75t底盘英文说明书

Operation and Maintenance Manual of

Special Truck Crane Chassis

BCW5481JQZ Emission Level: EURO Ⅲ

BQ-TADANO CRANE (BEIJING) CO., LTD.

FOREWORD

This manual has been prepared to provide technical document about the performance, structure, operation, maintenance and adjustment of the 75 T serial chassis designed by BQ-TADANO CRANE (BEIJING) CO., LTD. Chassis driver of crane truck and maintenance workers could reference it. Obtaining normal service life of the chassis, please read the manual carefully and familiarize you with the theory and operation procedures, only in this way it is possible to ensure proper operation and maintenance.

This manual is applied to the following crane truck chassis:

BCW5481JQZ (75 T CHASSIS with IMPORTED CUMMINS ISME385 30)

As the continuous upgrading and improvements, this manual may different from the crane. Cranes are subject to change without prior notice.

Welcome your suggestions and opinions to our crane truck chassis.

CONTENTS ⅠIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1. Security identifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. New vehicles ——Breaking-in period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ⅡVehicle Number and Engine Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1. Vehicle identification code and nameplates. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. Engine nameplate. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Ⅲ Controls In the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1. The interior devices in the cab are consist of controls, instruments, signal displays etc . . . . . . . . . . . .1

(1) Interior devices in the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 (2) Instruments panel in the cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 (3) Indicator lamp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 (4) Indicator lamp 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 (5) Switch group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 2. Main functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

(1) Instruments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(2) Indicator lamp and warning lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 (3) Switches and controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 (4) Others. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Ⅳ Starting and Driving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1. Start of engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

(1) The operation of the starter switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 (2) Process of starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

(3) Preheating of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 (4) Stop of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2. Start and gear shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

(1) Shifting gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 (2) Upshifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 (3) Downshifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 (4) To stop and park the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 3. Clutch operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 (1) The adjustment of clutch system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 4. Brake system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

(1) Service brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

(2) Emergency brake or parking brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 (3) Engine brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 5. Driving in the slope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 6. Attentions in winter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

(1) Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 (2) Brake apparatus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

(3) Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 7. Inspections and replacement of wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

(1) Inspections of tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 (2) Inspections of tire rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 (3) Replacing wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

8. Breaking-in period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

(1) Cautions in breaking-in period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Ⅴ Daily Checkups. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1. Inspect the following items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

(1) Please park the vehicle on the flat floor to make the inspection safe and easy. . . . . . . . . . . . . 19 (2) Make sure that the ignition switch is off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 (3) Make sure that the parking brake is applied. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 (4) Make sure that the gearshift lever is in neutral position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 2. Routine inspection items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20

(1) Whether the abnormalities are solved which were found yesterday. . . . . . . . . . . . . . . . . . . . . .20 (2) Outer inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20

(3) Inspection items for cab interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 (4) Inspection items after starting the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 (5) Inspections when traveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Ⅵ Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1. For routine inspection and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 2. For replacement interval of oil in each assy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

3. The key points of task and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

(1) Daily maintenance items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

(2) For maintenance items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 (3) Oils and greases table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Ⅶ The Principle Diagram of Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 1. The illustration of the principle diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Ⅷ The Tightening Torque For Main Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Ⅸ Structural Features and Technical Parameters of Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

ⅠIntroduction

1. Security identifier

The term of “warnings” used to remind you to avoid danger that may make you and others injured. The term of “cautions” relates to vehicle damage or the possibility of personal injury, the contents of “warning” and “caution” was printed in bold type figure.

2. New vehicles ——Breaking-in period

In order to extend the service life and improve reliability, the breaking in mileage provisions for 1,500 km. Before breaking-in, routine inspections to ensure the vehicle is in proper working condition, during the first 30 hours of travel, keep the rotated speed in the range of 75% of the rated rotate speed.

For special illustrations about breaking-in period, please refer to “start and steer of the vehicle”. After the first a few days of breaking-in period, routine inspections and maintenance in accordance with the manual and ensure the reliability of travel. Ⅱ Vehicle Number and Engine Number 1. Vehicle identification code and nameplates

Vehicle identification code is in the longer on the front right side of the frame. Nameplates are on the right side of the rear part of the frame. As follows:

Identifior Identification code ：

LE7D4827××××××××× 2. Engine nameplate

Nameplate is on the left of the cylinder cover, which indicates the important information of the engine. Do not replace the nameplate without the permission of the engine manufacturer. Ⅲ Controls In the Cab

1. The interior devices in the cab are consist of controls, instruments, signal displays etc. (1) Interior devices in the cab

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(2) Indicator lamp and warning lamp ① Direction indicator lamp

①.1 Left-turn signal lamp（No 1 in figure3-3-1）

Before turning left, pull the left switch group 2 back, the lamp will light up.

①.2 Right-turn signal lamp（No 8 in figure 3-3-1）

Before turning right, push the left switch group 2 forward, the lamp will light up.

② Fog lamp

①.1 Front fog lamp (No 1 in figure 3-3-2)

This lamp indicates when the front fog lamp is applied.

①.2 Rear fog lamp (No 2 in figure 3-3-1)

This lamp indicates when the rear fog lamp is applied.

③ Parking brake warning lamp（No 3 in figure 3-3-1）travelling.

This lamp indicates when the parking brake is applied. Please make sure that this lamp is off before

④ Engine hydraulic pressure warning lamp（No 4 in figure 3-3-1)）immediately stop the vehicle and turn off the engine.

If this warning lamp lights up, it indicates that the oil pressure is less than the normal pressure,

⑤ Low battery warning lamp（No 5 in figure 3-3-1）

This lamp indicates when the battery voltage is low; please charge as soon as possible.

⑥ Front axle air pressure warning lamp（No 6 in figure 3-3-1）

This lamp indicates when the air pressure in the braking circuit of front axle is too low.

⑦ Auxiliary air pressure warning lamp（No 7 in figure 3-3-1）

This lamp indicates when the air pressure in the auxiliary air circuit is too low.

⑧ Engine brake indicator lamp（No 9 in figure 3-3-1）

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This lamp indicates when the engine braking is applied.

⑨ Low fuel warning lamp（No 10 in figure 3-3-1）

This warning lamp lights up when the fuel is not sufficient, please add the fuel in time.

Cautions: Drivers should always check the fuel gauge and add fuel timely. If warning lamp lights up,

add the fuel in time.

⑩ Warning lamp for engine coolant temperature（No 11 in figure 3-3-1）

This lamp indicates when the coolant temperature of the engine is too high.

? High beam lamp（No 12 in figure 3-3-1）

This lamp indicates when the high beam lamp switch is pressed down.

? Warning lamp for middle and rear axle air pressure（No 13 in figure 3-3-1）

This lamp indicates when the brake circuit air pressure of the middle and rear axles are too low.

? Parking brake air pressure warning lamp（No 14 in figure 3-3-1）

This lamp indicates when the parking brake circuit air pressure is too low. Never relieve the parking brake before this lamp is off. ? Engine warning lamp

①.1 Engine fatal failure warning lamp（Red）（No 2 in figure 3-3-2）

If vehicle occurs have problems, “failure” red lamp lights up, it means the engine maybe safe shut-down, in order to reduce the possibilities to damage the engine, the driver must pull over and stop the vehicle at once. The engine will not be started unless problems were solved.

①.2 Engine general failure warning lamp（Yellow）（No 3 in figure 3-3-2）

If “warning” lamp (yellow) lights up, it may need to solve the problem at once.

? Top gear indicator lamp（No 4 in figure 3-3-2）

This lamp indicates when the top gear is working.

? Low gear indicator lamp（No 5 in figure 3-3-2）

This lamp indicates when the low gear is applied.

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? Turn signal indicator lamp in emergency（No 6 in figure 3-3-2）

1) Switch on the main power, insert and turn the key-indicator lamp on (it indicates that the emergency steering system is able to work)

2) Start the engine, then the vehicle is in idle speed-indicator lamp on (normal) 3) Drive the vehicle, once the speed is over 10 km/h,-indicator lamp out (normal)

4) If the general steering system is fault when traveling (such as fault occurs in steering pump and engine is stopped), emergency steering system is applied-indicator lamp on (normal, it indicates that the emergency steering system is working)

The four principles are the working status of emergency steering system; others are considered the parts fault or problems from the manufacturer.

? Engine standby lamp（Green）（No 7 in figure 3-3-2）

The engine does not start when it is too cold. Standby lamp lights up when it need to waiting.

? Low beam lamp（No 8 in figure 3-3-2）

This lamp indicates when the switch of the low beam lamp is pressed down.

? Air cleaner warning lamp（No 9 in figure 3-3-2）(3) Switches and controls

When the air cleaner filter is clogged, this lamp will light up, please clean or replace the air filter. ① Starter switch

Starter switch is placed into the steering column(No 4 in figure 3-1)。Depress down the clutch and turn the key when starting the engine. Position key into starter switch, there are four optional positions, please refer to figure 3-4。

The functions of them are as follows:

LOCK: The key can be inserted and removed in this position.

ACC: Accessories such as radio and cigar lighter could be used when the key is turned to“ACC”, even the engine is stopped.

Figure 3-4 Starter switch ON: While the engine is running, the key is in this position.

START: Turn the key to this position and hold on for a moment, release the key after the engine is started. Then the key returns to “ON” automatically.

Cautions: Keep the key in the position of “ON” while the engine is running,

Warnings: Never turn the key to the position of “LOCK”, or else the steering wheel will be locked, it

will make the vehicle out of control and resulting in severe personal injury or vehicle

damage.

② Switch group 2

Switch group is composed of steering switches, lighting switches, wiper switches and engine braking switches.

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Figure 3-5 Switch group 2

②.1 How to use steering switches:

Before turning left, pull the left switch group back, and the left-turn signal lamp flashes（No 1 in figure 3-3-1）. Before turning right, push the switch group forward, and the right-turn signal lamp flashes（No 8 in figure 3-3-1）. And at the same time, the corresponding indicator lamp on the instrument panel begins to flash. For lane changing, operate the switch in accordance with the operation-method of steering signal lamp. ②.2 How to use lighting switches:

②.2.1 High beam and Low beam lamp

Switch the combination switch handle on the left side to make the small arrow alignment level to and the position lamp starts to work. Switch the combination handle on the left side to make the small arrow alignment level to , high beam indicator lamp indicates and high beam lamp is working.（No 12 in figure 3-3-1）.When connected, the handle is in a low beam position (middle position).Lift up combination switch handle from the middle position, high beam position can be reached. Another lift will reach low beam position, the low beam lamp starts to work and low beam indicator lamp on（No 8 in figure 3-3-2）.

Switch the combination switch handle on the left side to make the small arrow alignment level to OFF. Lift up and hold the handle and high beam lamp is still lightening, release the handle, and the lamp goes off.

②.2.2 Emergency signal switch (dual-lamp flashing)

Emergency signal switch appears as red on the combination switch on the right side. Lift up the combination switch handle and emergency signal lamp starts to work, another lift will shut down the lamp.

If the vehicle has to be placed in a place that is dangerous, emergency signal lamp must be applied. (light the turn signals to demonstrate the emergency).When the emergency signal switch is connected, all the turn signal lamps begin to flash, and the hazard warning lamp is still flashing even if the key is on the “lock” position. Turn off the hazard lamp switch, and the warning was released.

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②.3 How to use wiper

Switch right handle of the combination switch to control the wiper, rotate the handle to make the small arrow alignment level to HI ,and the wiper is in high-speed working status, rotate the handle to make the small arrow alignment level to LO ,and the wiper is in low-speed wording status, switch the combination switch handle on the right to make the small arrow alignment level to INT ,and the wiper is in intermittent working status, rotate the handle to make the small arrow alignment level to OFF ,and ，and the washer starts to work. the wiper is turned off. Press the button②.4 Engine brake switch

Engine brake switch is on the right side of the combination switch handle. When the lever is pulled

backward, the engine brake starts to work; pull forward the lever, the engine brake released.

Before using the engine brake, please make sure that the engine speed is over 1020rpm, and put foot off the accelerator pedal, the clutch is engaged, or else the engine braking is unable to work. CAUTIOUS: when the engine braking is applied:

﹡The engine speed in 1600-2200rpm is more efficient for engine braking. When the engine speed is less than 980rpm, the engine braking is disabled. Never keep the engine speed more than 2300 rpm.

﹡If the vehicle is on ramp with load, and driver drive the vehicle more faster than the steady speed. The engine braking can be used at high gears while brake pedal is depressed down interruptedly to protect the engine from over speed and keep the vehicle in a safety speed. If the driver prefers slower speed than steady speed when traveling on the ramp, a lower gear and foot brake are required, all that are considered to keep lower speed and con troll engine speed.

﹡Injector will not work when the engine brake is applied, economic engine speed need not be considered.

﹡Never apply engine braking on the road covered with ice or snow, apply it cautious on wet road.

③ Horn switch

Horn switch(No 9 in figure 3-1) is on the steering wheel，air horn switch is on the instrument panel(No 1 in figure 3-3-3), press down the switch ,the horn blares.

④ Fog lamp switch

One of the fog lamps is on the instrument panel(No 2 in figure 3-3-3)，and the other one is in front of steering column, and they are represented by a symbol of . The switch of rear fog lamp is in the instrument panel, the switch of front fog lamp is in the steering column.

When this switch is connected, the fog lamps and indicators are light on.

⑤ PTO switch (No 3 in figure 3-3-3)

Behind the transmission is the PTO which drives hydraulic pump to operate the auto crane.

Operating instructions: Stop the vehicle and run the engine at idle speed, put the gearshift lever in the

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neutral position. Press the clutch pedal to release the clutch. Press the PTO switch，and then release the clutch pedal. Now PTO gears and transmission gears mesh smoothly and PTO functions. Or press the clutch pedal to release the clutch, close the PTO switch. PTO and transmission are out of now.

⑥ Differential lock between axles switch（No 4 in figure 3-3-3）

When the vehicle get into wet road and two wheels of an axle are tuning without moving, the driver should depress down the clutch and press down the switch of differential lock between axles, the middle and rear differential lock is engaged when the indicator lamp on.

⑦ Differential lock between wheels switch

When traveling on a road, wheels on one side are trapped in a wallow or lose driving force, differential lock (No 5 in figure 3-3-3) between wheels could be used, and wheels on another side will get driving force from the drive axle which is operated by electrical-pneumatic control devices through rigid connection. Cautions: When the differential lock is applied, the driver should do the following items:

﹡Before the differential lock is connected or released, be sure to cut off the power output of the engine, and the vehicle is in static condition or moving at the speed we walk.

﹡The differential lock could be used only when the vehicle is moving in a straight line.

﹡When traveling on well-paved road, release the differential lock immediately, or else it will damage the transmission system and increase the fuel consumption.

⑧ Diagnostic switch（No 6 in figure 3-3-3）

Engine failure indicator lamp flashes（No 2 or 3 in figure 3-3-2）when the engine got failure, please press down the diagnostic switch, then the diagnostic function applied and output the fault code. For example, general fault waning lamp flashes（No 3 in figure 3-3-2）when traveling, the driver should stop the vehicle at once, press down the TEST button to search for the problems. If the warning lamp flashes twice and after a short time, it flashes once again with three times flashes at last. It means the fault code is 213; you can track the faults from the chart of fault code.

⑨ Rear-view mirror heating switch（No 7 in figure 3-3-3） turned on to defrost the mirror.

The switch should be used when the mirrors are frosted or fogged in cold day. The heater should be

⑩ Engine power selecting switch（No 8 in figure 3-3-3）

When the engine braking switch in the steering column is connected, then the engine braking is applied, now, three cylinders participate in braking; it means 50% of braking force is engaged. When the switch for engine power selecting is pressed down on the instrument panel, another three cylinders were engaged in braking, 50% of braking force is engaged. Pressing down this switch again can serve 100% of braking force-all six cylinders are engaged in braking.

? Adjustment switch of rear-view mirror（No 6 in figure 3-2）

The rear-view mirror of the auto is electric. View range can be adjusted with adjustment switch which

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includes two control buttons. The one on the left can adjust the main left and right rear-view mirror angle. To adjust the rear-view mirror of the left side, rotate the knob until the white mark is directed to the left. According to the pointing of the arrow, the same method is applied in adjusting the rear-view mirror of the right side. The button on the right is for adjusting wide-angle rear-view mirror; please see the above instruments for reference.

? Parking brake lever (No 13 in figure 3-1)

Before you leave the vehicle, make sure that the parking brake has been applied by putting forward the parking brake lever. Before traveling, make sure that the parking brake is released. When the vehicle needs an emergency brake in distress, and foot brake is failure. Putting forward the parking brake lever and the vehicle stopped.

? Air conditioner switch (No 14 in figure 3-1)

Figure 3-6 is control panel of air conditioner. The on /off button is power switch, pressing it again will shut down the air conditioner. Wind direction could be adjusted by pressing down the air blowing mode switch. A/C button is air conditioner mode switch. Air blowing mode could be changed to defroster mode by pressing down the defroster switch, pressing down the recirculation/fresh air select switch, the fresh air will be blew into the cab. Blower speed could be adjusted by press down the blower speed setting switch. Temperature could be adjusted by pressing down the temperature setting switch.

The details refer to operation manual of air conditioner. Blower speed setting switch

Operation display panel

Temperature setting switch

Power switch Air conditioner mode switch

Air blowing mode switch

Recirculation/fresh air select switch

Defroster switch

Figure 3-6 Air conditioner operation panel

(4) Others

① Cigarette lighter and Ashtray

Pressed in the cigarette lighter (No 16 in figure 3-1), then it will return to the original position after a few seconds.

Cautions: Do not keep the cigarette lighter pressed in for more than 15 seconds, or else it will damage

the cigarette lighter.

Before using the ashtray (No 15 in figure 3-1), please open the lid first. In terms of cleaning the ashtray, lift up the lid and take out the ashtray.

Cautions: Before leaving the vehicle, make sure that the ashtray lid has been closed. ② Radio-cassette player (No 10 in figure 3-1)

This player can receive FM/AM. For usage, sees the operation manual of the radio-cassette.

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③ Door

Warnings: Do not travel with any of the doors open, it is dangerous to travel with the door open. Wear the seat belt to protect the members from being thrown out of the cab.

④ Seat（No 7 in figure 3-1）

Warnings: To ensure the vehicle is under control and decrease the injury, never adjust the seat while

traveling. Do not put anything under the seat, for they may block the movement of the seat

and damage the seat regulators.

Adjust the seat to a right position where the pedals and switches can be easily operated, be sure to fix the seats enough in their right position after adjusting.

This vehicle adopt a new generation seats：Air suspension seats. The sears with higher backs are equipped with air spring damper system, which can automiticly adjust the balance point in accordance with body weight. High quality air springs are import from Germany, the design and arrangement of seats, backs and controllers will make you comfortable, and they are all accord with human body engineering principles.

For details of adjustment, please refer to the seats instructions. Ⅳ Starting and Driving 1. Start of engine

Before starting the engine, please confirm the following items: ? Shift lever “Neutral”; ? PTO switch “Closed”;

? Parking brake lever “Park” side;

? Depress down the clutch pedal (the green lamp in the approach switch which was fixed on the pedal support sill flash.)

Engine operation requirement, sees《Engine operation and Maintenance Manual》.

Cautions: The rated speed of the engine is 1900 r/m; keep the engine speed does not exceed rated

speed at any time.

Warnings: Connect the battery to the electronic equipment of the carrier and turn the key to “ON”.

Observe the engine warning lamp; do not start the engine with the engine warning lamp

on. Make diagnose for the vehicle and remove the malfunction, start the engine.

Warnings: The user must not step on the accelerator pedal while starting the engine, or else it will

cause the engine over-speed and damage the engine. To avoid damaging the starter motor, do not keep the starter motor running for 30 seconds or more. If the engine does not start, wait for 2 minutes, and then try again. If the engine can not be started at the third attempt,

please examine the fuel supply system. If when starting the engine, there is no blue or white smoke in the exhaust gas, it means no fuel in the combustor.

(1) The operation of the starter switch

Turn the starter switch to “START”. When the engine is started, immediately release the key, the key will return to “ON” automatically.

(2) Process of starting

Make sure that the parking brake lever is set to “PARK” side, shift lever is moved to the neutral position and engine indicator is off. Then turn the key to “START”, the engine will be started. If the engine can not be started within 10 seconds, turn the key to “ON” at once, start it again in 2 minutes. If the engine failed to be started for three times, stop to search for the reason.

? Oil pressure

After the engine is started, the engine oil pressure should reach the setting pressure value of the engine,

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or else, engine oil pressure warning lamp on the instrument panel sill flash. And then stop the engine immediately and search for the reason.

(3) Preheating of engine

After the engine is started, run it at idle speed for 5 minutes, slowly increase the speed of the engine to 1000-1200 r/min, then run the engine with some loads. Do not run the engine with full loads until outlet water temperature, engine oil temperature and engine oil pressure are accordance with the use requirements of the engine.

Cautions: Steadily press down the accelerator pedal and slowly increase the engine speed to lubricate

the bearings enough, especially when the engine is started in low temperature. (4) Stop of engine

The engine temperature is very high after heavy-load work. To cool the piston, cylinder, bearings and turbo enough, run the engine at idle for 3-5 minutes before the engine is stopped. Turn the key to “ACC” (power off), then the engine is stopped, turn the key to “LOCK”, and pull out the key.

Cautions: To shut down the power switch properly, be sure to wait for 30 seconds after the electronic

Controlled engine is turned off.

2. Start and gear shift

speed ratio of every gear

Type 75t Transmission type 16S221 OD 1 gear 13.80 2 gear 11.54 3 gear 9.49 4 gear 7.93 5 gear 6.53 6 gear 5.46 7 gear 4.57 8 gear 3.82 9 gear 3.02 chassis reverse 10 gear 11 gear 12 gear 13 gear 14 gear 15 gear 16 gear reversegear2 10.80 gear1 12.92 2.53 2.08 1.74 1.43 1.20 1.00 0.84 Warnings: Before starting the engine, the driver must sit on the driver seat, and set the shift lever to

“Neutral”, set parking brake lever to “park” side and depress down the clutch pedal. (1) Shifting gears

① Make sure that the shift lever is in “Neutral” position and parking brake is applied; ② Depress down the clutch pedal, turn on ignition, start the engine; ③ Keep the air pressure of the vehicle in the range from 0.7 to 0.85 MPa; ④ Depress down the brake pedal; ⑤ Depress down the clutch pedal; ⑥ Set the lever to “LO”; ⑦ Release the parking brake; ⑧ Release the brake pedal; ⑨ Slowly release the clutch pedal;

⑩ Depress down the accelerator pedal after the clutch pedal is connected.

Warnings: while changing the gear, fully depress down the clutch pedal, otherwise, the synchronizer of

the gear-box may be damaged.

(2) Upshifting

① Depress down the clutch pedal, then move the shift lever to the shift you want;

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② Release the clutch pedal;

③ Depress down the accelerator pedal to speed up the vehicle; ④ Keep on upshifting;

⑤ Change gears by one range at a time.

Cautions: Neutral gear should be engaged before you switching low gear to high gear, turn the

high/low switch on the handle, then shifting high gears is allowable. Although the vehicle is

equipped with all synchromesh transmission, when downshift the gears, firstly decelerate the vehicle to a proper speed, otherwise, engine may overrun, resulting in engine damage.

(3) Downshifting

① Depress down the clutch pedal, then move the shift lever to the shift you want; ② Release the clutch pedal; ③ Decelerate the vehicle; ④ Keep on downshifting;

⑤ Change gears by one range at a time. Driving Skills:

? While changing the gear, depress down the clutch pedal;

? Do not operate the shift lever crassly while the gears are meshing;

? When the shift lever is moved to “Neutral”, do not coast the vehicle, still less, shut down the engine or depress down the pedal;

? Do not downshift the vehicle when the vehicle is at high speed. (4) To stop and park the vehicle

If it is too late to shift or stop the vehicle in emergency, driver must depress down the clutch pedal and brake pedal (or use the parking brake lever) to stop the vehicle and move the shift lever to “Neutral”. When parking the vehicle, driver must use the parking brake lever to park the vehicle.

Warnings: To stop the vehicle, put the shift lever to “Neutral”, in case the engine is started. And keep

the parking brake working.

Operations in emergency situations：

? When the driven system malfunctions, make sure that the speed of towed vehicle is less than 10 km/h, and be sure to turn on the hazard indicator lamps.

? Cut off the driven system in principle when the engine and transmission are damaged. ? Cut off the driven system in principle when driven shaft or driven axle is damaged. 3. Clutch operations

Hydraulic oil is applied to drive the pneumatic lifter of the clutch. (1) The adjustment of clutch system:

As the clutch is drove by hydraulic oil, the system should be added up with hydraulic oil (brake fluid), and the air should be pushed out from the system. ① To add braking fluid

Open the rear cover of the cab, then open the oil tank and add the brake oil to it until the oil level is between 3/4 and 4/5 of the oil tank. ② To exhaust air

Remove the rubber cap of the air bleeding plug of clutch booster, operation steps are as follows: 1) Release the air bleeding plug of the clutch booster. 2） Fully depress down the clutch pedal. 3） Tighten the air bleeding plug.

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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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