4） Release the clutch pedal.
Repeat the progress above until the bubble-free brake oil comes out through the air bleeding plug. Pay attention to the oil level of the oil tank during this time, and add oil to oil tank in time. 4. Brake system
Brake system includes service brake (foot brake), emergency brake or parking brake (hand brake) and engine brake. (1) Service brake
Service brake could be operated by depressing the brake pedal, pneumatic braking system with dual-loop is applied in the service brake system, and working pressure is 0.8 MPa. The second loop acts on the wheels of the first and second axles, the first loop acts on the wheels of the third and fourth axles. If the air pressure of any air tank is less than 0.45 MPa, the alarm buzzer for low brake air pressure sounds, stop the vehicle and search for the causes. In a short time, the repeated use of service brake will make the air pressure less than 0.45 MPa. (2) Emergency brake or parking brake
Hand brake is also used as emergency brake and parking brake and it works through the brake cylinder of each axle. When the service brake is failure or it is too late to apply the foot brake, driver could operate the parking brake lever to stop the vehicle. Then the driver operate the parking brake to make the vehicle motionless, it is called “parking brake”. Parking brake acts on the middle axle and rear axle. When the air pressure of the brake system is higher than 0.45 MPa, and the parking brake is released, the parking brake indicator lamp is off, and then the spring of the brake chamber could be released.
Leakage of pipes which are connected to the brake chamber may result in unexpected brake; it could be cancelled by removing the rear bolt of the brake chamber. Before the brake is cancelled, be sure to engage the first gear and check the service brake.
(3) Engine brake
Engine brake is the auxiliary brake that used for continuous heavy long slope. It can greatly reduce the use of service brake, so as to reduce wear of the hoof piece, greatly reduce the hoof piece of continuous brake overheating in safety risk. But it can't instead of service brake for emergency brake, also can not be used in parking brake. When using the engine brake can use service brake at the same time.
5. Driving in the slope
The exhaust brake should be used to limit the vehicle speed while driving in the slope, and keep the speed less than the maximum speed for each shift.
Warnings: Keep the engine speed less than the maximum speed (1900rpm) at any time, or else it will
seriously damage the engine. Warnings: Do not place your foot unnecessarily on the brake pedal or step on it for a long time.
Otherwise the brake drum can be overheated, and the brake lining wears prematurely or
the air pressure for brake will be decreased, resulting in low braking power.
6. Attentions in winter (1) Cooling system
Coolant could be selected in accordance with the operating requirements of the engine, or the coolant recommended by this manual. Considering many bands of coolant for engine, we recommend -35 ethylene glycol based coolant for engine, amount: 45L.Make sure that the freezing point of the coolant is 5 degrees lower than the lowest temperature in the local area.
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(2) Brake apparatus
Check if any condensed water is in the gas circuit.
(3) Battery
① Inspect the electrolyte level and specific gravity of electrolyte periodically. The electrolyte level should be 10-15 mm above the pole plate, and the specific gravity is more than 1.24 g/cm3. When the vehicle not in use for along time and the temperature is low, please detach the battery and store it in warm place. Cautions of inspection:
? The battery should be clean and dry. Release the terminal connection and clear the terminal, otherwise the contamination of the terminal connection may cause slightly discharge. Then lubricate the terminal with acid-free and acid-proof lubricant, notice that the fill port should be oil-free; ? Do not leave anything on the battery;
? Do not detach the battery cable with the engine running;
? Check the acid amount of the electrolyte periodically, and add distilled water if necessary. The battery needs less maintenance. If it is used properly, it does not needs distilled water within one year. ② Charging:
If the electrolyte is add up with distilled water, please wait half an hour to test the density by hydrometer, and you’d better test it at 20℃, and the measured value indicates the state of charge. Pay more attention to charge the battery in cold season, the power consumption is so much that the battery requires constant maintenance. Attentions when charging:
? Charge the battery with direct current, the current must be less than one tenth of the battery capacity. For example, to charge the battery of 165Ah, the required current is less than 16.5 A. 7. Inspections and replacement of wheels
(1) Inspections of tires
① Tire tread depth on the tire crown is equal or more than 3.2 mm;
② Tire cord will not be exposed because of the local wear;
③ The splits or cuts on the tire are less than 25 mm, and they are unlikely to expose the tire cord.
Tires which can not meet the requirements above should be repaired to be installed to the vehicle. Please do the following items:
? Install tires with same type and pattern to each axle; ? The retreaded tires should not be used as steerable tires. (2) Inspections of tire rims
Tire rim is an important part of the drive system. Inspect the following items while you replacing the tire.
① The rusting condition of the tire rim; ② The distortion or deformation of the tire rim; ③ Flows on the tire rim;
④ Inspect the conditions of bolts and nuts of tire rim, rim seals and mounting holes.
If there are any deformations or damages on the components, please repair or replace them at once. If the paint is cracked, remove the rust and paint the component.
Cautions: Do not weld the damaged thread holes and repair the deformed bolts, please replace them
with new components. (3) Replacing wheels
① Do not bump the thread of the bolts;
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② Make the contact surfaces of brake drum and tire rim free of paint, grease and other dirt; ③ Keep the contact surfaces of bolts clean;
④ Brush the mating surfaces such as thread of wheel bolts and nuts with a little grease, oil or other anti-adhesion agent;
⑤ The thread of wheel nuts is right-hand thread. Tighten the wheel nuts diagonally and alternately with the tire out of ground. Lay down the tire, and the tightening torque should in the range 650N.m;
⑥ After replacing the tires, check for loose wheel nuts after approximately 50 km of traveling. Retighten the loose ones;
⑦ Change the tire positions as shown every 10000 kilometers, please refer to diagram 4-1.
Figure 4-1 Tire-changing map
8. Breaking-in period
Breaking-in period determines the vehicle reliability and service life. Please adhere to the following items to extend the service life and fulfill the performance of the vehicle:
Carry out checkup when the traveling distance reaches 1000 km and 5000 km. Be sure to check the oil level, check for the leaks in accordance with the instructions. If a leak develops in any component, please repair it.
(1) Cautions in breaking-in period: ① Do not speed up the vehicle soon after a cold start; do not increase the engine speed until the engine reaches the normal working temperature. Keep the rotated speed in the range of 75% of the maximal speed; ② Try to drive the vehicle on the even ground;
③ Chose the proper gear in accordance with the load and road condition; do not accelerate or brake the vehicle suddenly;
④ Inspect and control the engine oil pressure and the coolant temperature; ⑤ Pay attention to the temperature of brake drums and wheel rims of the middle and rear axles. If serious heat occurs, find out the causes and solve them;
⑥ When the traveling distance reaches 50 km or tires were replaced, please tighten the wheel nuts in accordance with the required torque.
Inspect and maintain the vehicle in accordance with the operation manual of the engine after breaking-in period. Ⅴ Daily Checkups
To prevent accidents and ensure the safety for traveling, every day, the driver should check the vehicle and conduct inspections before traveling. Do not neglect these.
1. Inspect the following items:
(1) Please park the vehicle on the flat floor to make the inspection safe and easy; (2) Make sure that the ignition switch is off;
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(3) Make sure that the parking brake is applied;
(4) Make sure that the gearshift lever is in neutral position. 2. Routine inspection items:
(1) Whether the abnormalities are solved which were found yesterday; (2) Outer inspections:
① Check if the tire pressure is in proper condition, and whether the tires have flaws, damages, abnormal wears and thin metals or ballasts;
② Check if the tire tread depth is normal; ③ Check if the tire nuts are tightened; ④ Check if the coolant level is too flow;
⑤ Inspect the coolant level through the observation window or the filler of the expansion vessel; ⑥ Cautions:
⑥.1 Pay attention not to be burnt by the high-temperature liquid and steam while inspecting the coolant level with the engine very hot;
⑥.2 Do not add coolant to the hot engine, otherwise, it will result in damage to the engine part. Add coolant to the engine when the engine temperature decrease to 50℃ or lower.
⑦ Items for checking the level of the engine oil
Pull out the oil level gauge (see engine manual for details), refer to the oil level gauge, and add required oil to engine when needed.
⑧ Examine the oil level of the transmission
The oil level of the transmission is not lower than the inspection hole which is mounted on the side of the transmission assy, which could mean, the oil level of the transmission is not lower than the axis of the intermediate shaft.
⑨ Check if the condense water appears in the air reservoir of the brake system
Open the manual valve which is mounted on the bottom of the air reservoir, if condense water run out of air reservoir, drain off the water and replace the reservoir of the air dryer. ⑩ Check the working condition of the circuitry; ? Check the leak of oil and coolant;
? Inspect the air cleaner
If the vehicle is used in dusty area, please empty and clean the dust collection cup every day. (3) Inspection items for cab interior ① Check if the lock works properly; ② Angle of the mirror.
(4) Inspection items after starting the engine
① Check if the pressure of the gas system is normal; ② ③ ④ ⑤
Check if the fuel in the tank is sufficient;
Check if the instruments and meters are normal; Check if the lamps and indicator lamps are normal; Check if the horn and wiper are normal;
⑥ Check if the stroke of clutch pedal and brake pedal are normal; ⑦ Check if the exhaust sound is normal;
⑧ Check the leak of the engine oil, fuel and cooling system. (5) Inspections when traveling
① Check if the brake effectiveness is normal;
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② Check if the exhaust brake system is normal; ③ Check if the steering wheel is normal.
Ⅵ Maintenance
1. For routine inspection and maintenance, refer to figure 6-1
figure 6-1 units: 1000km Routine inspection 5 85 165 Routine inspection 45 125 205 1st level maintenance 10 90 170 1st level maintenance 50 130 210 Routine inspection 15 95 175 Routine inspection 55 135 215 2nd level Maintenance 20 100 180 2nd level Maintenance 60 140 220 Routine inspection 25 105 185 Routine inspection 65 145 225 1st level maintenance 30 110 190 1st level maintenance 70 150 230 Routine inspection 35 115 195 Routine inspection 75 155 235 3rd level maintenance 40 120 200 4th level maintenance 80 160 240 2. For replacement interval of oil in each assy, refer to figure 6-2
Figure 6-2
Item Engine ● ● ● ● ● Transmission ● ● ● ● ● Front and rear axle ● ● ● ● ● Remarks First inspection Routine inspe ction tenance 1st level main2nd level maintenance 3rd level maintenance 4th level maintenance PS: “First inspection” means the inspections after breaking-in period
3. The key points of task and maintenance
(1) Daily maintenance items
① Check the performance of the foot brake and parking brake;
② Check the performance of the lighting system, signal system and all kinds of indicator lamps (engine oil pressure, air tank pressure and charging indicator lamp);
③ Check the performance of negative pressure indicator of the air cleaner; ④ Check the performance of wiper;
⑤ Check the tire air pressure, tire status and the fastness of the bolts;
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