dedicated vehicle: 7,500~9,000 km or within 12 months from the date of last maintenance (whichever comes first).
Dump truck: 7,500~9,000 km or within 12 months from the date of last maintenance (whichever comes first).
Offset terminal tractor: 2,000~3,000 km or within 12 months from the date of last maintenance (whichever comes first).
Wide-body mining dump truck: 3,000~5,000 km or within 12 months from the date of last maintenance (whichever comes first).
Grade and standard No.
Assembly
Consumption (L)
Remarks
Name of medium
Service in winter Service in summer
Weichai WD415 series
19
Weichai WD615 series
24
Weichai WD12 series
24
Weichai WP6 series
20
Weichai WP7 series
24
Weichai WP10 series
24
Weichai WP12 series
27
Weichai Deutz 6-cylinder
engine
28
Diesel oil
GB111222006API diesel
oil standard CF
grade
CI-4 l5W-30
CI-4 l5W-40
Engine
Special note:
Diesel oil
GB111222006API diesel
oil standard CI
grade
CI-4 15W-30
CI-4 15W-40
E22, E201 and E32
products can use CF
grade oil.
The oil consumption in this table is theoretical value, and the amount of engine oil for maintenance and
replacement is subject to the fact that the oil level is between the high oil level and the low oil level of the engine oil dipstick
scale.
The oil used for the first and regular maintenance of vehicles must be approved by SHACMAN's overseas office (or project
team), and its grade is not lower than the special oil of Shaanxi Heavy Duty Automobile. If the specified or approved oil is not
used as required, the vehicle losses caused shall be borne by the responsible party.
Maintenance of vehicle
1.1 Engine oil change cycle and filling amount
② Cummins engine
First maintenance: No first maintenance requirement
Regular maintenance:
Truck and tractor: 15,000~18,000 km or within 12 months from the date of last maintenance (whichever comes first).
Dedicated vehicle: 7,500~9,000 km or within 12 months from the date of last maintenance (whichever comes first).
Dump truck: 7,500~9,000 km or within 12 months from the date of last maintenance (whichever comes first).
Offset terminal tractor: 2,000~3,000 km or within 12 months from the date of last maintenance (whichever comes first).
Wide-body mining dump truck: 3,000~5,000 km or within 12 months from the date of last maintenance (whichever comes first).
Grade and standard No.
Assembly
Engine
Consumption
(L)
ISM340E20，
ISM340E20,
ISM380E20、
ISM380E20,
ISM405E20，ISM440E20、
26.5 to 34
ISM405E20, ISM440E20,
ISMe34030
ISMe38530、
ISMe38530,
ISMe42030
37
Cummins ISMe450
Special note:
Name of medium
Diesel engine oil
GB111222006API diesel oil
standard CH
grade
Remarks
Service in winter Service in summer
CH-4 15W-30
CH-4 15W-40
Diesel engine oil
GB11122-2006API
CI-4 15W-30
diesel oil
Standard CI grade
CI-4 15W-40
Subject to dipstick
The oil consumption in this table is theoretical value, and the amount of engine oil for maintenance and
replacement is subject to the fact that the oil level is between the high oil level and the low oil level of the engine oil dipstick
scale.
The oil used for the first and regular maintenance of vehicles must be approved by SHACMAN's overseas office (or project
team), and its grade is not lower than the special oil of Shaanxi Heavy Duty Automobile. If the specified or approved oil is not
used as required, the vehicle losses caused shall be borne by the responsible party.
147
148
Maintenance of vehicle
1.1 Engine oil change cycle and filling amount
③ Other engines
First maintenance: 3,000-5,000 km
Regular maintenance:
Truck and tractor: 15,000~18,000 km or within 12 months from the date of last maintenance (whichever comes first).
Dedicated vehicle: 7,500~9,000 km or within 12 months from the date of last maintenance (whichever comes first).
Dump truck: 7,500~9,000 km or within 12 months from the date of last maintenance (whichever comes first).
Offset terminal tractor: 2,000~3,000 km or within 12 months from the date of last maintenance (whichever comes first).
Wide-body mining dump truck: 3,000~5,000 km or within 12 months from the date of last maintenance (whichever comes first).
Grade and standard No.
Assembly
Shanghai Diesel Engine
D6114 series
Shanghai Diesel Engine
SC9DT280Q3
Consumption
(L)
Name of medium
Service in winter
Service in summer
CF-4 15W-30
CF-4 15W-40
Above CJ-4 ade
CJ-4 15W-40
Diesel engine oil
22.4
24
GB11122-2006API diesel oil
Standard
Diesel engine oil
Engine
Yuchai YC6J220-52
20
GB11122-2006API diesel oil
Standard
Yuchai YC6J225N-52
Special note:
20
Special oil for natural gas vehicles of Shaanxi Heavy Duty Automobile
Special note: The oil consumption in this table is theoretical value, and the amount of engine oil for
maintenance and replacement is subject to the fact that the oil level is between the high oil level and the low oil level of the
engine oil dipstick scale.
The oil used for the first and regular maintenance of vehicles must be approved by SHACMAN's overseas office (or project
team), and its grade is not lower than the special oil of Shaanxi Heavy Duty Automobile. If the specified or approved oil is not
used as required, the vehicle losses caused shall be borne by the responsible party.
Maintenance of vehicle
1.2 Oil replacement cycle and filling amount of transmission gear oil
The effective service life of the compulsory insurance-free initial oil is 60,000 km for road vehicles (tractors and trucks), 30,000 km
for off-road vehicles (dump trucks, off-road tractors and dedicated vehicles) and 5,000 km for off-road wide-body mining dump
trucks, and the gear oil must be replaced after the mileage is used up.
The compulsory insurance-free initial oil shall be replaced according to the above standards. The effective service life of the noninitial oil is:
30,000 km for road vehicles (tractors and trucks), 15,000 km for off-road vehicles (dump trucks, off-road tractors and dedicated
vehicles) and 5,000 km for off-road mining dump trucks, and the gear oil must be replaced.
① Fast transmission
Grade and standard No.
Assembly
Consumption
(L)
Remarks
Name of medium
Service in winter Service in summer
Transmission
9JS135
10
9JS150
4.5
9JS180
14
9JS220
12.5
8JS100
12.5
8JS118
14
8JS130
13.5
7DS100
12.5
7DS118
15
12JS160
13.5
12JS200
15
16JS180T/200T/240T
14
SAEJ3062005GL-5
Heavy duty
hyperbolic gear
oil SAEJ3062005GL-5
75W-90
85W-90
When fitting the
power take-off,
add oil. The
front power
take-off is about
1L, the rear
power take-off
is 1 ~ 1.5L, and
the bottom
power take-off
is 3 ~ 3.5L.
Special note: The oil consumption in this table is theoretical value, and the amount of gear oil for transmission maintenance
and replacement shall be subject to the oil level observation port.
The oil used for the first and regular maintenance of vehicles must be approved by SHACMAN's overseas office (or project
team), and its grade is not lower than the special oil of Shaanxi Heavy Duty Automobile. If the specified or approved oil is not
used as required, the vehicle losses caused shall be borne by the responsible party.
149
150
Maintenance of vehicle
1.2 Oil replacement cycle and filling amount of transmission gear oil
② Other transmissions
Assembly
Engine
Consumption
(L)
ZFAK/S6-90
4.5
Rt9 series
4.5
16S221
hydraulic
mechanical
transmission
39
Name of medium
Gear oil
SAEJ3062005
GL-5
Special oil for
automatic
transmission
Grade and standard No.
Service in winter Service in summer
75w-90
GL-5
85w-90
GL-5
Remarks
When fitting the power take-off,
add oil. The front power take-off is
about 1L, the rear power take-off is
1 ~ 1.5L, and the bottom power
take-off is 3 ~ 3.5L.
SAEJ300 diesel engine oil
ALLSONMD356
0 automatic
ransmission
25
TRANSYNDTMDEXRON - Ⅲ
ALLSON4430
45
TRANSYND Allison ansmission
special oil
Special note: The oil consumption in this table is theoretical value, and the amount of gear oil for transmission maintenance
and replacement shall be subject to the oil level observation port.
The oil used for the first and regular maintenance of vehicles must be approved by SHACMAN's overseas office (or project
team), and its grade is not lower than the special oil of Shaanxi Heavy Duty Automobile. If the specified or approved oil is not
used as required, the vehicle losses caused shall be borne by the responsible party.
Maintenance of vehicle
1.3 Transfer case gear oil change interval and filling quantity
The effective service life of the initial oil loading without strong protection is: 60,000 kilometers for road vehicles (tractors and
trucks), 30,000 kilometers for off-road vehicles (dump trucks, off-road tractors and special vehicles), and 55,000 kilometers for offroad wide-body mine dump trucks. Gear oil must be replaced after the mileage is full.
The replacement of the first oil without compulsory protection shall be carried out according to the above standards.
The effective service life for replacing non-initial oil is:
For every 30,000 kilometers of road vehicles (tractors and trucks), 15,000 kilometers of off-road vehicles (dump trucks, off-road
tractors and special vehicles) and 55,000 kilometers of off-road mine dump trucks, gear oil must be replaced.
Dosage
(L)
Assembly
Transfer
actuator
VG1200
5
ZQC800
5
Media
Name
10
EQC1600
5
1 Oil plug (hole)
Winter use
2 Upper and lower
oildrain plugs (holes)
Summer use
3 Oil surface inspectionscrew
plug (hole)
Gear Oil
SAE J306-2005
ZQC2000
Brand and standard number
4 Ventilation plug
75W-90
85W-90
GL-5
Transfer case
Special note:
The amount of oil used in this table is the theoretical value, and the specific amount of oil used for
maintenance and replacement shall be subject to the oil level observation port or scale line.
The oil used for the first maintenance and regular maintenance of the vehicle must be approved by SHACMAN Overseas Office
(or Project Team), and its grade shall not be lower than that of SHACMAN Special Oil. If the designated or approved oil is not
used as required, the responsible party shall bear the vehicle losses caused.
151
152
Maintenance of vehicle
1.4 Oil replacement cycle and filling amount of axle gear oil
The effective service life of the compulsory insurance-free initial oil is 60,000 km for road vehicles (tractors and trucks), 30,000 km
for off-road vehicles (dump trucks, off-road tractors and dedicated vehicles) and 5,000 km for off-road wide-body mining dump
trucks, and the gear oil must be replaced after the mileage is used up.
The compulsory insurance-free initial oil shall be replaced according to the above standards. The effective service life of the noninitial oil is:
30,000 km for road vehicles (tractors and trucks), 15,000 km for off-road vehicles (dump trucks, off-road tractors and dedicated
vehicles) and 5,000 km for off-road mining dump trucks, and the gear oil must be replaced.
① STR series drive axle
Grade and standard No.
Consumption
(L)
Assembly
First front-wheel
Final drive
drive
7
Second frontwheel drive
11
Final drive
Wheel reducer
1.2 per
wheel
Name of medium
Gear oil SAE J3062005GL-5
Service in winter
75W-90
Service in summer
85W-90
STR series
drive axle
Middle axle
Final drive
11
Rear axle
Final drive
7
Wheel reducer
Special note:
2.5 per
wheel
The oil consumption in this table is theoretical value, and the amount of gear oil for axle maintenance and
replacement shall be subject to the oil level observation port.
The oil used for the first and regular maintenance of vehicles must be approved by SHACMAN's overseas office (or project
team), and its grade is not lower than the special oil of Shaanxi Heavy Duty Automobile. If the specified or approved oil is not
used as required, the vehicle losses caused shall be borne by the responsible party.
Maintenance of vehicle
1.4 Oil replacement cycle and filling amount of axle gear oil
② MAN single-stage deceleration axle
Consumption
(L)
Assembly
HD425
MAN single-stage
deceleration axle
Middle axle
Final drive
15
Rear axle
Final drive
11.5
Middle axle
Final drive
18.3
Rear axle
Final drive
14
Final drive
14.3
Name of medium
Grade and standard No.
Service in winter Service in summer
Gear oil SAEJ3062005GL-5
75W-90
85W-90
HD469
HD485
Special note: The oil consumption in this table is theoretical value, and the amount of gear oil for axle maintenance and
replacement shall be subject to the oil level observation port.
The oil used for the first and regular maintenance of vehicles must be approved by SHACMAN's overseas office (or project
team), and its grade is not lower than the special oil of Shaanxi Heavy Duty Automobile. If the specified or approved oil is not
used as required, the vehicle losses caused shall be borne by the responsible party.
③ MAN twin-stage deceleration axle
Consumption
(L)
Assembly
Front-wheel drive
Middle axle
MAN twin-stage
deceleration axle
Final drive
6
Wheel reducer
1.5
Final drive
14.5
Final drive
11.5
Middle axle Final drive
11.5
Rear axle
MAN small
main reducer
(for M3000) Rear axle
Final drive
Wheel reducer
Name of medium
Grade and standard No.
Service in winter Service in summer
Gear oil SAEJ3062005GL-5
75W-90
85W-90
9
3.5 per wheel
Special note: The oil consumption in this table is theoretical value, and the amount of gear oil for axle maintenance and
replacement shall be subject to the oil level observation port.
The oil used for the first and regular maintenance of vehicles must be approved by SHACMAN's overseas office (or project
team), and its grade is not lower than the special oil of Shaanxi Heavy Duty Automobile. If the specified or approved oil is not
used as required, the vehicle losses caused shall be borne by the responsible party.
153
154
Maintenance of vehicle
1.4 Oil replacement cycle and filling amount of axle gear oil
④ Other axles
Grade and standard No.
Consumption
(L)
Assembly
Name of medium
Service in winter
Off-road
Middle axle
Final drive
15
Rear axle
Final drive
11.5
Wheel reducer
5 per wheel
First rear axle
15
Second rear axle
11
Eq153 final drive
12
Gear oil SAE J3062005GL-5
75W-90
Service in summer
85W-90
CITIC axle
Dongfeng axle
Special note: The oil consumption in this table is theoretical value, and the amount of gear oil for axle maintenance and
replacement shall be subject to the oil level observation port.
The oil used for the first and regular maintenance of vehicles must be approved by SHACMAN's overseas office (or project
team), and its grade is not lower than the special oil of Shaanxi Heavy Duty Automobile. If the specified or approved oil is not
used as required, the vehicle losses caused shall be borne by the responsible party.
155
Maintenance of vehicle
1.5 Engine oil change
1.6 Fuel service condition
Clean and check the thread and sealing face of the oil drain
plug. If it is damaged, use a new one.
Unscrew the oil drain plug ① at the bottom of the oil pan,
Ambient temperature
Grade
Minimum temperature >4°C
0#
Minimum temperature >-5°C
-10#
Minimum temperature >-14°C
-20#
Minimum temperature >-29°C
-35#
Minimum temperature >-44°C
-50#
drain the oil completely, and then screw on the oil drain
plug.
Open the fuel filler cap, add oil from the fuel filler ②,
observe the scale of the dipstick until it meets the
requirements, and then install the fuel filler cap.
Note
The fuel added must conform to the provisions of Table
D.1 in Appendix D in the national standard GB176912018, and the vehicles conforming to China VI emission
standard must use fuel that meets China VI emission
standard.
1.7 Engine oil service condition
CK-4 grade of engine oil is used for China VI diesel engine.
①
Oil drain plug
Refer to the table below for viscosity selection according to
temperature.
SAE viscosity grade Service ambient temperature (°C)
Weichai
②
Fuel filler cap
Note
The engine oil should be replaced in a hot state. Pay
attention to the temperature of the oil when draining,
and be careful not to burn.
Waste engine oil should be put in designated places
and containers for recycling.
The replaced engine oil must be the engine oil of the
designated brand, and it is not allowed to be filled with
other brands of engine oil or mixed.
0W-20
-35～20
5W-30
-30～30
10W-30
-25～30
15W-40
-20～40
20W-50
-15～45
Note
Before starting the diesel engine, first check the oil
level in the oil pan.
Do not check the oil level when the diesel engine is
running.
Weichai special engine oil and Cummins special
engine oil are not allowed to be mixed with engine oils
from other manufacturers.
156
Maintenance of vehicle
1.8 Inspection and replacement of
transmission oil
1.9 Oil change period of retarder
The retarder oil (Fast FL-03A hydraulic retarder oil) is
changed every year or 150,000km, and it is necessary to
shorten the oil change period in harsh environment.
④
The Fast retarder oil (Fast FL-03A hydraulic retarder oil)
needs to be changed every year or 150,000km.
Voith retarder oil (special oil for Voith hydraulic retarder VR
Fluid S 10W-40) needs to be changed every year or
60,000km.
It is necessary to shorten the oil change period in harsh
environment.
Oil change method
Oil should be changed in the warm-up state. Unscrew the oil
③
①
②
plugs at the bottom oil drain and the rear oil drain first,
drain the oil in the transmission, clean the oil plug (the
magnet on the oil plug absorbs the iron filings accumulated
in the oil), replace the sealing ring and reassemble it,
unscrew the oil plug at the fuel filler, add new lubricating oil,
1
Rear oil drain
2
Bottom oil drain
and replace the sealing ring of oil plug at the fuel filler and
3
Side observation port
4
Fuel filler
reassemble the oil plug. After filling oil up, start the vehicle,
check the oil level after running the heat engine, and refill oil
if it is insufficient.
Warning
Inspection method
Unscrew the oil plug of the observation port on the
transmission side. The oil level is subject to the lower edge
of the observation port. If oil is insufficient, add it, as shown
Too low oil level may burn bearings or gears, while too
high oil level may cause overheating and oil leakage.
The vent plug should always be kept unblocked.
in the figure below.
When checking the oil level or changing the oil, please
pay attention to preventing burns!
Oil level
Incorrect
Oil level
Oil level
Incorrect
Correct
Maintenance of vehicle
1.10 Inspection and filling of urea
solution
There is a blue nameplate with filling instructions on the
front of the urea tank. Please do not remove it or smear it.
Please fill urea according to the filling instructions on the
blue nameplate. Be sure to use the urea solution for
vehicles in accordance with ISO22241 or GB29518 standards
at regular filling stations.
a.Turn off the engine before filling urea.
b.Open the filler cap in the direction indicated by the arrow
Fill urea
on the filler cap when filling.
c.In case of self-filling, use a special filling tube and keep it
clean. Please refer to the following figure for the operation
method.
d.When filling, prevent impurities from entering the urea
tank.
e.Stop filling when the liquid level reaches the filling port.
f.After filling, lock the filler cap in time to avoid the
emission of the vehicle failing to meet the standard due to
urea volatilization.
g.The consumption of urea is about 2,000km/ tank,
depending on the actual situation. When the urea level is
lower than 10% or the urea level light shows yellow, urea
should be replenished in time.
h.During the normal maintenance interval, vehicles need to
Install the urea tank cover
and its protective cover
be added with urea solution, and the liquid level should not
be lower than 10%, and the consumption of urea is about
2,000km/ tank, depending on the actual situation.
i.It is suggested that urea should be supplemented as
appropriate while adding fuel.
Warning
a.This model needs to consume urea solution to reduce
emissions. If urea solution is not used, it may be illegal.
b.It is forbidden to use substandard urea solution or add
other liquids such as water to urea solution, so as to
avoid insufficient engine power.
c.It is forbidden to fill urea solution into the fuel tank.
d.The driver alert system monitors the vehicle's urea
stock, urea quality and urea consumption in real time
through the urea tank sensor and engine ECU. When it is
detected that the urea stock is low, the urea quality is
wrong and the urea consumption is low, the driver alert
system will be activated. If the warning is ignored
continuously, the driving performance limiting system
(speed limit and torque limit) will be activated, thus
affecting the vehicle's performance.
Remove the urea tank lock cover and its
protective cover
e.Be sure to keep the sales vouchers of urea solution
issued by all regular filling stations/regular sales shops
during the warranty period. If they cannot be provided,
the Company will not bear the relevant warranty
responsibilities if the emission-related parts fail or are
damaged.
157
158
Maintenance of vehicle
It is forbidden to open the radiator blowoff valve and the
1.11 Coolant replacement
pressure cover on the expansion tank when the radiator is in
④
①
a high temperature state to avoid being scalded.
Long-term anti-freezing and anti-corrosion coolant should
be used, and it is forbidden to add tap water or hard water
from wells and rivers.
Coolant discharge
Coolant replacement cycle is 2 years. The lower part of the
radiator water chamber is provided with a drain cock, which
is tight clockwise and loose counterclockwise. The
tightening torque is 2N.m~3N.m, and the breaking torque is
③
②
10.5N.m. When discharging, the filler cap of the expansion
tank can be removed to facilitate emptying. Pay attention to
Lowest level warning sign
drain the coolant in the radiator, engine and transmission oil
cooler, and disconnect the hose for discharge. After draining
the coolant, remove the scale on the radiator. Clean
softened water should be used for cleaning to prevent
accelerated scale generation and corrosion of radiator water
pipes.
Regularly remove weeds, flying insects, gravel, dust and
grease from the core of radiator and intercooler to prevent
blockage.
Regularly check whether the cooling system pipe clamp is
loose according to the maintenance requirements, and
tighten it if necessary.
It is forbidden to apply negative pressure exceeding -20kpa
When the liquid level drops below the lower observation
or positive force higher than 200kpa to the inside of the
window, the coolant should be replenished in time. When
cooling system.
the alarm indicator light
of low coolant level on the
instrument lights up, the coolant must be replenished.
Coolant filling after emptying
When the engine is cold (the coolant temperature is not
higher than 50°C), open the filler cap ①, and slowly fill the
expansion tank with the required coolant to the edge of the
Engine
WP13H
WP15H
X12
Z14
neck (visually overflowing), and the liquid level can be
observed from the upper observation window. After free
filling of the vehicle, degas and replenish coolant in strict
Coolant
Long-term anti-freezing and anti-corrosion coolant
(year-round use)
Coolant
grade
High-load all-year long-term anti-freezing and
anti-corrosion coolant-No.35 (the coolant is selected
in special areas according to that the freezing point
is about 10° lower than the local temperature)
accordance with the instructions on sign ③. After filling, the
filler cap must be tightened to prevent failure.
Observe the coolant level regularly through the filler ① and
the observation window according to the maintenance
requirements (the vicinity of the filler neck is level with the
MAX line ④).
Except for vehicle maintenance, it is forbidden to open the
Consu
mption (L)
57
63
43
45
pressure cover of the cooling system (behind and above the
vent pipe ②).
Please use the original antifreeze of the vehicle
manufacturer or the antifreeze brand recommended by the
OEM, and do not mix different brands of antifreeze.
Remarks
Retarder models need to be added with about 15L
coolant;
The values here are for reference, subject to the actual
vacuum filling to the MAX line.
159
Maintenance of vehicle
1.12 Inspection and replacement of
steering hydraulic oil
Replace the filter of the steering fluid reservoir
Replace the filter of the steering fluid reservoir when
replacing the steering hydraulic oil.
Inspect the liquid level of steering fluid reservoir.
a.Clean the surface of the fluid reservoir before unscrewing
a.During the use of the vehicle, check the amount of fluid in
the fluid reservoir cover.
the fluid reservoir and whether the fluid has deteriorated
b.Open the fluid reservoir cover, and press and release the
regularly. If any bad condition is found, add or replace it in
locking device of the filter.
time.
c.Lift the old filter and put your finger under the central
b.When checking the liquid level, clean the surface of the
hole of the filter so that impurities in the filter will not fall
fluid reservoir first.
into the fluid reservoir.
c.The normal height position of fluid should be between
d.Replace with the new filter:
two marking lines MIN and MAX.
According to the correct positioning, press and ensure that
the locking is reliable.
Replace the steering hydraulic oil
The steering hydraulic oil is replaced for the first time after
the vehicle runs for 2,000 to 4,000km, and then replaced
every13,000 to 15,000km, or depending on the specific
situation (deterioration of oil, high impurities, etc.).
Replacement method:
a.Jack up the steering axle.
b.Loosen the steering gear oil outlet connector. Turn the
steering wheel to the limit position on the left and right 2 ~
3 times to ensure that the oil is drained.
c.Clean the surface of the fluid reservoir, open the upper
cover of the steering fluid reservoir, fill the specified
hydraulic oil into the fluid reservoir until it is higher than the
upper cover of the filter, and run the engine at idle speed
1.13 Drive axle lubricating oil
On vehicles with a single-stage speed reducer, the final
drive is filled with lubricating oil to the edge of the oil level
hole, and the hub bearing is maintenance-free.
The first maintenance is 5,000km, and the lubricating oil
should be changed every 120,000 km after the first
maintenance. The maintenance interval longer than the
standard maintenance can be selected, and special
lubricating oil is required.
Lubricating oil filling quantity is as follows:
for 2 minutes.
d.Turn the steering wheel to the limit position on the left
Model
Middle axle
Rear axle
and right (note that the steering wheel shall not stay in the
440
13.7L
13.5L
to add fluid to the fluid reservoir until the liquid level
469
14L
11.5L
exceeds the upper cover of the filter, without lowering or
485
/
14.3L
limit position for more than 5 seconds), and then continue
bubbles.
e.The oil level height should be between the upper and
lower marking lines.
160
Maintenance of vehicle
Replace lubricating oil
Lubricating oil grade
With load vehicle gear oil GL-5, the viscosity grade of
lubricating oil depends on the ambient temperature:
Tropical area (above +30°C): 85W-140-GB13895-1992;
When the lubricating oil needs to be replaced, remove the
oil drain plug ② to drain the lubricating oil. If there is a seal
washer, the seal washer must be replaced.
Normal temperature area (-10°C-+30°C): 85W-90-
1.14 Filling windshield washer fluid
GB13895-1992;
Cold area (-30°C--15°C): 80W-90-GB13895-1992;
Alpine region (below -30°C): 75W-GB13895-1992.
1
2
The filling port of windshield washer fluid reservoir is
Inspect the lubricating oil level
located at the bottom right side of the front cover. Before
If there is lubricating oil leakage in the drive axle, or after a
filling, open the front cover first.
long mileage, it is necessary to check the lubricating oil level
as follows:
Clean around the filler plug ①;
Note: The washer fluid should be glass water, and water
Remove the filler plug ① and check and confirm that the
filling is forbidden.
oil level reaches the edge of the filler hole;
If the vehicle is used in cold area, the washer fluid should
Fill it up when necessary;
be low-temperature glass water.
Install the filler plug. If the filler plug has a seal washer,
After filling the washer fluid, the spraying pot should be
the seal washer must be replaced.
covered tightly.
Avoid dry scraping of wiper and glass.
Maintenance of vehicle
2. Cleaning
2.1 Vehicle cleaning
2.2 Polishing and waxing
Paint
Cleaning engine
After a period of time, the paint will lose its luster. By
Use hot water when cleaning the engine and use the high-
waxing the cab regularly, the process can be delayed. If the
pressure washer carefully to avoid splashing water on the
cab paint becomes dull, moderate polishing is required.
electrical components.
Follow product manufacturer's recommendations and
general guidelines. First, clean the vehicle as described
Cleaning chassis
above and dry it. Then use a polishing agent or deep
When the chassis and cab are dirty, clean them as soon as
detergent with a small amount of abrasive ingredients. Only
possible. Be especially careful when cleaning axle and other
clean cloth/rag can be used when liquid wax is applied.
moving parts with high pressure, because water and dust
may be brought in by pressure. If this problem occurs,
Maintain moderate pressure throughout the operation.
repaint the parts with lubricant with special care. Be careful
not to splash water directly on the seal/gasket.
Chrome plated parts
Cleaning cab
clean the chrome plated parts. Use concentrated washing
Firstly, use the cleaning agent of other parts of the cab to
The vehicle should be cleaned when it becomes dirty,
liquid to remove the film layer. Then wax the chrome plated
especially when the road surface is sprinkled with salt in
parts, with the same wax used for other parts of the cab.
winter and the weather is wet; otherwise, it will cause
Never use a detergent containing abrasives to clean chrome
corrosion.
plated parts.
Cleaning method
In order to avoid paint damage and achieve better cleaning
effect, the following aspects should be paid attention to:
The high-pressure cleaning should be used as much as
possible. Dust that cannot be removed by this method
should be carefully wiped with cloth or sponge, and the
most suitable cleaning agent should be used. If you brush
without using high-pressure cleaning first, or use poorly
maintained brushing equipment (broken or dirty brush,
etc.), there is a risk of scratching the coating.
2.3 Cleaning interior trims
Knitted fabric
Firstly, perform vacuum cleaning to remove floating ash.
Then use foam detergent to remove the remaining dirt.
Avoid scratching with a hard brush. After all the knitted
fabric surfaces are treated, let them dry overnight.
Thoroughly clean with vacuum to remove dry foam and
remaining dirt.
For seats, sleepers and knitted mattresses, water and
synthetic detergents can be used. However, do not use
Cleaning agent
It is recommended to use different detergents for different
types of dirt. Be sure to follow the manufacturer's
recommended instructions on the scope of use, dosage and
maximum temperature. Avoid chemicals drying on the
coating.
Avoid using strong alkaline cleaning agents (PH >12). Do
not clean the vehicle in direct sunlight. If the temperature is
above 30°C, wash the vehicle with clean water before using
chemical cleaning agent. Clean small areas and rinse them
water or water-soluble detergent to clean the roof liner and
siding.
Leather
Adopt vacuum cleaning. Use special cleaning agent for
leather interior.
Roof liner and siding
Do not use water or water-based cleaning agents.
Plastic
Do not scratch or rub. Never use strong solvents such as
gasoline, petroleum solvent oil or ethanol.
with water to avoid long-term drying or chemical killing.
Note: When cleaning the front cover and the rear of the
cab, avoid spraying water obliquely upward with a water
gun to prevent water from spraying from the front grille
to the front electrical components and the rear
ventilation holes from entering the cab.
Before cleaning the outside of the cab, close the doors
and windows, sunroof, toolbox cover, and front cover,
etc. Prevent water from entering the cab.
161
162
Maintenance of vehicle
3. Air filter
3.2 Maintenance of ordinary air filter
3.1 Air filter maintenance
When the air filter reaches the service life, the signal will be
transmitted to the instrument panel of the cab through the
sensor, and the alarm on the instrument panel will show red
or the alarm indicator light will light up, so the air filter
element should be maintained at this time;
If the air filter blocks the alarm light from lighting up, clean
the dust collection device and remove the dust on the filter
element.
Pull the air filter end cover buckle or twist the butterfly nut,
remove the end cover, clean the dust in the end cover and
wipe it with a clean rag.
Note: For the air filter with side elevation arrangement, it is
necessary to turn over the cab first.
Alarm light for air
filter blocking
If the maintenance indicator light does not light up for a
long time, it is recommended to carry out maintenance
according to the following mileage:
When the road is dominated by national highways and
provincial highways, it should be maintained every 40,000
km;
When the road is mainly expressway, it should be
maintained every 60,000 km.
Note: This maintenance refers to replacing the filter
element kit, and it is forbidden to use the main filter
element again.
Gently pull out the main filter element, and use dry
compressed air with a pressure not higher than 500kPa to
blow clean the inner and outer surfaces of the filter element
along the diagonal direction, preferably from the inside out.
And clean the sealing end face.
163
Maintenance of vehicle
Put the lighting tools (such as mobile phones and flashlight
Safety filter element: Safety filter element can only be
lamps) into the filter element, and then check the external
changed but not cleaned. The main filter element is
surface for cracks, perforations or other damage.
replaced after it is cleaned 5 times or damaged, or the
safety filter element is replaced every two years. If the
indicator light turns on immediately after the main filter
element has been cleaned, the safety filter element shall
be replaced.
Installation sequence:
① Gently insert the safety filter element into the air filter
shell, assemble the sealing ring with radial seal structure
and adjust it, and fasten the axial seal structure with heavy
series hexagon nut.
② Gently insert the main filter element into the air filter
shell, assemble the sealing ring with radial seal structure
and adjust it, and fasten the axial seal structure with light
series hexagon nut.
③ Install the cover with the dust discharge valve (its mouth
must face backwards or downwards), and fasten the buckle
or tighten the nut on the central bolt.
End cap
Note: It is forbidden to tap one end of the filter element
on the vehicle tyre to shake off the dust inside. This
method cannot remove all the dust.
It is strictly forbidden to use filter elements with cracks
and perforations; otherwise, it will lead to abnormal
engine wear.
Sealing ring
Main filter element
Safety filter element
Check the sealing ring. If the sealing ring is damaged or any
other damage is found in the filter element, it must be
replaced.
Install safety filter element
164
Maintenance of vehicle
3.3 Maintenance of oil bath type air
filter
3.4 Maintenance of desert air filter
Desert air filter is composed of shell, cyclone tube coarse
filter, main filter element and safety filter element. Every
time the vehicle runs for one week, squeeze the dust bag to
discharge dust, and check the integrity of the dust bag.
Maintenance of coarse filter
① Remove the main filter element according to the
maintenance method of the main filter element, and remove
the safety filter element at the same time, and disconnect
The new vehicle is not filled with engine oil before leaving
the factory. When it is put into operation, it must be filled
with 4L engine oil first, and the viscosity of the engine oil
must be similar to that used in the same period of the
engine.
When the vehicle runs for 5,000 km or is continuously used
for 80-150h, the oil pan should be removed for inspection.
When the oil pan is shaken and the oil is not easy to flow, it
is necessary to clean the filter element assembly and replace
the oil.
Under particularly harsh use conditions, it is necessary to
check, clean and change the oil every day.
The filter element should be maintained or replaced
regularly, and the seal should be good. The method of
maintaining and replacing the filter element is the same as
that of ordinary air filters.
the air outlet from the engine or plug it with clean objects;
② Open the clip and remove the lower cover to clean the
surface dust;
③ Use compressed air to repeatedly blow off dust
accumulated in various parts;
④ Install the components in reverse order, and check
whether the installation is in place.
The filter element should be maintained or replaced
regularly, and the seal should be good. The method of
maintaining and replacing the filter element is the same as
that of ordinary air filters. Warning: Users should use the
same model of filter element produced by the original
factory; Never use unqualified filter elements; otherwise,
abnormal engine wear will occur.
165
Maintenance of vehicle
4. Urea system
Note
4.1 Urea system maintenance
Do not disconnect the connecting joints at will;
a.It is suggested that the filter screen of urea tank and
otherwise, foreign objects will bypass the filtering device
sensor should be cleaned once every year, and the vent
and directly invade the system.
valve of urea pipe and urea tank should be cleaned once
If it is necessary to disconnect, it is necessary to clean
ever y six months. The cleaning method is to use
the interface and its adjacent parts before disconnecting,
compressed air to empty the residue after washing with hot
and protect the joints, such as installing a dust cover to
water with appropriate pressure.
prevent foreign objects from entering the pipeline or
b.Replacement cycle of urea pump filter element: 60,000 km
metering pump.
or 6 months, whichever comes first.
If the vehicle is not used for a long time, a new urea
c.The bottom of the urea tank is provided with a liquid
solution should be replaced before it is used again.
discharge port, which can discharge precipitate regularly.
d.If you need to replace parts, please go to the exclusive
store or service station designated by Shaanxi Heavy Duty
Automobile.
5. Exterior light
5.1 Routine maintenance of light
Vent valve
Keep the light surface clean, and wipe dust and acid
liquor on the surface (if found) in time. First wipe them with
Filling port
a piece of cloth dipped in soda water and then wipe them
with a piece of cloth washed with clean water.
Inspect the light housing and lampshade for sediment,
and clean them in time.
Inspect the bulb in time if the light luminance is found
to be decreased and replace the bulb with degraded
performances if necessary.
5.2 Replacing bulb
The bulb shall be selected in strict accordance with the
model and power for design configuration, which shall not
be changed without permission.
Turn off the power to replace the bulb, and prohibit live
replacement. When replacing, avoid touching the lightemitting surface of the bulb and polluting the light-emitting
surface to reduce efficiency.
2
1
3
5
4
166
Maintenance of vehicle
1
Position light/turn light/daytime running light
2
High beam light
3
Low beam light
4
Auxiliary high beam light
5
Front fog light
Layout 2: Rear battery box
Brake light
Reverse light
Rear fog light
Turn light
6. Battery
6.1 Battery box layout
Layout 3: Side stacked battery box
6.2 Battery maintenance requirements
Maintenance-free battery with liquid seal needs to be
recharged if its storage period exceeds three months.
The air outlets on both sides of the upper cover of the
battery should be always checked to prevent them from
being blocked by dust and ice water, etc., so as to avoid
Layout 1: Side battery box
deformation of the battery housing.
The battery should be kept away from sparks and high
temperature, and it is forbidden to charge the battery in a
confined space.
When the battery is often exhausted, after checking that the
battery is normal, it is necessary to check whether there is
electric leakage in the circuit of the vehicle.
Battery charging
Maintenance of vehicle
6.3 Battery charging
Note
Be sure to keep the terminal clamp and battery surface
clean and dry.
Lubricate the underside of the battery terminal clamp
with a small amount of acid-resistant grease.
Only use commercially available detergents to clean the
battery housing.
Note
Before using the battery, measure the terminal voltage
of the battery. If the voltage is above 12.6V, it can be
used directly. If the voltage is low, it should be recharged
before use.
Charging with direct current, the positive pole of power
supply is connected with the positive pole of the battery,
and the negative pole of power supply is connected with
the negative pole of the battery.
The battery is charged by constant voltage charge, the
charge voltage is 14.4V±0.5V, and the maximum allowable
charge current is 0.5VC20 A (C20 is the capacity of the
battery for 20 hours), until the charge voltage no longer
rises, and the charge current approaches zero and remains
unchanged for 2-3 hours.
The vehicle charging regulator is limited in the range of
13.8 V ~ 14.2 V. In case of exceeding this range, it is easy
to damage the service performance of the battery.
When the battery is connected and installed, the "+" and
"-" terminals of the battery are respectively connected
with the positive and negative connecting lines of the
vehicle. Connect the positive connecting line first, and
then connect the negative connecting line. It is
suggested that after the battery is installed, a layer of
vaseline should be coated on the connecting terminal to
prevent the connecting terminal from corrosion.
Battery maintenance
There is a state of charge indicator (electric eye) on the
Dirty battery terminals and battery surfaces will lead to
top of the battery. See the description on the battery
electric leakage. This may cause the battery to discharge.
label for state of charge details.
Do not use any detergent containing fuel. Detergents
The battery must not be tilted or inverted.
containing fuel will corrode the battery housing.
Battery replacement
For vehicles with BMS (Battery Management System), be
sure to replace the two batteries together. Otherwise, the
on-board computer cannot correctly judge the charging
state. After replacing the battery, the BMS self-learning
process is carried out again. Shaanxi Heavy Duty
Automobile suggests that you use the battery of the same
model as the original vehicle for replacement.
167
168
Maintenance of vehicle
7. Braking system
7.1 Inspection of travel of brake pedal
Gently step on the brake pedal and check its free travel.
The normal value is (30 ~ 40) mm.
There should be no unsmoothness when stepping on the
brake pedal to the end.
There should be an exhaust sound when the pedal is
relaxed.
Front axle drive wheel
7.4 Check for stagnant water
Check whether there is water in the air reservoir every
week (check after vehicle shutdown every day in cold areas
in winter).
Inspection method: Pull the blowoff valve under the air
reservoir or the steel wire hook under the air cylinder frame.
If there is water accumulation, drain it in time.
7.2 Replacing air handling unit
The drying cylinder of the air handling unit should be
replaced once a year or after driving for 100,000km
(whichever comes first), and the replacement cycle should
be appropriately shortened for vehicles running in harsh
working conditions for a long time (such as humid air and
mountainous areas).
7.3 Clearance adjustment of wheel
brake
a.Adjustment of drive wheel brake clearance: The brake shall
be adjusted when the brake cylinder travel (piston rod
travel) exceeds 30mm.
b.Adjustment method: Turn the screw on the clearance
adjustment arm inward until the wheel locks, Back off
the adjustment screw again and hear three sounds
c.Adjustment of the front axle brake clearance:
Rotate hexagon bolt ② at the worm shaft end until the
wheels are locked, and then reverse the bolt until three
sounds are heard.
Note
One month before the frost in winter every year, focus on
checking the water accumulation in the air reservoir, and
replace it with a new drying reservoir at this time to
ensure the air drying effect, avoiding that the water
accumulated in the air discharge path will freeze.
Maintenance of vehicle
Clutch wear travel
8. Clutch
8.1 Clutch fluid inspection
Check whether the liquid level in the liquid storage tank of
the clutch master cylinder is between the "MAX" and "MIN"
marks. If the liquid level is too low, fill the brake fluid
through the filler to make the liquid level reach a suitable
height.
DOT3 or HZY3 synthetic brake fluid is adopted for the clutch
hydraulic system, and must be cleaned up during
maintenance, and the same batch and brand of brake fluid
shall be used. If there are no special instructions, the brake
fluid for clutch control generally needs to be replaced every
year or 24,000km.
Note
This indicator needs to be initialized after the initial
installation of the slave cylinder and every time the
clutch friction plate is replaced.
In any case, it is not allowed to remove the wear
indicator or pull the indicator bar out of the base.
Don't press the indicator bar inward with excessive force,
which may cause internal damage and leakage.
8.2 Clutch wear indication
When the clutch slave cylinder is equipped with a
mechanical wear indicating device, the wear of the friction
plate can be reflected by the wear indicating device.
After the initial installation, both the indicator bar and the
gasket are pushed backwards by the piston. In the
initialization operation, the gasket is pushed to contact with
the base along the indicator bar, which is the initial position.
With the wear of the clutch, the indicator bar and the gasket
are pushed backwards, and the distance between the gasket
and the base reflects the wear of the clutch friction plate (for
example, clutch wear 14mm× lever ratio of the release fork
2= movement of the wear indicator gasket 28mm). That
means that the friction plate needs to be replaced.
169
170
Maintenance of vehicle
8.3 Clutch exhaust
Remove the dust cap of the booster bleed screw and
9. Fuel supply system
9.1 Replacing the coarse fuel filter
unscrew the bleed screw for 1/4 turn.
Slowly depress the clutch pedal to the maximum travel
position.
When the pedal reaches the maximum travel position,
lock the screw immediately.
Then slowly release the pedal and return to the upper
limit position.
Repeat the above operation until no bubbles appear.
Note
Check the brake fluid level in the oil pot every 10 cycles
to prevent air from entering the pipeline.
Check the travel of the pushrod of the booster cylinder
every 10 cycles (the exhaust screw is locked and the
pedal is pressed to the bottom).
The loosening and locking of the exhaust screw and the
slow stepping and releasing of the pedal must be well
coordinated to achieve the ideal exhaust effect.
The operating frequency of the driver's rapid and
continuous stepping on the clutch pedal should not be
higher than the response frequency of the system;
otherwise, too much brake fluid will be transferred from
the oil pot of the master cylinder to the booster cylinder,
which will cause the travel of the booster cylinder to be
Loosen the drain plug at the bottom of the coarse filter
and drain the waste oil.
Use the special filter wrench to remove the coarse filter
and the water collecting cup.
Apply oil to the gasket of the water collecting cup, put it
on a new coarse filter, and tighten the drain plug by hand.
too large. At this time, if it exceeds the normal travel
Apply oil to the gasket of the coarse filter, and tighten
application range of the booster cylinder, the load will be
the coarse filter on the base with a tightening torque of
discharged and the excess brake fluid will be discharged
20N.m.
from the air outlet.
Start the engine to ensure that the coarse filter has no
leakage.
Note
Be careful not to let the fuel flow out and damage the
electrical components.
Don't miss the gasket.
Maintenance of vehicle
9.2 Drainage of coarse fuel filter
Observe the water collecting cup at the bottom of the
coarse filter and drain the standing water regularly. Loosen
the bottom waterproof plug by hand until clean fuel flows
out, and then tighten the waterproof plug.
9.3 Fuel tank blowdown
Drain impurities and condensed water from the bottom
of the fuel tank once a year.
10.2 Routine maintenance of air
suspension
Ensure that the airbag does not contact hydraulic oil,
lubricating oil or solvent for a long time.
The vehicle shall not overload by 10% even in the fine
pavement such as expressway and Class 1 highway.
Please conduct maintenance as required to ensure the
service life of air suspension.
Place a container under the oil drain plug at the bottom
of the fuel tank.
Loosen the plug and screw it out several times to let
impurities flow out of the.
The height control mechanism is an important component
and has a direct impact on vehicle safety, so users shall not
disassemble or change settings without permission to avoid
safety accidents.
9.4 Tightening of fuel tank fastening
tape
The airbag and air pipeline shall be well protected during
welding and spark cutting of the vehicle.
In order to prevent the fuel tank from moving, the fuel tank
bracket and the fastening tape bolt must be checked and
When users set up the superstructure, any superstructure
tightened when the vehicle reaches 2,000 km, and the
part shall not affect the motion space of height regulating
tightening torque of the fastening tape bolt is 40±8Nm.
mechanism, and there shall be no obstacles
Check the fuel tank for displacement, etc. Check the fuel
within 30mm of the circumference of the airbag (when the
tank for oil leakage.
suspension height is at the initial position).
Air spring
10. Axle and suspension system
10.1 Inspection of disc brake friction plate
Disc brakes are equipped with wear alarm sensors. When
the friction plate is worn to the limit, the driver will be
reminded to make changes through the instrument.
When manual inspection is required, it is necessary to
remove the tyre for inspection.
Thickness inspection of friction plate: The thickness of
worn material part of friction plate shall not be less than
2mm.
In order to give full play to the performance of air
suspension, the suspension should be checked routinely
every day or before driving.
Inspection contents
Visually check whether the air spring airbag is twisted,
deformed or wrinkled.
The suspension height is normal and the system has no
leakage.
171
172
Maintenance of vehicle
10.3 Inspection method of air
suspension
10.5 Height valve adjustment
Height valve adjustment has been completed when the
vehicles leave factory. Unless the connecting rod mechanism
When vehicles are used for the first time, the vehicles
of height valve is accidentally damaged during the use of
under good conditions are parked on the level ground. Four
the vehicle, users shall not adjust the connecting rod
easily measured points (these points should be lower than
mechanism of height valve without permission.
the lowest point of the airbag) should be selected all around
the suspension, and the distance between the point and the
If necessary, the adjustment of the height valve shall follow
frame is measured and recorded. In the subsequent
the following principles:
inspection, it is only necessary to park the vehicle on a level
The distance between the lower wing surface of the frame
ground and measure the distance from the four points to
and the center surface of the axle is 200mm, and part ②
the frame. If the value changes little, the suspension height
should be horizontal.
is normal and there is no leakage for the system.
There is a boss mark on the swing shaft (part ①) on the
If the vehicle fails to pass the inspection, it is required to
find out the reason and eliminate the fault, and repair if
height valve, and the boss should be placed directly above
when installing part ②.
necessary.
The recommended effective length of part ② is200mm.
10.4 Regular inspection
When the height is adjusted well, the recommended angle
Safety inspection shall be performed regularly (Interval
between part ② and part ③ is90°.
mileage2,000 ~ 3,000km). During inspection, the vehicle
shall be parked on a clean and flat road and braked. The
The pin shafts between the connecting rods should be
inspection items are as below:
parallel to each other, and rotate sensitively, without
No looseness is found in fasteners.
sticking.
At the air pressure of no less than 6 bar, the air spring is
inflated normally and the airbag on both sides of the same
In the process of axle bounce, the larger the swing travel of
axle is of the same degree of integrity; the air spring is free
part ②, the better (the limit swing angle is ±45°).
of fold, wear, damage and inappropriate bulging and there
is a surrounding space of 30 mm or more.
The shock absorber is free of oil and damage and works
properly. A simple judgement method is as below: When
there is no obvious fault, the heat of the shock absorber
after running indicates normal operation. Be careful, it may
be hot.
No crack is found for all parts and welds.
Note:
The bearing capacity of the air suspension is
selected according to the rated load requirements of the
front axle and rear axle of the vehicle. When the vehicle is
driving in poor road conditions, overload should be
avoided as far as possible. Even when driving on
expressways or Class 1 highways, the overload load cannot
exceed 10% of the maximum bearing capacity of the air
suspension.
Users (including service stations without training and
calibration equipment) are not allowed to adjust the swing
length of the height sensor by themselves; otherwise, the
system may not work normally, or the vehicle may run at
an abnormal suspension height for a long time, resulting
in the damage of airbags and shock absorbers.
1
2
3
Maintenance of vehicle
10.6 Tightening of fastening bolt for
key parts of suspension
11. Steering system
11.1 Inspection and adjustment of front
wheel toe-in
Before vehicle traveling, the U-bolts of front and rear leaf
springs must be firmly fastened to avoid early abnormal
Positioning parameters
damage to the leaf spring. Before vehicle traveling, the
Front axle positioning parameters mainly include kingpin
fixing bolts of all bearing parts of the suspension system
inclination angle, kingpin caster angle, wheel camber and
must be fastened completely, including front and rear
toe-in, and other parameters are not adjustable except toe-
suspension leaf spring brackets, leaf torsion spring brackets,
in.
V-push brackets, air springs, airbag brackets, shock
absorber brackets, stabilizer bar brackets, U-bolts, thrust
The total toe-in of the front wheel shall meet the
bars and other positions, so as to improve the operating
requirements of 1.5mm±1mm or 6′±4′.
reliability of the vehicle and the service life of all
components and parts.
At the beginning of the running-in period of a new vehicle,
the bolts and nuts at key points of the front and rear
Check whether the toe-in is within the specified range
during vehicle maintenance. If not, it should be adjusted in
time.
suspension systems, such as leaf spring brackets, leaf
torsion spring brackets, V-push brackets, air springs, airbag
brackets, shock absorber brackets, stabilizer bar brackets,
U-bolts, thrust bars and other positions, should be
11.2 Measurement of front wheel
toe-in
tightened according to the torque values specified in the
Operating Manual.
Four-wheel positioning equipment measurement
Measure according to the requirements of equipment
use.
After running-in of a new vehicle and when starting to use
Manual measurement
under heavy load, the bolts and nuts of key parts of the
In the absence of measuring equipment, manual
front and rear suspensions should be tightened again
measurement can be used:
according to the specified torque value under full load, and
Park the vehicle on a flat ground, lift the front axle so
should be tightened again for 2 ~ 3 times after driving
that the wheels are off the ground, and put the wheels in a
mileage of about 200 ~ 300 km, so as to really tighten the
straight driving position.
bolts and nuts of key parts of the front and rear
suspensions.
When the vehicle travels every 8,000 ~ 10,000 km, the bolts
and nuts at the key parts of the front and rear suspensions
should be tightened in the fully loaded state according to
the specified torque value requirements.
Make a mark in the middle of the tread pattern of the
left and right tyres, measure A value at the right ahead of
the mark, and then measure B value at the right astern of
the mark.
The total toe-in is the B-A value.
173
174
Maintenance of vehicle
11.3 Adjustment of front wheel toe-in
Warning
Loosen the clip bolt on the front axle tie rod, turn the tie rod
Tyre pressure should be kept within the specified range. If
body or adjusting sleeve, and adjust the length of the tie
the tyre pressure is too high, it will accelerate the wear
rod to change the toe-in value.
and shorten the tyre life; If the air pressure is too low, it
will produce cracks and affect the driving speed of the
After proper adjustment, tighten the clip bolt according to
vehicle, increasing fuel consumption.
the specified torque.
M12：（70~90）N·m
12.2 Tyre wear inspection
M12: (70~90) N·m
M14：（150~180）N·m
In the process of tyre use, different positions of tyre tread
M14: (150~180) N·m
will cause different degrees of wear. Therefore, the tread
pattern depth and tread condition of all tyres throughout
the tyre width should be checked regularly.
The tyre is marked with a tread wear indicator (as shown by
the arrow). When the tyre is worn flush with the tread, the
tyre reaches the minimum tread pattern depth, and the tyre
should be replaced before reaching the minimum tread
pattern depth.
Adjusting sleeve
1
12. Wheels and tyres
12.1 Regular inspection of tyres
Check the tyre tread for scratches, cracks or abnormal
wear.
Check whether the tyre tread is embedded with metal
12.3 Tyre service life
pieces, stones and other sundries, and remove them in time
Tyres will age even if they are not used frequently or at all.
if any.
Operation and driving safety will decrease with tyre aging.
Check whether there are stones and other sundries
between the dual tyres of rear wheel, and remove them in
Therefore, tyres with an age of more than 3 years should be
replaced. This period also applies to spare tyres.
time if any.
Check the tyre pressure.
The tyre age can be known from the date of manufacture ①.
The tyre pressure shall be measured when the tyre is at
The first two digits indicate the calendar week of the
room temperature, and shall meet the following
production date, and the first calendar week of the year
requirements:
starts with "01". The third and fourth digits indicate the year
of manufacture. For example, the tyre marked "3808" was
Tyre model
Tier (PR)
Air pressure (kPa)
12R22.5
18
930±20
295/80R22.5
18
900±20
315/60R22.5
20
900±20
315/70R22.5
20
930±20
425/65R22.5
18
760±20
manufactured in the 38th calendar week of 2008.
1
Maintenance of vehicle
12.4 Tyre type and load capacity
Load capacity (kg)
Tyre model
Tier (PR)
Single tyre
Dual tyres
12R22.5
18
3550
3250
295/80R22.5
18
3550
3250
315/60R22.5
20
3650
3350
315/70R22.5
20
3750
3450
425/65R22.5
18
4750
/
13.2 Hydraulic oil filling
a.Open the oil filler plug, and fill the specified hydraulic oil
until the liquid level reaches the bottom edge of the filler
hole.
b.Use the hand pump to slowly tilt the cab, and meanwhile,
continue to fill oil.
c.Put down the cab, while making excessive oil spill.
d.Next, tilt the cab via an oil pump, and after the cab falls
back to the original position, check the oil level and
replenish oil.
e.Tighten the oil filler plug (tightening torque is 5~10Nm).
12.5 Tyre pattern selection
Longitudinal pattern: Small rolling resistance, and good fuel
economy and guidance;
Mixed and transverse patterns: Strong resistance to tearing
and good driving performance.
The guide wheel and the hanging wheel are selected with
longitudinal patterns, and the driving wheel is selected with
mixed or transverse patterns. The damage rate of the guide
wheel tyre is large, so the spare tyre is generally consistent
with the guide wheel tyre.
13. Cab tilt device
13.1 Replacing the tilt cylinder
a.Remove the oil pipe joint (pay attention to protect the
joint to avoid pollution).
b.Loosen the nuts of the upper and lower mounting points
of the oil cylinder.
c.Before installing a new oil cylinder, apply a proper amount
of grease inside the lifting ring of the oil cylinder.
Note
d.Tightening torque of oil cylinder fastening nut is
When using the oil pump for reversing operation, please
100±10N‧m.
rotate it to end. If the rotation is not in place, it is easy to
e.Connect the oil pipe according to the schematic diagram,
damage the oil pump seal when there is pressure,
with the fastening torque of 30~35N‧m.
resulting in functional failure.
f.Check the tilt function, and pay attention to the fact that
the piston rod of the oil cylinder must be exposed for about
45mm after the cab is completely lowered, so as to ensure
that the oil cylinder has enough floating travel.
Warning
Before replacing the oil cylinder, it is necessary to ensure
that the cab is locked or has a reliable lifting device to
ensure safe operation.
175
176
Maintenance of vehicle
14. Protective measures for electric
welding
14.1 Procedure
e.Cable clamps should be in contact with welding
materials to prevent damage to electrical components.
The connecting clip must also have good contact with the
welding material. This can prevent damage to electrical
components. If two parts are to be welded together, they
a.Turn off the engine and the master power switch.
must be connected to the grounding of the welding
b.Disconnect the battery positive and negative power cords
machine.
to protect the battery positive and negative poles to avoid
f.Welding usually uses DC.
short circuit.
g.When welding in the cab, turn the starting key OFF, and
c.Carry out welding operation.
then disconnect the plugs to the instrument panel and
d.After the welding operation is completed, restore the
other electrical control units.
battery power cord connection.
h.After welding is completed, paint the welding area after
e.Turn on the master power switch.
removing welding slag.
Warning
When disassembling the power cord, pay attention to
prevent short circuit of the power supply.
Restore all wiring after arc welding is completed.
15. Long-term parking of vehicles
Long-term parking of vehicles
a.If the vehicle is to be parked for a long time, please pay
If the arc welding operation is not carried out according
attention to the following contents:
to this method, the vehicle electronic devices will be
b.Wash and wax the vehicle.
permanently damaged.
c.Adjust the tyre pressure to the full load specified value.
d.Park the vehicle in a dry and well-ventilated place. Put in
first gear or reverse gear, or put the shift lever in P gear to
Pipeline protection
prevent the vehicle from moving.
a.The following provisions must be observed when welding,
e.Pull the parking brake.
cutting and drilling near the pipeline:
f.Turn off the master power switch.
b.Release pressure in the pipe.
g.Check and close all doors, windows and storage boxes,
c.Cover the pipe in case it may be damaged by sparks,
and lock the vehicle.
flames or hot cuttings.
h.If the vehicle is parked for more than 3 weeks, disconnect
d.For the pipe without pressure, the maximum allowable
the terminal of the negative pole of the vehicle battery. Note
temperature for heating is 130°C and the duration is not
that all electronic systems of the vehicle will stop working at
more than 1h.
this time.
i.The battery of vehicles that have been parked for a long
Safety precautions :
a.When welding, the following measures must be taken
to avoid personal injury and damage to the vehicle.
b.Welders must have enough experience in welding on
vehicles. They must have received professional training.
c.It is very important to prepare the welding area
carefully. Heat-sensitive parts near the welding area, such
as cables and air pipes, should be protected or removed.
d.The welding area and the grounding joint of welding
machine must be clean, that is, paint, corrosion,
lubricating oil, lubricating grease and dust should be
removed.
time should be charged at least once every 3 months.
Vehicle reuse
If the vehicle is reused after long-term parking, please pay
attention to the following contents:
Charge the battery.
Connect the terminal of the negative pole of the vehicle
battery.
Check the tyre pressure.
Check the engine oil level.
Check the coolant level.
Check the glass cleaning liquid level.
Appendix
VI. Appendix
1. Brake line diagram
177
178
Appendix
2. Common tyre load and air pressure
Common tyre model
Tyre level PR
Rated inflation pressure (kPa)
Rated load (single type/dual tyres) kg
12.00-20
18
810±20 (single tyre), 740±20 (dual tyres)
3750/3350
12.00R20
16/18
830±20
3750/3450
11.00R20
18
930±20
3550/3250
10.00R20
18
930±20
3250/3000
12R22.5
18
930±20
3550/3250
11R22.5
16
830±20
3000/2725
275/70R22.5
18
900±20
3000/2725
295/80R22.5
18
900±20
3550/3250
315/80R22.5
18
830±20
3750/3450
315/70R22.5
20
930±20
3750/3450
315/70R22.5
18
830±20
3450/3150
315/60R22.5
20
900±20
3650/3350
315/60R22.5
18
830±20
3450/3150
385/65R22.5
20
900±20
4500
425/65R22.5
20
830±20
5000
Unit of air pressure: kpa(≈1kg/cm2)
3. Allowable total mass and axle load mass
Drive form
Drive form
4×2
6×2
6×4
8×4
6×6
7000
5500/7500
7500/9500
7500/9500
6500/9000
Rated axle load mass of middle and rear axles
11000
13000
Vehicle maximum allowable total mass
18000
25000
25000
31000
25000
Train maximum allowable total mass
43000
46000
49000
/
49000
Total mass and axle load mass
Rated axle load mass of front axle
13000/16000 13000/16000 13000/16000
Unit: kg
Appendix
4. Tightening torque of main bolts and nuts
No.
Name
Tightening torque
1
Cylinder head main bolt
Tighten by rotation method
2
Nut for cylinder head auxiliary bolt
Tighten by rotation method
3
Connecting rod bolt
Tighten by rotation method
4
Flywheel bolt
Tighten by rotation method
5
Flywheel housing bolt
Tighten by rotation method
6
Exhaust manifold bolt
Tighten by rotation method
7
Main bearing bolt
250N·m
8
Rocker arm bracket bolt
100N·m
9
Crankshaft pulley bolt
65N·m
10
Bolt for timing intermediate gear shaft
180N·m
11
Bolt for lubricating oil pump intermediate gear shaft
65N·m
12
Clamp bolt for front axle brake chamber fastening belt
10N·m
13
Fastening nut for front axle tie rod arm
300N·m
14
Front axle wheel bolts and nuts (installed with M22×1.5 wheel nuts)
15
Front drive axle wheel bolts and nuts (installed with M22×1.5 wheel nuts)
16
Rear axle wheel bolts and nuts
17
Front drive wheel and rear axle input flange nut
750-800N·m
18
Steering gear and its bracket connecting bolt and nut
415N·m
19
Steering pitman arm fixing nut
Over 500N·m
20
Slotted nuts for connecting tie rod arm and steering tie rod
Over 500N·m
21
Bolts and nuts for straight tie rod clamp arm
280N·m
22
Steering tie rod and straight tie rod ball pin nuts
M20 220N·m±10 N·m
M24 300N·m±30N·m
23
M18×1.5 Hollow bolt tightening torque
50 N·m±10N·m
24
M26×1.5 Hollow bolt tightening torque
75 N·m±15N·m
25
M22×1.5 Sleeve pipe joint thread tightening torque
75 N·m±10N·m
26
Steering wheel fastening nut
80 N·m ±5N·m
27
Transmission shaft flange bolt
28
Transmission shaft intermediate support bolt
20N·m
M2×1.5 115N·m
M16×1.5 295N·m
M14×1.5 195N·m
29
Bolts for fixing the airbag bracket and the axle
400±40 N·m
30
Bolts for fixing airbag bracket and air spring
270±27 N·m
550-600 aluminium alloy wheels
610-680 N·m
550-600 aluminium alloy wheels
610-680 N·m
550-600 aluminium alloy wheels
610-680 N·m
179
180
Appendix
5. Main parameters of engine
Parameters
Engine model
Maximum net power
Rated power/speed
Maximum torque/speed
WP12.430E50
311kW
316kW/1900rpm
2060N·m/1000~1400rpm
WP12.460E50
333kW
338kW/1900rpm
2110N·m/1000~1400rpm
WP13.500E501
363kW
368kW/1900rpm
2400N·m/950~1400rpm
WP13.550E501
400kW
405kW/1900rpm
2550N·m/1000~1400rpm
ISM11E5 440
318kW
324kW/1900rpm
2080N·m/1200rpm
WP13NG400E61
289kW
294kW/1900rpm
2100N·m/1100-1300rpm
WP13NG430E61
311kW
316kW/1900rpm
2200N·m/1100-1300rpm
WP13NG460E61
333kW
338kW/1900rpm
2300N·m/1100-1300rpm
X12N NS6-340
/
250kW/1900rpm
1500N·m/1100-1400rpm
X12N NS6-370
/
272kW/1900rpm
1800N·m/1100-1400rpm
X12N NS6-400
/
294kW/1900rpm
1900N·m/1100-1400rpm
X12N NS6-430
/
316kW/1900rpm
2000N·m/1100-1400rpm
X12N NS6-440
/
322kW/1900rpm
2100N·m/1100-1400rpm
15NNS6B430A
/
316kW/1900rpm
2200N·m/900-1300rpm
15NNS6B470A
/
338kW/1900rpm
2300N·m/1000-1400rpm
15NNS6B500A
/
368kW/1900rpm
2400N·m/1000-1400rpm
15NNS6B530A
/
390kW/1900rpm
2500N·m/1100-1400rpm
15NNS6B550A
/
404kW/1900rpm
2600N·m/1100-1400rpm
Appendix
6. Main assemblies and configurations of the vehicle
Engine
See engine nameplate for detailed parameters
Clutch
￠430 diaphragm spring clutch, hydraulically operated.
Transmission
Double countershaft transmission, long-distance mechanical control. Double countershaft
transmission, mechanically operated
Transmission shaft
Tubular open type, universal joint is of cross needle roller bearing type
Front axle
5.5-ton class/7.3-ton class/7.5-ton class/9.5-ton class front axle
Drive axle
11-ton class/11.5-ton class/13-ton class/16-ton class drive axle
Steering gear
Recirculating-ball power steering gear
Front suspension
Non-independent longitudinal leaf spring suspension
Single rear axle model: Non-independent longitudinal leaf spring suspension or air suspension or
suspension
compound air suspension; Double rear axle model: Non-independent longitudinal leaf spring
balanced suspension or air suspension or compound air suspension
Service braking: Two-circuit compressed air brakeParking braking:
Braking system
Spring energy-stored air-break brake Auxiliary braking: Engine exhaust brakeTrailer braking: Double
pipeline trailer brake.
All-metal flat-head hydraulic tilt cab is selected
Cab
7. Front wheel alignment parameters
Front axle model
HDZ7.3t
MAN 7.5t
Rated axle load
7300kg
7500kg
Kingpin inclination angle
7.5°
7.5°
Kingpin caster angle
2.5°±0.5°
0°
Wheel camber angle
0.5°
0.5°
Toe-in
（1.5±0.5）mm
（1.5±0.5）mm
Maximum turning angle (inside/outside)
47.5°/31.2°
47.5°/31.24°
181
Declaration
Vehicle is further driven when encountered with failure or
In the under mentioned cases, Shaanxi Heavy Duty
hidden failure which is not timely removed, giving rise to
Automobile Co., Ltd will not undertake liabilities for the
expanded secondary defect and damage of associated
reliability, safety, or adaptability of vehicles.
component and part.
The nameplate of vehicle and the certificate of conformity
Traffic accident is self disposed after traffic accident, without
for complete vehicle or chassis issued by our Company are
confirmation of responsibility by public security and traffic
not compliant with or altered comparing the actual vehicle.
administrative department, insurance company, and other
related departments.
The vehicle is not correctly used and normally operated
according to the requirements of this Manual.
Vehicle is used in an overloaded and over-limited way.
Periodic maintenance (including running-in maintenance
Non-self defects of product arise from external factors such
and mileage maintenance) have not been
as collision impact, burnout, and scoring dropout, etc.
implemented according to the specifications of this Manual.
Vehicle is damaged arising from impact of natural
The use of oil products, coolant, air filter element, and
environments, such as flood, lightning, storm, hail, and other
engine oil filter element are not meet the requirement of
force majeure.
our Company.
Wearing and tearing situations of vehicle arise from normal
Within the period of quality assurance, the vehicle is self
noise, vibration, wear, and ageing etc.
repaired rather than treatment by the Customer Service
Center of Shaanxi Heavy Duty Automobile Co., Ltd, after
Delayed damages arise from stop or denial of service station
failure has occurred.
for normal vehicle inspection, analysis, and identification.
Without permission of our company, our Company will not
Vehicle has exceeded the quality warranty period.
take responsibility for the following operations, that is the
original structure of vehicle delivered from our Factory is
Repairs are caused by other non-material, non-design, and
refitted, added or changed with components, such as
non-manufacture factors.
capacity increase in carriage, reinforcement of vehicle frame,
thickening or sheet adding of leaf spring, or tyre ply
Attention: prior to use of vehicle, please read this manual
addition or enlargement, etc.
carefully, and keep it properly, for timely reference.
Copyright Reserved.
When servicing the vehicle, use the genuine parts that are
not approved by our company for the failure.
Youtube
Facebook
SHAANXI HEAVY DUTY AUTOMOBILE IMPORT & EXPORT CO.,LTD
Unified Social Credit Code: 91610000220524252T
Operation Address: Shanqi Avenue, Jingwei Industrial Park, Economic and
Technological Development Zone, Xi'an City, Shaanxi Province, China
E-mail:shacman@shacman.com
Fax: 0086-29-86956916
Web: www.shacman.com