Foreword

The Product Manual gives brief instructions to the performance parameters and key points in operation and maintenance of the following

models (chassises) for driving reference: 6 × 4 mining dump truck and chassis TFW812R

The 6 × 4 wide body slag dump truck adopts the newly developed one-sided offset cab of K20 project of the company. The cab is a

mechanical leather seat with panoramic curved glass and can be turned forward. The vehicle has smooth lines, beautiful appearance, comfortable

ride and convenient operation, which is suitable for short-distance cargo transportation in mining area and plant area

The product is under “Three Guarantees” provided users observe the Product Manual, with the product assurance, warranty scope and

basic conditions subject to the prescriptions of the Company’s Users’ Warranty Services Manual. Users may contact with the company Nanjing

Xugong Automobile Manufacturing Co., Ltd or the technical service stations designated by the company. The company’s 24h special line for

auto parts and service: 400-881-6018.

Your opinions are welcomed and valued, and the company’s mailing address is:

Zhujiang East Road 19, Hi-tech Industrial Development Zone, Xuzhou, Jiangsu Province, XUZHOU

XUGONG AUTOMOBILE MANUFACTURING CO., LTD. P.C.: 221100

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 6 × 4 Dump Truck

Note: La—total length Ha—total height Ba—total width LF—front overhang LR—rear overhang L1—wheelbase from

front Axle to middle axle L2—wheelbase from middle axle to rear axle

B1—front wheel tread LH—carriage length (inside) H1—carriage height (inside)

Please see specific values in the master data sheet.

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 Table of Contents

I.Main Technical Characteristics and Data .................................................................................................................................................................................................... 4

(I) Basic data ..................................................................................................................................................................................................................................................... 4
(II) Usage data .................................................................................................................................................................................................................................................. 7
(III) Capacity data ............................................................................................................................................................................................................................................ 8
(IV) Adjustment data ........................................................................................................................................................................................................................................ 9
(V) Brief description of structures .................................................................................................................................................................................................................. 10
II. Operation of the Truck............................................................................................................................................................................................................................ 15
(I) Inspection of new truck ............................................................................................................................................................................................................................. 15
(II) Running-in of new truck ............................................................................................................................................................................................................................ 17
(III)Driving and operation ............................................................................................................................................................................................................................... 19
(1) Notes before driver’s cab tilting: ......................................................................................................................................................................................................... 24
(1) Seat height adjustment: ....................................................................................................................................................................................................................... 31
(2) Seat position adjustment: ..................................................................................................................................................................................................................... 32
(4) Backrest angle adjustment: ................................................................................................................................................................................................................... 34
(5) Vibration damping performance: ........................................................................................................................................................................................................ 35
A B ............................................................................................................................................................................................................................. 46
① Constant voltage charge: ........................................................................................................................................................................................................................... 55
② Constant current charge: ............................................................................................................................................................................................................................ 56
3. Vehicle Maintenance .............................................................................................................................................................................................................................. 98
1. Maintenance of Air Heating System ...................................................................................................................................................................................................... 104

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4. Troubleshooting .................................................................................................................................................................................................................................... 106
1. Cautions & scope .................................................................................................................................................................................................................................. 109
4. Brief introduction on cylinder .................................................................................................................................................................................................................. 116
5. Operation method ..................................................................................................................................................................................................................................... 139
6. Common faults and treatment methods .................................................................................................................................................................................................... 147
7. Routine maintenance ................................................................................................................................................................................................................................ 152
Annex table 1 Lubrication Table ............................................................................................................................................................................................................ 156
Annex Table 2 The Accessory Tools ....................................................................................................................................................................................................... 159
Annex Table 3 Tightening Torque of Main Bolts and Nuts .................................................................................................................................................................... 160
Annex Table 4 Tightening Torque of Common Bolts and Nuts ............................................................................................................................................................. 163
Annex Table 5 Technical Information of the Vehicle ............................................................................................................................................................................. 163

I.Main Technical Characteristics and Data

(I) Basic data
Item Unit XGA5902D3T
Vehicle model DFW817
Chassis Model /
Length mm 9045
Outline Width mm 3460
dimension Height (no load) mm 4050
Front overhang mm 1755
Rear overhang mm 1890
Wheelbase mm 3800+1600
Number of axle 3

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 Item Unit XGA5902D3T
Vehicle model DFW817
Chassis Model /
Front mm 3800
Wheel track
Rear mm 1600
Min. ground clearance (full
mm 380
load)
Min. turning diameter m 9.9
Passing Approach angle （） 28
ability (full
Departure angle （） 42
load)
Total weight of whole
kg 30000
vehicle
Gross weight kg 60000
Manufacturer’s maximum
kg 90000
total mass
Number of people in the cab person 1
Inner wheel
Max. （） 40
(axle I)
corner of
Outer wheel
front wheel （） 30
(axle I)
Wheel camber （） 2
Positioning
Kingpin
angle of （） 8
inclination
front wheel
Kingpin caster （） 0

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 Item Unit XGA5902D3T
Vehicle model DFW817
Chassis Model /
Toe-in mm 2-3
Fuel Tank Volume L 600
Interior Length mm 5900
dimension of Width mm 3200
compartment Height mm 1650

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(II) Usage data

Vehicle model Max. travel Max. gradeability

speed (km/h) (%)
XGA5902D3T 48 37

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(III) Capacity data
Diesel oil tank 700L

Engine lubricating system

WP12G460E310 25L
(including oil filter)
Including
Without
hydrodynamic
retarder
Engine cooling system retarder
WP12G460E310 55L 100L
Transmission lubricating
8DS240A 30L
system
Retarder cooling system FHB400 5.5L

Final drive of middle axle 35t 22L

Single-side wheel redactor
35t 5L
of middle axle
Final drive of rear axle 35t 20L
Single-side wheel redactor
35t 5L
of rear axle
Power steering system Steering wheel + servo 4L
Clutch hydraulic oil 1L
Windshield glass washer 1.5L

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(IV) Adjustment data
Adjustment item Adjustment data
Fan belt deflection (mm) 10～15
Normal temperature of engine
≤104
coolant(℃)
Free travel of clutch pedal (mm) 19.8～27.42
Total travel of clutch pedal (mm) 96.17～111.47
Clearance
between Front (mm) 0.4～0.8
brake drum
and brake Rear (mm) 0.4～0.8
shoe
Max. braking air pressure(kPa) 1000
Tire Front wheel (kPa) 575Kpa
pressure Rear wheel(kPa) 575Kpa

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 (V) Brief description of structures
1. Engine:
Engine model WP12G460E310
6-cylinder in-line, four stroke, water cooling, ω-type combustion
Type
chamber, exhaust turbocharging, inter-cooling
Displacement （L） 11.596
Net power（kW/r/min） 338/2100
Max. torque
2000/1200～1600
（N.m/r/min）

GB 20891-2014
Emission
(China stage Ⅲ)

0# light diesel oil (select corresponding brand according to ambient

Fuel
temperature in winter)
2. Transmission:
See the following table for speed ratio:

Transmission model Speed ratio

7DS200 Max./min. speed ratio ：8.15/0.71

3. Propeller shaft:
Transmitted torque 22000 N·m，axle tube:Φ140.

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4. Front axle:
The axle housing adopts steel plate welded box-shape structure.
5. Rear axle:
Inblock casting axle housing, the main reducer is skew gear with wheel reduction.
6. Frame:
The frame adopts box-shape beam and welding structure, height is 450mm, width is 1060mm.
7. Suspension:
Front suspension a longitudinally symmetrical semi-elliptical leaf spring with an eye-ring structure at the rear end, and a bi-directional
hydraulic telescopic shock absorber is equipped for front suspension. The rear suspension is a longitudinally inverted semi-elliptical leaf
spring balanced suspension.
8. Wheel:
With 14.00-25 engineering tires, tire tread type is E3, rated bearing capacity of 10000Kg (10km/h) changes correspondingly with the
change of travel speed. Wheel rim adpots 10.00-25, offset is 199mm, spoke width is 16mm.
9. Steering system:
Trapezoidal structure is located at rear side of front axle, the steering gear has two lardan universal joint. The steering gear is a circulating
ball integral hydraulic power steering gear with cylinder bore of 130 mm. The steering oil pump is a steering booster pump equipped with
the engine, the additional hydraulic power steering device is a servo steering gear that is located on the right side.

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 10. Braking system:

(1) Driving brake: double-circuit air brake, the wheel brake is drum brake.
(2) Parking brake: hand control valve and the energy storage spring brake air chamber acting on rear wheel are adopted. Hand control valve
can be used for emergency braking.
(3) Auxiliary brake: engine exhaust brake, linked switch is installed in clutch operating mechanism and accelerating mechanism, exhaust
brake valve is located in the middle of intake manifold of muffler; automatic transmission is equipped with hydrodynamic retarder, whose
control lever is located on auxiliary console in driver’s cab.
(4) Braking pipeline: air dryer, water drain valve, four-circuit protective valve, serial double-chamber brake valve, quick release valve,
relay valve and etc. are equipped.
(5) Air reservoir: there are totally four air reservoirs, one is separate space type, the other three are single cavity type.

11. Electric equipment and instruments

Circuit system: single line, negative ground;
Circuit voltage: 24V;
Battery: 6-QAW-165, common maintenance-free lead-acid battery, 165AH, 2 batteries in series; or 6-QAW-180DMF, low temperature
maintenance-free lead-acid battery, 180AH, 2 batteries in series;

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Generator: silicon rectifier alternator;
Starter: electromagnetic operating starter motor;
Heater: the motor is permanent magnet type, power is 240W;
Others: headlamps adopt four-lamp combination lamp, protective fence structure is installed at headlamps and combined taillamps,
working lamps are installed at upper right of rear enclosure of driver’s cab and the rear end of frame. Combined instruments, large-screen
display and infrared camera probe technology are adopted. Hoisting alarm device is installed, 180AH low temperature starting battery and
fuel heating system are adopted, electrical load calculation of the whole vehicle is necessary. Combined solenoid valve is adopted, first
group (three units): exhaust brake, PTO, electronic power off; second group (three units): inter-axle differential, inter-wheel differential
(middle axle), inter-wheel differential (rear axle).
12.Driver’s cab:
Single side offset driver’s cab, max. tilting angle is 38°.
13.Compartment:
The interior dimension of compartment is 6000×3200×1600. The structure type of compartment: bottom 12 edge 8, front inclination
angle of front plate and rear door is 8°. The underframe adopts five longitudinal beam structure, rectangular tube for main longitudinal
beam 180 × 120, the middle longitudinal beam 180 × 140, other longitudinal beams 180 × 120. The rear overturning shaft is
cutthrough shaft. The hydraulic system uses Hyva front-end cylinder with cylinder bore of 179mm. Effective volume of hydraulic tank is
95L, front located at left side.

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14.Supplied tools:
A set of supplied tools is equipped with the vehicle.

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 II. Operation of the Truck
Refer to Diesel engine operation and maintenance manual for running-in, operation, maintenance, service and etc. of diesel engine, this
manual will not explain any more.

(I) Inspection of new truck

The new truck has been strictly checked before leaving the factory, but individual parts may be loosened or damaged during shipping.
Therefore, the following checks should be performed before a new truck is put into operation:
1. Check every part for connection and tightness, especially pay attention to check driveline, steering system, brake system, suspension and
wheels;
2. Check water storage quantity of radiator and its connection for coolant leakage;
3. Check engine, transmission, rear axle and steering reservoir for oil level and oil filling condition of each lubricating point;
4. Check fuel supply system for fuel leakage;
5. Check engine accessories and tightness of drive belt;
6. Check whether the battery level meets the specification;
7. Check working conditions of electric equipments, lights, horn and instruments;
8. Check working conditions of brake system and each pipeline for air leakage;
9. Check working condition of steering system, whether there is looseness and seizing;
10. Measure whether tire pressure meets the specification;

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11. Check whether supplied tools and accessories are complete.

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(II) Running-in of new truck
The service life, the operation reliability and the economy are largely depended on the running-in of the truck in initial stage. Therefore, the
running-in regulations must be strictly executed. The running-in mileages of this series of trucks are provided for 2500km, the following
provisions must be complied with:
1. Select a flat and good road section, travel with no load in the first 200km driving. Abrupt acceleration and emergency braking should be
avoided in running-in period;
2. Drive correctly, engage the clutch smoothly, shift gears timely, it is strictly forbidden to slide in neutral position;
3. When driving to 200km and 500km, check whether U-shape bolt and nut of leaf spring are tightened in load bearing condition;
4. In 1500km, the travel speed in 1st, 2nd, 3rd, 4th, 5th, 6th and 7th gear positions does not respectively exceed 3, 5, 6, 8, 11, 16 and
28km/h;
5. In 1500km, the loading mass cannot exceed 70% of rated loading mass, after running-in of 1500km, the loading mass can be increased to
90% of rated loading mass;
6. Always pay attention to the temperatures of transmission, intermediate support of propeller shaft, rear axle, hub and brake drum, if there
is abnormal heating, reasons should be found out and removed timely;
7. Special attention should be paid to normal engine oil pressure and coolant temperature;
8. After running-in of 2000km, check tightening and working conditions of each part, and tighten the bolt on engine cylinder head for once
according to specified torque;

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9. At the end of running-in, go to authorized maintenance department of our company for mandatory maintenance, remove the limit lead
seal on the engine oil pump (at this time running-in mileage should not exceed 2500 km).

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(III)Driving and operation

-
Radio cassette player

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1. Starting
The following preparations should be done before starting diesel engine:
(1) Check whether the oil quantity in oil pan and oil injection pump is sufficient, refill to specified position if not.
Loosen the screw cap of oil inlet connector of supercharger in order to refill lubricating oil into supercharger so that the bearing of
supercharger can get lubrication when diesel engine is starting. The oil filter of supercharger that has been cleaned or replaced should also
be refilled with lubricating oil. The brand of oil refilling into fuel injection pump and supercharger should be the same with that of diesel
engine oil, and the oil must be clean.
The diesel engine should use diesel engine oil of CF-4 grade or above, the relationship between CF-4 grade oil brand and using area (see
the following table):
Using area Cold area Common area (all year round) Southern area (summer)
Oil brand 5W/40CF-4 15W/40 CF-4 40
(2) Check whether the diesel oil in oil tank is sufficient, pay attention to refill if not. The diesel oil should be precipitated and filtered
before refilling to ensure normal operation of diesel engine and increase service life.
(3) Check the level of power steering reservoir, refill to specified level when it is insufficient.
(4) Check whether there is enough coolant in coolant tank, refill if there is not enough coolant, F35 anti-rust antifreeze must be refilled, this
antifreeze is water-glycol type, which contains a variety of additives to prevent corrosion of the radiator, reduce scale deposit, improve
service life and heat dissipation performance.
Cautions on operation of antifreeze:

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① The freezing point of F35 anti-rust antifreeze is -35℃, decide whether to drain the coolant depending on the low temperatures that may
occur in this area.
②When refilling anti-rust antifreeze, should pay attention to refill the same model to avoid precipitation phenomenon.
③ When white aluminum hydroxide suspended matters are found in the coolant or the antifreeze becomes smelly, it indicates that the
antifreeze has been deteriorated, this time all antifreeze should be replaced.
(5) Check whether every part of electrical appliance is normal, whether battery quantity is sufficient and whether battery liquid is sufficient.
(6) Check and exhaust the air in fuel pipelines.
(7) If ABS system is optional on the truck, turn ignition switch from “OFF” to “ON” position, do not start the engine. The ABS indicator
lamp goes out after about 3 seconds after the truck is powered on, it indicates that the system is normal. If the lamp does not light or always
on, it indicates that there is trouble in the system, at this time diagnose ABS system and remove the trouble.
ABS trouble diagnosis and troubleshooting steps:
① Press down ABS diagnosis switch, engage the switch for 0.5s to 3s, then reset (disengage) the switch, ABS indicator lamp may appear two
groups of flash codes.
② Observe and record flashing condition of ABS indicator lamp, then according to flashing times of indicator lamp, refer to ABS Operation
Manual for “ABS fault flash codes comparison table”, the cause of fault can be found immediately.
(8) When starting the engine in low temperature, the following methods can be used to improve engine cold starting performance,
accelerate the engine warm-up process and reduce smoking.

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① Air intake heater: the temperature sensor on the engine is used to induce ambient temperature, the closing of intake preheating relay coil is
controlled by ECU, then the operation of grid heater is controlled by intake preheating relay. The intake heating system automatically controls
the heating of heater according to engine intake temperature. The heating time is different depending on different ambient temperature.
Generally the preheating time is within one minute, later heating time is rather longer, usually 2 minutes (-10 ℃), its working process:
a. Power on (put ignition switch to “ON” position)
b. Cold starting lamp goes on and the preheating begins
c. The preheating finishes when cold starting lamp flashes, wait to start, the cold starting lamp flashes for 3 times during waiting period
d. Cold starting lamp goes out
e. The heating begins after starting finishes (at this time cold starting lamp is not on)
② Fuel heater: press down fuel heating switch, the fuel water hanbao activates temperature control switch according to temperature sensor
and automatically heats the fuel by bimetallic strip, when fuel temperature meets the requirements, it automatically stops heating, at this time
fuel heating switch can be pressed again.
After finishing the above preparatory work, you can start according to the following procedure:
① Put accelerator in middle position, and put transmission shift lever in neutral position.
② Turn electric switch to “Start” position, the starting motor may rotate and drive diesel engine start, if the diesel engine cannot be started
after the switch is engaged for 10 seconds, it should be stopped and then restarted after one minute, if it fails for consecutive three times, check
the reason, and restart after removing the fault.

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2. Operation
The diesel engine should be operated in idle speed for a period of time after starting, and check whether the following indicators are
normal:
(1)The diesel engine runs without noise.
(2)Check whether coolant temperature gauge changes, insulation pad should be added in front of coolant tank in cold season to see whether
the coolant temperature gradually increases.
When the coolant temperature of diesel engine increases to 50℃, it can be operated normally. The following should also be paid attention
during operation:
(1) The travel speed gradually increases, it cannot be started means travel in high speed.
(2) Note whether the data indicated by various instruments are normal, especially take care whether coolant temperature and oil pressure
are normal.
(3) Check whether there is abnormal noise, if there is, stop the truck in time for disposal.
(4) The new engine and just overhauled engine should have running-in period of 2500km, do not open full load accelerator for full speed
travel during running-in period.
3.Stopping
Try not to stop the truck by using emergency brake during traveling, after the truck is stopped, generally shut off the engine after the diesel
engine is run in idle speed for 3-5 minutes, this more should be done in the case of high diesel engine temperature, especially pay special

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attention to supercharged engine.
4.Parking brake
It is achieved by air inflation and air release of spring brake air chamber controlled by manual control valve, air inflation (air pressure
should be higher than 500kPa) is to release, air release is parking brake.
5.Transmission gear positions layout

8DS240A
Transmission gear positions layout
6.Driver’s cab tilting
(1) Notes before driver’s cab tilting:
① Try to park the vehicle on flat ground.
② Before cab tilting, pay full attention to the height of ceiling and whether there is enough clearance between the cab and front wall.
③ Confirm whether it is in parking brake state again, and put transmission shift lever in neutral position.

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④ If necessary, please block each tire with triangle filling chock.
⑤ Please confirm whether bits and pieces in driver’s cab are put away properly, for the items that easily fall during tilting period, please
move them away and place them in place.
⑥ Please confirm the middle cover plate in the front of driver’s cab has been opened.
(2) Tilting operation
① When the driver’s cab is raising, first open the middle cover plate in the front of driver’s cab, put reversing lever of fuel pump clockwise
to I position shown in the figure, then insert the rocker into jack and swing up and down, the fuel pump supplies fuel to lower chamber of the
cylinder, the piston rod of cylinder extends so that the driver’s cab is raised.
② When the driver’s cab is lowering, put reversing lever of fuel pump anticlockwise to II position shown in the figure, then insert the rocker
into jack and swing up and down, the fuel pump supplies fuel to upper chamber of the cylinder, the piston rod of cylinder retracts so that the
driver’s cab is lowered.

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 摇杆插孔
Rocker jack
II II
position
I位 位
I position

Manual fuel pump

Caution:
① The reservoir capacity of manual fuel pump is 600mL, fuel filling capacity is 450-500mL, tighten the plug after filling, the torque is
28-30Nm.
② This cylinder is ratchet anti-lowering cylinder, when the driver’s cab is hoisted for long time and needs lowering, please be sure to
manually press to make it rise for 3 to 5 times, then reverse to lower the cab so as to avoid that ratchet and stopper block cannot be
disconnected due to locking. If you forgot to manually press rise procedures, the driver’s cab has not been lowered after pressing for several

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times, immediately stop, please change to rise, then reverse to lowering after 5 times.
Warning:
① During traveling or not in tilting state, the reversing lever of fuel pump must be in II position shown in the figure.
② The reversing lever must be put in place when reversing.
③ The middle cover plate must be opened before tilting.
7.Water injection into spraying pot
The spraying pot is installed at left side below cab floor, the water level in the pot cannot be lower than the min. water line, water should be
injected into the pot when water level is lower than min. water line. When injecting water, open the pot lid as the direction shown in the
figure, align proper water pipe with the port of pot to inject water into the pot, the water level cannot be higher than max. water line.

Filler

Spraying pot

Water injection into spraying pot

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8.Opening of middle cover plate
The middle cover lock body is located in the middle position of the front middle cover, as shown in the figure below. When opening, pull
the buckle outwards, and the middle cover opens under the action of the air strut. Push down and lock the lock cylinder with the key after
locking.

Opening of middle cover plate

9.Opening and closing of doors

(1) Opening the doors
① Opening from outside: turn the key backward to unlock, then open the door as shown in the figure.

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 Opening the door from outside

②Opening from inside: pull up the inner lock button, then open the door as shown in the figure.

Opening the door from inside

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 (2) Locking the doors
① Locking from inside: after the door has been closed well, press down the lift button.

Locking the door from inside

②Locking from outside: after the door has been closed well, turn the key forward to enable it in locking state.

Locking the door from outside

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Caution: after the doors have been closed, please check again whether they are closed tightly. It is very dangerous to drive with doors
half-open and half-closed.The door opening operation is prohibited.
10.Adjustment of seats in driver’s cab
(1) Seat height adjustment:
Adjusting range: stroke is 60mm,The vibration of the rest position of the seat is 30 mm.
Operation method: hold the front (rear) lifting operating handle with hand and lift upward, apply force forward (backward) by using its
own weight to achieve seat height adjustment to desired position, then release the hand to lock.

Height-adjustable handle

Seat height adjustment

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(2) Seat position adjustment:
Adjusting range:The height adjustment handle rail travel adjustment amount is 190 mm, from the design initial position, the forward
adjustment amount is 110 mm, and the backward adjustment amount is 80 mm.
Operation method: hold the control lever of slide rail and lift upward, move forward (backward) to desired position by using its own weight,
then release the hand.

Front and back adjusting

handle

Seat position adjustment

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(3) Headrest height adjustment
Operation method:
1. When the headrest is adjusted upward: hold the headrest with hands and lift to desired position, then release the hands.
2. When the headrest is adjusted downward: press headrest unlocking button with thumb, press down the headrest with hands to desired position,
then release the hands to lock.

Headrest height adjustment

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(4) Backrest angle adjustment:
Adjusting range: The initial design position is 22 ° rearward in the vertical direction, the back is the most forward (the design position is
forward)25 ° ± 3 °, and the rear tilt angle (rearward of the design position) is 17 ° ± 3 °.
Operation method:
1. Hold the backrest adjustment handle with hand and twist upward, people applies force by using the back, release the hand to lock, then
backward adjustment is achieved.
2. Hold the backrest adjustment handle with hand and twist upward, people does not apply force to the backrest, then the backrest is adjusted
forward, release the hand to lock the backrest, then forward adjustment is achieved.

Backrest angle adjustment

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(5) Vibration damping performance:
Adjusting range: vibration damping stroke is 30mm
Caution: it is strictly forbidden to adjust driver’s seat during driving.
11.Operation of ventilation device
When doors and windows need to be opened, first lock the windows, then pull the glasses to desired positions.

window glass

Window locks

Window closing diagram

In order to better solve the problem of cab sealing, the right side window glass is non-push-pull type, that is, all-in-one glass, which does not
have the window opening function and is always in the sealed state.

35
12.Operation method of air conditioning system
I. Operation method of electric air conditioning
(1) Description of button layout on control panel of air conditioning system

(2) Operation method of air conditioning control panel

36
 Item
Operation purpose Operation method System state
Mode
Press AUTO key for twice, the system automatically turns on immediately
Turning on Press AUTO key
and runs in automatic mode.
Turning on, In the operation of air conditioning, every time you press AUTO key, the
turning off and Mode switching Press AUTO key system operating mode will switch between manual mode and automatic
mode mode.
switching
Turning off Press OFF key In any state, press OFF key for once, the system automatically turns off.

Internal and external

Press external/internal Every time you press external/internal air selector key, the air inlet mode will
circulation
air selector key switch between internal and external cycles.
switching
Every time you press air blowing mode switching key, the air blowing mode
Air blowing mode Press air channel
will switch among blowing face, blowing feet and defrost and blowing feet in
switching selector key
turns.
Manual
Press air volume Every time you press air volume increase key, the air volume will increase
control mode Air volume increase
increase key one level, until it is increased to 8 level.
Press air volume Every time you press air volume decrease key, the air volume will decrease
Air volume decrease
decrease key one level, until it is increased to 1 level.
Press the defrost key, the system enters defrost state, at this time the system
Defrost Press defrost key state is: the maximum air volume, external circulation, showing refrigeration
and defrost icon (the compressor works).

37
 Item
Operation purpose Operation method System state
Mode
Press set temperature increase key for once, the set temperature will increase
1 ℃, the temperature setting range is between 18 ℃-29 ℃. When set
Increase set Press set temperature
temperature exceeds 29℃, the system enters forced hot HI state, at this time
temperature increase key
the compressor can not be manually opened. The system is in maximum
heating, maximum air volume, the internal circulation, blowing feet state.
Press set temperature decrease key for once, the set temperature will decrease
1 ℃, the temperature setting range is between 18 ℃-29 ℃. When set
Decrease set Press set temperature
temperature is lower than 18℃, the system enters forced cold LO state, at this
temperature decrease key
time the compressor can not be manually opened. The system is in maximum
cooling, maximum air volume, blowing face state.
Press manual refrigeration key A/C for once, the compressor is forced to
work, the refrigeration symbol is displayed, the air conditioning system is in
refrigeration state. In manual refrigeration state, warm air will be moderately
Manual refrigeration Press A/C key
opened to meet the demands of the user to set the temperature, the
compressor will not be automatically turned off. This is a constant
temperature control mode.
Natural ventilation Press A/C key
Shifting to
Press AUTO key for once, the air conditioning system exits manual control
automatic control Press AUTO key
mode and enters automatic control mode.
mode

Turning off Press OFF key Press OFF key for once, the system is in OFF state.

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 Item
Operation purpose Operation method System state
Mode
Entering automatic
Press AUTO key Press AUTO key for once, the system enters automatic control mode.
control mode
Existing automatic
Press AUTO key Press AUTO key, the system exits automatic control mode.
control mode
Press set temperature decrease key, when set temperature is adjusted 2 ℃
lower than actual temperature inside the truck or lower, the system will
Automatic Press set temperature automatically enter refrigeration state. For example: when the actual
refrigeration decrease key temperature inside the truck is 29 ℃, adjust set temperature to 27 ℃ or
below, such as 24 ℃ , at this time the air conditioning system will
automatically enter refrigeration state.
Press set temperature increase key, when set temperature is adjusted 2 ℃
Automatic higher than actual temperature inside the truck or higher, the system will
control mode Automatic heating Press set temperature automatically enter heating state. For example: when the actual temperature
(warm air) increase key inside the truck is 18 ℃, adjust set temperature to 20 ℃ or above, such as
26 ℃, at this time the air conditioning system will automatically enter
heating state.
Internal and external
Press external/internal Every time you press external/internal air selector key, the air conditioner air
circulation
air selector key inlet mode will switch between internal and external circulation for once.
switching
Air blowing mode
The air conditioning system automatically switches air blowing mode depending on set temperature,
switching
Every time you press set temperature increase key, the set temperature will
Increasing set Press set temperature
increase 1℃, the temperature setting range is between 18 ℃-29 ℃. At this
temperature increase key
time the working state of the system is automatically controlled by controller

39
 Item
Operation purpose Operation method System state
Mode
depending on actual temperature inside the truck.
Every time you press set temperature decrease key, the set temperature will
Decreasing set Press set temperature decrease 1℃, the temperature setting range is between 18 ℃-29 ℃. At this
temperature decrease key time the working state of the system is automatically controlled by controller
depending on actual temperature inside the truck.
Compulsory Press A/C key, the compressor is forced to open, the system enters
Press A/C key
refrigeration compulsory refrigeration state. The position of air door is unchanged.
The air volume level in automatic control mode is automatically controlled by controller depending on the temperature
difference between set temperature and actual temperature inside the truck
Temperature difference =|Set temperature – actual temperature inside the truck|
Temperature difference range Air volume level
Air volume Temperature difference≤2.5℃ 1
level in 2.5℃< Temperature difference≤4.0℃ 2
automatic 4.0℃< Temperature difference≤5.5℃ 3
control mode 5.5℃< Temperature difference≤7.0℃ 4
7.0℃< Temperature difference≤8.5℃ 5
8.5℃< Temperature difference≤10℃ 6
10℃< Temperature difference≤11.5℃ 7
Temperature difference >11.5℃ 8
Fault tolerance
When the temperature sensor is faulty, the manual function should still work normally.
function
Memory
The last state that the system stays in is taken as the default state for the next powering on.
function

40
 Item
Operation purpose Operation method System state
Mode
This system real-time monitors the operating status of air mode motor, inside and outside temperature sensor, evaporator
temperature sensor and pressure sensor. When any of these devices is faulty, the set temperature will flash. Especially when the
temperature sensor inside the truck is damaged, words ERR will also be indicated on temperature display.
Press OFF key for long time (about 10 seconds) to enter fault inquiry mode, fault code is indicated on set temperature display,
Fault the meanings are as follows:
diagnosis, C0: normal
display and C1: air blowing mode motor faulty
inquiry C2: abnormal pressure
C3: indoor temperature sensor is not installed or damaged
C4: outdoor temperature sensor is not installed or damaged
C5: evaporator temperature sensor is not installed or damaged
Stop pressing OFF key for about 10S, the system automatically exits fault inquiry mode

(3) Notice:
It is recommended to use AUTO function key to control air conditioning system. In automatic mode, the air conditioning system will
automatically turn on or turn off the compressor as required so as to prolong service life of the compressor. On the contrary, in manual control
mode, the compressor will not automatically turn off even reaching set temperature, thus service life of the compressor is shortened.
In addition, it is recommended that the set temperature is adjusted to (18 - 20) ℃ in summer and adjusted to (27 - 29)℃ in winter so that
the air conditioning enters cooling or heating balanced recycle state as soon as possible. Normally, it is not advisable to turn on cooling key "
" when heating in winter, which will reduce heating efficiency (except when defrosting is needed). And once opened the cooling key "

41
 ", remember to turn off the cooling key " " after using defrosting function, we must. Otherwise, the compressor will stay in working
condition for a long term, its life will be greatly shortened!
(4) Maintenance method of air conditioning system
① Maintenance of heating system

No. Item Period Contents

Check water pipeline for crack, aging, brittleness, bruise, wafering,
Pipeline, connector, water Once a
1 damage and other phenomena, check drain valve of engine, drain
drain valve month
valve and pipe joint of engine radiator for water leakage.

Internal and external Once a

2 Remove the dust in internal and external circulation air inlet screen.
circulation air inlet screen month

Open middle cover plate, unscrew three tapping screws for fixing
water tank in heater assembly, remove water tank, remove the dust
Once a
3 Water tank or debris on cooling fin of water tank.
year

Remove glove compartment, apply 2# industrial lithium grease on

guide plate slide, locking sleeve and other moving parts.
Drive mechanism of air Once a
4
door connecting rod year

42
② Maintenance of cooling system
No. Item Period Contents
Pipeline, Check water pipeline for crack, aging, brittleness, bruise, wafering,
1 connector, water Once a month damage and other phenomena, check drain valve of engine, drain
drain valve valve and pipe joint of engine radiator for water leakage.
Internal and
external
2 Once a month Remove the dust in internal and external circulation air inlet screen.
circulation air
inlet screen
3 Water tank Once a year Remove the dust or debris on cooling fin of water tank.
Drive
mechanism of air Apply 2# industrial lithium grease on guide plate slide, locking sleeve
4 Once a year
door connecting and other moving parts.
rod
Check pipeline connector for leakage or oil stains, check each hose
Pipeline,
5 Once a month and pipeline for crack, aging, brittleness, bruise, wafering, damage and
connector
other phenomena.
Check shaft seal of compressor for leakage or oil stain; check the lead
once a week
of electromagnetic clutch for any damage; check the belt pulley and
(air
sucker components of electromagnetic clutch for sludge and debris. In
conditioning
particular, check the gap between sucker components and belt pulley
6 Compressor seasons)
for debris.
Check the bolts for fixing compressor bracket and compressor for
Once a month looseness, check the belt for looseness or abnormal wear; do not start
the engine, put on electricity to check whether electromagnetic clutch

43
 No. Item Period Contents
can be quickly engaged and disengaged, whether there is slipping and
seizing, run the compressor for several minutes to check whether the
sound is normal.
Check cooling fin and flat tube of condenser for completeness, check
7 Condenser Once a month passage for blocking, ensure cooling air flows smoothly. Remove
sludge, leaves, insect, plastic bag and other waste on cooling fin.
Adjust air volume to maximum, turn on the air conditioning, set the
temperature to minimum value, start the engine, observe from
inspection window, if the refrigerant turns from bubble to clear state
Quantity of within 1 minute, it indicates that the refrigerant is normal. If there are
8 Once a quarter
refrigerant constant bubbles, it indicates that there is insufficient refrigerant,
refrigerant should be filled. If it always stays in clear state, and the air
conditioning is sufficient, it indicates that sufficient refrigerant is
filled, part of the refrigerant should be discharged.
II. Operation method of manual air conditioning

MIN

风量旋钮
Air volume knob Air blowing
吹风模式旋钮 暖风旋钮
Warm air knob
mode knob
Controller panel diagram

44
III. Brief introduction of controller function:
(1) Operation and corresponding state of air volume knob:
A) Air blower is turned off: B) Air volume first level: C) Air volume second level: D) Air volume third level:

A B C D

(2) Operation and corresponding state of air blowing mode knob:

A) Blow head state: B) Defrosting state: C) Defrosting and blowing feet state: D) Blowing feet state:

A B C D

45
(3) Operation and corresponding state of warm air knob:
A) Warm air fully-closed state: B) Warm air fully-opened state:

MIN MIN

A B

IV. Maintenance and trouble check list

In order to obtain good operational performance of air conditioning and ensure safe and reliable air conditioning system and extend its service
life, periodical maintenance and service is very important, we should always check the condenser, evaporator, compressor, pipeline and circuits
for abnormal noise, wear and looseness. In addition, the dry filter must be replaced after each replacement and inspection to maintain the air
conditioning in good operating condition.
Table 1: Periodical maintenance and service table

46
 Maintenance period
Maintenance item Maintenance contents
Daily Weekly Monthly Quarterly Annually
Check whether there is bubble in flowing liquid
Refrigerant quantity O
in level glass
Air conditioning Check hoses for crazing and damage O
unit Connecting pipeline Check each connector for leakage and fixation
O
clamp for looseness
Refrigeration oil Replace 25# refrigeration oil O
Oil seal Check oil leakage spots with white paper O

Compressor Belt Check the belt for tension degree and abrasion O O
Check bolts for looseness, remove and replace
Bolt O
if there is damage
Check whether it is blocked by dirts, clean if
Evaporator O
necessary
Evaporator Air screen Clean O
Blower Check whether operation is normal O
Check whether it is blocked by dirts, clean if
Condenser core O
necessary
Condenser
Blower motor Check whether operation is normal O

Electronic Control box Check electric components for completeness O

components Connector Check cable clamp plug for looseness O

47
 Maintenance period
Maintenance item Maintenance contents
Daily Weekly Monthly Quarterly Annually
Temperature control Check whether motions are normal O
Electromagnetic
Check whether it meets specified requirements O
clutch
Note: O indicates check, adjustment and repair, replace if necessary
*When replacing refrigeration oil, replace with new oil according to the following standard:
① If the remaining oil quantity inside the compressor is more than 138ml, then replace with new oil according to remaining quantity,
②If the remaining oil quantity inside the compressor is less than 138ml, then refill new oil to 138 ml.
Table 2: Trouble inspection and troubleshooting table

Inspection
Trouble Cause analysis Measure
item
Check air
Air screen of evaporator is blocked Wash air screen
screen
Open
Evaporator Normal circuit of
Insufficient Insufficient Repair/replace
blower rotation Frost on evaporator thermistor
refrigeration air flow thermistor
rotates Damage in
thermistor
Air hose separates from its position Check Repair
Abnormal Power supply system faulty Check Repair or replace

48
 Inspection
Trouble Cause analysis Measure
item
rotation Check wire
Battery connector loose or damaged Repair
terminal
Check
Blower damaged Repair or replace
blower
Fuse blown Replace
No rotation Check
Evaporator Blower damaged Repair or replace
in both high blower
blower does
and low Air volume switch damaged Check Repair or replace
not rotate
speed Blower relay damaged Check Repair or replace
Wiring junction loose Check Repair or replace
Determine
Check the
Insufficient refrigerant (observe from level whether
leakage, repair,
glass to see bubble or frost on expansion there is
then refill
valve) leakage in
High and low refrigerant
system
pressures are
Wash flow air
Compressor both lower Flow air screen blocked Check
Normal air screen
rotates
flow Expansion valve blocked or frost on
normally Replace
expansion valve or temperature difference at Check
expansion valve
the port is rather great
Refrigerant leakage (if excessive leakage is Check the
High and low
found, refill refrigerant until the pressure leakage, repair,
pressures are Check
indicates about 0.1M pa, then check the then refill
both over low
leakage) refrigerant

49
 Inspection
Trouble Cause analysis Measure
item
Check vent hole
Normal Excessive hot air enters the compartment Check
and window
pressure
Temperature controller faulty Check Repair
Discharge
appropriate
Excessive refrigerant Check
refrigerant from
low pressure side
Repair or replace
Cooling fin deformed Check
and wash
Repair or replace
High and low Cooling fin blocked Check
and wash
pressures are
Blower
both over Insufficient
relay Check Replace
high cooling of
damaged
condenser Condenser
Blower
blower
motor Check Replace
failure
damaged
Wiring
Check Replace
drop
High pressure
Pipeline blocked (determine pipeline blocking
side over
position, you can try cold or hot with hand, Determine
high, low Repair or replace
the temperature difference of the position that the cause
pressure side
has been blocked is rather great)
over low

50
 Inspection
Trouble Cause analysis Measure
item
High pressure Excessive opening of expansion valve Check Adjust or replace
side normal, High air temperature at inlet of evaporator Check Check vent hole
low pressure
side over Damage in compressor (internal leakage) Check Replace
high
Damage in compressor Check Replace
Compressor rotates Electromagnetic clutch failure Check Replace
abnormally Tension or
V-shape belt damaged or slipping Check
replace

13.Operation of tire inflation device

The tire inflation device takes air from air reservoir to inflate the tires.
Operation method:
(1) Connect the coupler of tire inflation hose with the test connector on air reservoir, and tighten the connector.
(2) Start the engine, the air compressor begins to work, keep the engine speed at 1500r/min while inflating, do not let the engine run in idle
speed.
(3) Align the other end of the hose with tire valve for inflation, and test with pressure gauge to make tire pressure reach specified value.
(4) Dismantle inflation hose, then stop engine operation.

14.Refilling coolant to cooling system

51
The expansion tank of cooling system is arranged behind driver’s cab, the compound coolant filling port of the tank is at the highest position in
cooling system to facilitate the discharge of water vapor. The air outlet pipe of coolant filling port is connected with expansion tank. When filling
the coolant, it is only necessary to top up the tank. When the system pressure increases, the outlet valve of compound coolant filling port is
opened, the steam and cooling water in the cooling system are pushed into expansion tank. The system is cooled down when stopping the engine,
a certain degree of vacuum is reached in the tank to urge air inlet valve of compound coolant filling port opens, part of the coolant is sucked back
to the tank, thus the consumption of coolant can be reduced to improve coolant circulation efficiency and relief local overheating phenomenon of
engine water jacket. Turn on the lower chamber of the tank and drain valve at engine cylinder side when discharging the water, meanwhile open
he cover of compound coolant filling port, the cooling water can be smoothly exhausted. After that, start the engine and run in idle speed for 1
minute and then shut down to completely exhaust the cooling water.

15.Water draining of air reservoir

The lower part of each air reservoir is equipped with a water drain valve. The air reservoir must be discharged after stopping traveling daily. Too
much water in air reservoir will cause water in brake pipelines and braking failure, the main reservoir should be regularly discharged. During
draining the water, just pull the ring handle of water drain valve, the air reservoir can be discharged.

52
 Water draining of air reservoir

16.Operation of jack
In order to ensure safety, the lifting capacity of the jack shall not exceed 16t. If the jack is inoperative and there is no leakage, check the oil level.
Refill 2# spindle oil or 10# oil if there is insufficient oil. If the jack is still inoperative, you can slightly unscrew the needle valve, pull the lifting
screw rod up and down with hand for 2 to 3 times, when using in cold areas in winter, the oil in the jack is thicker, the jack can be properly
heated first.
17.Adjustment of steering wheel
Loosen the locking lever, the maximum stroke of forward and backward adjustment of steering wheel is 30mm; the maximum stroke of upward
and downward axial adjustment is 60mm; before adjusting the steering wheel, the seat should be adjusted well depending on driver’s own
condition. After the steering wheel is adjusted well, the adjustment mechanism of steering wheel should be locked again to prevent automatic
change of steering wheel position during driving.

53
Caution: the adjustment of steering wheel is carried out when the truck is stopped, it is strictly forbidden to adjust the position of
steering wheel during driving.

Forward Upward

When adjusting
Backward
Downward

Fasten

Adjustment of steering wheel

18. Operation and usage of electrical equipments and instruments

(1) Battery

54
 The driver should clean the outer surface, the top surface and polarity terminal of the battery in weekly (every half a month in winter)
routine maintenance, check the wiring for fastness and check electrolyte level. The electrolyte level should be 15 - 20mm higher than the polar
plate, add distilled water when it is insufficient, clean snow, rain and cold water can be replaced when there is no distilled water, do not add
concentrated sulfuric acid. Hydrometer should be used to check the electrolyte density in secondary maintenance, electrolyte density is
1.280±0.005(20℃), when the density decreases to l.22, it should be recharged.
Notes on charging:

① When maintenance-free battery is charged, it can be directly charged without opening battery cover: “+” and “-” ends of battery respectively connected with

positive and negative cables of the charger.

② The battery should not be tilted or inverted during operation or transportation.

If the truck is not operated for a long term, the method of recharging every twenty-one days can be adopted, the constant current/constant voltage charging is as

follows:
Constant current charge Constant voltage charge
Model (12V) C20 (Ah)
Charging current (A) Charging time (H) Charging voltage (V) Charging time (H)
680 25D (low temperature type)
6-QW-180MF (low temperature 180 18 8 14.8 4～5
maintenance-free type)

Determination method:

① Constant voltage charge:

The battery uses charging voltage of 14.4 ± 0.2V, constant voltage charging method with allowable maximum current of 0.1 C20A (C20 is 20 hour rate capacity of

55
the battery), the charging current approaches to zero value and unchanged within 2-3 hours.

② Constant current charge:

The battery is charged with current of 0.1C20 A, at the end of charging, when the battery voltage change ≤ 0.05V/h, it is regarded that the battery has been fully

charged. In addition, before the use of battery, please measure the voltage at battery terminal, the battery can be directly used if the voltage is above 12.6V.

Several factors that may affect the battery life:

a. Over high/over low charging voltage of engine controller

b. Large static leakage current of the truck

c. Loose engine belt

d. Increase electrical load at will

e. Start the truck frequently

f. Add additional electrical load at will

g. Loose connector of battery and the truck

h. The truck stops operation for a long period but the negative cable of the battery has not been dismantled

i. Charge the battery with large current for a long time

The following items should be done for maintenance-free battery:

a. Maintenance-free battery is equipped with electrical charge state indicator (commonly known as electric eye), please refer to the description of relevant marks on

the battery for electrical charge state shown on the battery. If the voltage is rather low or the state is insufficient, please recharge it before using.

56
b. Always check the exhaust vents on both sides of battery cover, they must not be blocked by dust, ice water, etc., in order to prevent the housing from deformation

and explosion.

c. The battery should be fully charged for storage when battery and truck are not used for a long time, otherwise the service life of battery will be affected.

d. When the charging of battery is finished, please turn off the charger, then remove the cable of charger and battery to guard against burst injury.

e. The battery can no longer be used after damage by fire.

f. The maintenance-free batteries should not be added water during operation, therefore constant voltage charging is recommended, try to avoid constant current

charging method.

Caution:
1. Do not let electrolyte touch with eyes, skin or clothes, and do not drink electrolyte. The battery is lead-acid battery with strong corrosivity, please keep it

away from children, users should wear protective glasses and rubber gloves when operating the battery, once sulfuric acid is splashed into eyes, skin and

clothes, immediately wash with plenty of water, go to hospital for medical treatment at once for serious cases.

2. Please do not turn over and impact the battery so as to avoid the damage caused by splashing electrolyte.

3. The battery should be kept far away from heat and open flame, kept ventilated in charging and operation to guard against burst injury.

4. When installing or dismantling the battery, the engine must be shut down. When dismantling the battery, start from the negative pole; when installing the

battery, start from the positive pole. In addition, the battery must not be connected reversely, otherwise truck electrical equipment will be damaged, the "+"

and "-" terminals marked on it should be respectively connected with truck's positive and negative cables, the wiring should be solid and reliable; unfirm

wiring will generate sparks, cause explosion or burning downing of end post. In addition, to avoid the damage to truck engine, do not operate the engine

57
before the charging circuit of battery is connected. It is strictly forbidden to knock the end post to avoid acid penetration caused by loose end post.

5. The maintenance-free battery is sealed battery with liquid, it shall not be opened without permission so as not to cause explosion.
(2) Starter
Please refer to Diesel Engine Maintenance Manual for details of starter model and maintenance.
Cautions on operation:
① The starter is designed according to short-term operation, there is large current during operation, therefore the time for operating the starter
each time should not exceed 10 seconds, wait for 1 minute when restarting, otherwise the lives of battery and starter will be seriously affected.
② After the engine is started, the ignition key should be released at once to enable drive pinion of the starter exit in time so as to reduce
unnecessary wear of one-way clutch.
③ When the engine cannot be started for several times, the starter switch, battery and its cables and the engine should be checked, and then
restart it after troubleshooting.
(3) Generator and transistor regulator
① When installing or replacing the battery, negative ground must be strictly maintained, otherwise the diode of generator will be burnt out.
② Test whether the generator is generating electricity. Do not short-circuit the "armature" terminal and the "magnetic field" terminal or ground
the "magnetic field" terminal in generator running condition to avoid the damage to diode and the burning out of regulator.
③ When the engine is shut down, the starter switch should be disconnected, otherwise the current of battery will flow through the exciting
winding and the regulator for a long time to make the battery be discharged for a long time and burn out the coil.

58
④ When the generator is found not generate electricity, fault should be found in time and removed, do not keep it in long-term operation.
⑤ The integrated generator (built-in regulator) is equipped on the engine.
(4) Key switch
Anti-theft button
Anti-theft button: the key can only be pulled out after pressing the anti-theft button.
LOCK (open circuit): standby.
ACC (accessories): when the engine is not operating, turn the key to this position when any accessory (such as
radio-cassette player, wiper, cigarette lighter, etc.) is used.
ON (power on): when the key is turned to this position, the engine will work normally after starting. When the
Key switch
engine is operating, do not turn the key to any other position.
START (start): turn the key to this position to start the engine. When releasing the key in “START” position, the key will automatically return to
“ON” position.
The gears of key switch are as follows:

Gears
1 2 3 4 5 6 7 8
Terminal

LOCK ● ●

ACC ● ● ● ●

ON ● ● ● ● ●

59
 ST ● ● ● ● ●

Caution: after the engine has been started, do not turn the key to START position.
(5) Lamp combination switch
This switch is the combination of front signal lamp, rear signal lamp, headlamp, instrument lamp, license
lamp, overtaking lamp and dimmer, steering signal indicator lamp switch.
① Light switch
When the knob at the end of combination switch joystick is turned forward, the lamp listed in the list below
Figure 2-24
will be lighted (O means it goes on, X means it goes out).
Front Rear Roof Clearance Side marker
Knob License Instrument
Headlamp signal signal decoration
position lamp lamp lamp lamp
lamp lamp lamp
OFF X X X X X X X X
First
X O O O O O O O
position
Second
O O O O O O O O
position
② Steering signal indicator lamp switch
Operate this switch by joystick, the steering signal indicator lamp will go on as your intention.
③ Dimmer switch
Move the joystick of combination switch up and down to realize dimming function that is changing from upper beam to lower beam or
from lower beam to upper beam. If a car is coming from opposite or a car is just in front, then dimmer switch must be used.

60
④ Overtaking lamp switch
Lift the joystick upward from lower beam position, the upper beam of headlamp will be always lighted.
This switch can be used to indicate that you want to overtake, lift and release the joystick, the upper beam and
lower beam of headlamp will change alternately to tell the truck in front. In normal driving conditions,
regardless of operating condition of any light, turn on overtaking lamp switch, the overtaking lamp will be
lighted.
(6) Wiper, washing, exhaust brake and warning switch
① When front windshield is not clean and needs washing, press the button on the end of joystick inward to allow the washer work. The washing fluid is continuously
sprayed on the glass, along with interval wiper (three-speed type), both of them work at the same time to wash the windshield clean, after the washing liquid stops
spraying, then the wiper scrapes for two or three times. Turn the knob on the end of joystick forward, the wiper begins to work, the wiper has three positions, interval,
low and high, turn the control lever back to OFF position, the wiper is turned off.
Caution:
a. Using the wiper alone on a sunny day may scratch the glass, be sure to use in conjunction with a scrubber.
b. If the washer is used without washing liquid, the continuous operating time cannot exceed 5 seconds, otherwise the washer motor will be burnt down.
Please do not use the washer without washing liquid.
② Push the joystick forward, the exhaust brake switch is engaged. The accelerator pedal, clutch pedal and exhaust brake switch have linkage function, when the
exhaust brake switch is engaged, no matter step on accelerator pedal or clutch pedal, the exhaust brake will be released.
③ Lift up the joystick and release, the warning switch is engaged; turn on the hazard warning lamp to remind the drivers of other trucks, the warning switch is not
controlled by main power switch. When it is switched on, the front, rear, left and right turn signal lamps flash at the same time, and the left and right steering signal
indicator lamps also flash at the same time. Lift up the joystick again and release, the warning switch can be turned off.
(7) Operation and function of the panel

61
1. Notes on switch operation for manual TFM111 transmission:

Instrument switch

62
Blanking Blanking
cap cap

63
1). Instrument switch
① Air and electric horn change-over switch

The change-over of air and electric horn is controlled by this switch, press the horn button, the electric horn is connected and sounds; press the horn button again,

the solenoid valve of air horn is connected, the valve is opened and the horn sounds.
② PTO switch
Press this switch, PTO works and supplies power to realize self-discharging function of the dumping truck.
③ Rear working lamp
When pressing this switch, two rear working lamps at the tail of frame will work.
④ Working lamp behind driver’s cab
When pressing this switch, the rear lamp at left side of driver’s cab will work.
⑤ Air dryer switch
When pressing this switch, the heating wire inside air dryer will dry the air from air compressor, which effectively prevent air pipelines and pneumatic
components from corrosion and damage due to freezing in cold areas so that driving safety can be greatly improved.
⑥ Differential switch
When the wheels are slippery or fall into the mud pit, the differential lock can be used to improve passing ability of the truck. Press this switch to activate
differential lock, the clutch must be disengaged before engaging.
After the truck passes bad roads, the differential lock should be immediately released. Release the accelerator and depress the clutch, pull the rocker switch of
differential lock back to its original position.
⑦ and ⑧ front and rear fog lamp switch
Turn on the signal lamp, press front fog lamp switch, front fog lamp is lighted, then press rear fog lamp switch, then front and rear fog lamps, signal lamp,
license lamp, instrument lamp and roof decoration lamp are lighted. When driving in heavy fog day, use this switch to control the above lamps.

64
2). Control panel switch
① Power switch of whole truck.
② Engine brake switch.
The engine brake switch controls the operation of engine brake selector switch ③, only after engine brake switch is engaged, the selection of engine brake
selector switch ③ is effective.

③ Engine brake selector switch.

After engine brake switch ② is engaged, the engine brake selector switch can work effectively.
④ Fuel heater switch
In cold days, after turning ignition switch from “OFF” to “ON” position, press this switch to heat the heater in primary fuel filter for several minutes, then start
the engine. The fuel heater is bimetallic strip type that is automatically controlled by induction of internal circuit temperature control switch.
⑤ Engine diagnosis switch
⑥ Engine idle speed regulator switch
⑦ Working lamp and rear working lamp
When pressing working lamp or rear working lamp switch, their indicator lamps are lighted respectively, which indicates that this function work in normal state.
⑧ Waiting-to-start lamp and service lamp
When the engine is in waiting-to-start state or service state, their indicator lamps are lighted respectively, which indicates that this function work in normal state.
⑨ Warning lamp and stop lamp
When the engine is in warning state or stopping state, their indicator lamps are lighted respectively, which indicates that this function work in normal state.
2. Notes on switch operation for full drive manual transmission TNM111, full drive automatic transmission TNM112, TNM211, TNM311 and TNM411.

65
Instrument switch

66
Control panel switch

67
1). Instrument switch
① Air and electric horn change-over switch

The change-over of air and electric horn is controlled by this switch, press the horn button, the electric horn is connected and sounds; press the horn button again,

the solenoid valve of air horn is connected, the valve is opened and the horn sounds.
② PTO switch
Press this switch, PTO works and supplies power to realize self-discharging function of the dumping truck.
③ Rear working lamp
When pressing this switch, two rear working lamps at the tail of frame will work.
④ Working lamp behind driver’s cab
When pressing this switch, the rear lamp at left side of driver’s cab will work.
⑤ Air dryer switch

68
 When pressing this switch, the heating wire inside air dryer will dry the air from air compressor, which effectively prevent air pipelines and pneumatic
components from corrosion and damage due to freezing in cold areas so that driving safety can be greatly improved.
⑥ Differential switch
When the wheels are slippery or fall into the mud pit, the differential lock can be used to improve passing ability of the truck. Press this switch to activate
differential lock, the clutch must be disengaged before engaging.
After the truck passes bad roads, the differential lock should be immediately released. Release the accelerator and depress the clutch, pull the rocker switch of
differential lock back to its original position.
⑦ and ⑧ front and rear fog lamp switch
Turn on the signal lamp, press front fog lamp switch, front fog lamp is lighted, then press rear fog lamp switch, then front and rear fog lamps, signal lamp,
license lamp, instrument lamp and roof decoration lamp are lighted. When driving in heavy fog day, use this switch to control the above lamps.
2). Control panel switch
① Power switch of whole truck.
② Engine brake switch.
The engine brake switch controls the operation of engine brake selector switch ③, only after engine brake switch is engaged, the selection of engine brake
selector switch ③ is effective.

③ Engine brake selector switch.

After engine brake switch ② is engaged, the engine brake selector switch can work effectively.
④ Fuel heater switch
In cold days, after turning ignition switch from “OFF” to “ON” position, press this switch to heat the heater in primary fuel filter for several minutes, then start
the engine. The fuel heater is bimetallic strip type that is automatically controlled by induction of internal circuit temperature control switch
⑤ Engine diagnosis switch

69
⑥ Engine idle speed regulator switch
⑦ Front axle clutch switch
⑧ High and low gear switch
⑨ Working lamp and rear working lamp
When pressing working lamp or rear working lamp switch, their indicator lamps are lighted respectively, which indicates that this function work in normal state.
⑩ Waiting-to-start lamp and service lamp
When the engine is in waiting-to-start state or service state, their indicator lamps are lighted respectively, which indicates that this function work in normal state.

○,11 Warning lamp and stop lamp

When the engine is in warning state or stopping state, their indicator lamps are lighted respectively, which indicates that this function work in normal state.

○,12 High and low gear switch

When pressing high and low gear switch, their indicator lamps are lighted respectively, which indicates that this function work in normal state.

○,13 Front axle clutch switch

When pressing front axle clutch switch, its indicator lamp is lighted, which indicates that this function work in normal state.
3. Description of automatic transmission:

70
 -

Notes on operation of retarder

① Press retarder enable switch at lower left of instrument panel, then automatic transmission retarder mode is activated, each gear position can
be adjusted by retarder lever on instrument panel.
② Oil temperature gauge indicates the temperature of exclusive oil for automatic transmission.

See electric control section in Allison “4000” Series Transmission (5th generation control system) Installation Instruction Manual for detailed operation.
Note: see Hydrodynamic Retarder Operation Manual for operation of manual retarder.
(7) Distribution box
TFM111

71
 -

When overhauling with cover plate of electrical box opened, do not spray water onto the box, test the electric circuit with a multimeter test, short-circuit test fire

is not allowed for testing. When replacing the fuse, it is necessary to confirm the load of the fuse that is used. If the fuse that has been newly replaced is easily burnt

out, you must find out the cause and repair.

Caution: never use ordinary leads or fuses with other load instead.

72
 Small fuse Large fuse
For large fuse, the electric circuit must be checked correctly after the fuse has been blown, after the circuit failure is solved, install the same size of fuse firmly.
The electrical box is equipped with working lamp socket for night use. At the same time, the buzzer will automatically alarm when the air circuit of the whole
truck is below 4.5MPa. When the air circuit ≥4.5MPa, the buzzer stops and the cab is in lifting state that means the buckle has not been stuck, the buzzer will
automatically alarm.
When maintaining and checking the electric circuit of whole truck, in order to disconnect the circuit and protect other electrical equipments,
please disconnect the main power switch that controls the mechanical power switch in electric circuit system. Turn the switch clockwise, the
contact of power switch is closed, the electric circuit of whole truck is connected. Turn the switch anticlockwise, the electric circuit of whole
truck is disconnected.
In addition, before the whole truck needs welding, be sure to cut off the terminal of main power switch. For automatic transmissions, the
automatic transmission controller (TCM) of automatic transmission must be disconnected at the same time. Detailed operation: loosen the bolts
of the controller with a spanner, and then pull out the connector terminal.

73
 Cautions on inspection and repair of automatic transmission:
a. Before dismantling the components in electronic control system, the ignition switch must be turned off first, the earth wire of battery
terminal negative should be disconnected if necessary to avoid the damage to computer or short circuit. It is strictly forbidden to dismantle the
components in electronic control system in engine operation;
b. When connecting the battery, "+" and "-" of the battery should be carefully distinguished, do not connect "+" and "-" incorrectly.
Otherwise, the computer, circuit components and electric wiring harness will be burnt out;
When checking and repairing electric circuit, digital multimeter should be used. It is strictly forbidden to use of "test lights" and "fire
burning" and other methods to test any electrical device connected with ECU;
c. No open flames when dismantling and checking oil circuit, the fuel that has been leaked should be collected and cleared in time. When
performing “flashover test” of ignition system, the flashover position should be ensured clean without oil stains. Dry powder fire extinguisher

74
should be prepared beforehand on the spot;
d. Prevent the damage to electric control unit due to high pressure: for quick charging, the positive and negative cables of the battery should
be disconnected from the truck first, then the battery is charged separately;
e. The electronic control unit and relevant components in electronic control system should be removed in high-temperature varnish baking;
f. Severe vibration and shock should be avoided during disassembly and reassembly;
g. Before dismantling earth wire of battery terminal negative, the fault codes of electronic control system should be read first. Otherwise,
the fault codes stored in the system may be automatically cleared, which brings inconvenience to check and repair;
h. When cleaning engine components, prevent electrical system from water entering or looseness of wiring harness;
i. Besides, pay attention to the influences on other electronic control systems when checking and repairing engine electronic control system;
j. The electrical equipments with high current should be kept far away from TCM, speed sensor and other sensors to prevent interference or
install anti-interference shielding facilities;
k. Avoid oil stains, moist and vibration, keep wiring harness connector clean and reliable connection. After water enters TCM, the chip is
easily damaged;
l. The polarities of battery should not be connected reversely, it is prohibited to start the engine with external power so as not to damage the
components in electronic control system due to over high voltage;
m. After the troubles are removed, the fault codes should be cleared.
(8) Ceiling Lamp

Adopt the combined ceiling lamp composed of the reading lamp and door lamp.

75
② Turn towards the left to turn on the reading lamp button, the reading lamp will be on, used for indoor lighting.
② Turn towards the right to switch on the door lamp switch. In the meantime, switch off the indoor auxiliary switch. When the door is open or not closed securely,

the incandescent lamp will be on; when the door is closed securely, the lamp will be off.

(9) Front Combination Lamp (Front View)

（ ） （ ） （ ）

（ ） （ ）

(10) Rear Combination Lamp (Front View)

76
77
(11) Lamp Bulb
Lamp Name Lamp Bulb Lamp Name Lamp Bulb
Rear Steering Signal
Inner Side 24-70W 24-10W
Head Lamp Lamp
Outer Side 24-75/70W Rear Brake Lamp/Rear 24-21/10W
Combination Position Lamp
Front Steering Signal Lamp 24-21W Lamp License Plate Lamp 24-10W
LED Decorative Lamp 24V Reversing Lamp 24-21W
Width Lamp 24-21/10W Rear Fog Lamp 24-21W
LED Lighting Indicator Lamp of
Ceiling Decorative Lamp 24-10W 24V
Combination Instrument
Front Fog Lamp 24-70W Reading Lamp 24-10W
Side Steering Lamp 24-10W Incandescent Lamp 24-10W
Side Marker Lamp 24-21/5W / /

(12) Combination Instrument

78
1. Engine Tachometer 2. Liquid Crystal Display (LCD) 3. Speedometer 4. Forward Air Cylinder of Air-pressure Meter (I) 5. Rear Air Cylinder of Air-pressure Meter

(II) 6. Fuel Gauge 7. Water Thermometer 8. Left Adjusting Knob of Display Screen 9. Right Adjusting Knob of Display Screen 10. Alarm Indication Liquid Crystal

Display

79
The LED functions of the manual mechanical gear box (TFM111) are shown as follows:

80
The LED functions of the automatic gear box (TFM112) are shown as follows

When the key switch is on the “On” position, the instrument will display Screen 1 and then Screen 2 2S later.
① Electronic Speedometer
The speedometer pointer indicates the mileage per hour while the odometer accumulates the running distance with kilometer as the unit.
② Electronic Tachometer
The tachometer pointer indicates the revolution per minute of the engine.
③ Air-pressure Meters (I) and (II)
The pointer of the gas-pressure meter (I) indicates the air pressure in the air reservoir of the front axle braking system; the pointer of the
gas-pressure meter (II) indicates the air pressure in the air reservoir of the rear axle braking system; the indication range of the air pressure
meters is 0-1.2MPa.

81
④ Water Thermometer
The water thermometer of the engine is used for indicating the coolant temperature of the engine. When the key switch is on the “ON”
position, such meter will work.
⑤ Fuel Oil Gauge
The fuel oil gauge is used for indicating the oil volume stored in the oil tank. When the key switch is on the “ON” position, such gauge will
work. The indication of the fuel oil gauge has the memory function. After the power is turned off, the pointer of the fuel oil gauge will stay still
in the formerly-indicated position. The pointer of the fuel oil gauge will point to the new position according current oil volume only after the
powered is turned on again.
⑥ Oil Pressure Gauge
The pointer of the engine oil pressure gauge indicates the lubricating oil pressure of the engine.
⑦ Voltmeter
The voltmeter indicates the terminal voltage of the accumulator when the engine stops running; when the engine is started, the voltmeter
indicates the charging voltage of the motor. At this time, the voltage value must be higher than 24V; when the engine is started, the value
indicated by the voltmeter will be lower than 24V.
LCD:
a. LCD is located in the middle-upper area of the instrument and its visible area is 76mmX32mm with green background and black
character;
b. Function & measuring range of oil pressure gauge: 0-1MPa (upper left area)
c. Voltmeter function & measuring range: 16V-32V; (right upper area)

82
 d. Functions of accumulative mileage total and mileage subtotal with the display exchanged via the adjustment lever (left lower area);
e. Functions of clock and display of oil consumption per hundred kilometer with the display exchanged via the adjustment lever (right
lower area);
f. Gear position (middle lower area).
Other parts:
a. Adjustment lever: It is located in the middle lower area of the instrument and provides the functions such as the instrument lighting
dimming, liquid crystal display switchover, zero returning of mileage subtotal and so on;
b. XCMG sign: Located in the middle upper area of the instrument, it is formed via the die;
c. The back lighting of the instrument is white and the pointer lighting is red.
Instructions on instrument display:

Alarm symbol:

a. The alarm symbol area is located in the dead center of the instrument with the relatively visualized display;

b. When the symbol lamp is not on, the color is the same with the background color; (hidden type)

c. Provide the display space for 31 alarm symbols;

d. The instrument wiring harness of the complete truck provides the CAN interface and instrument data communication function.

83
Definition of alarm indication function:

无照明
Black

- -
ABS

Black

Black

MIL Emergency

Black

Over High water

temperature

Black

Over Speed Alarm

Blue

Black

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 (13) Cooling Water Heater
① Function display:
a. Turn on the oil valve and ignite the heater for 3 minutes. At this time, the ignition sensor does not send out the ignition signal, the controller shuts down the heater
and the burning indicator lamp HL2 flashes incessantly with f=1. Then, conduct the shutdown and inspect whether all the sealing surfaces of the oil circuit is sealed
securely or whether the solenoid valve is started reliably.
b. The ignition sensor sends out the ignition signal but the flame dies out again. Then, start another ignition. If the heater is no ignited within 90s and the HL2 lamp
flashes incessantly with f=1, conduct the shutdown and inspect the conditions of fuel oil in the oil tank.
c. The heater is overheated due to the faults such as the lack of water, air accumulation in the circulating system and so on, the HL2 lamp flashes incessantly with f=1
and the buzzer gives the alarm simultaneously. Then, conduct the shutdown. Inspect whether the exported water volume of the water pump is too small, or whether
there is the air accumulation in the system or whether there is the temperature sensor fault.
d. Conduct the shutdown. After the time is delayed for 4 minutes, if the heater is not off, the HL2 lamp flashes with f=2, the buzzer is buzzing urgently and the heater
host is still not off after the continuous working for 90s, the controller will shut down the main motor automatically but the water pump will still operate.
Caution:
a. When arranging the heater wiring harness, the user shall guarantee that such harness is far away from the truck and the heater heat source (waste
pipe). In the meantime, adopt the glass cement seal or other ways to protect all the plug-in connector from the splashed muddy water and guarantee the
good contact of all plugs.
b. For the use in the winter, it is necessary to switch on such switch for sufficient preheating before the driving.
c. It is forbidden to shut down the heater via the main power switch of the truck so as to prevent the main engine internal from overheating.

② Fault analysis and troubleshooting for cooling water heater:

If there is the fault, inspect the following contents first:

85
•Line fault (short circuit or open circuit) •Inspect whether the fuel oil in the oil tan is sufficient
•Connector corrosion •Inspect the power supply conditions
•Inspect the insurance •Inspect whether there is the summer diesel oil in the oil pipeline for the
use in winter
• Inspect the wiring and connectors of electrical •Inspect whether the waste pipe and combustion-supporting air pipe are
appliances unimpeded
• Mechanical fault of the component

Fault Cause Troubleshooting

1S or 2S switch is The main fuse is broken. Replace the fuse.
switched on and the The impeller of the water pump is stuck or the main
Repair or Replacement
main engine and the motor or water pump motor has the fault.
water pump does not Inspect the wire and eliminate
Line Fault or Wrong Wiring
work the fault
The oil pipeline is blocked or the main oil tank lacks the Unchoke the oil line or
oil. conduct the refueling.
The connector of the oil pipeline has the poor sealing and
Tighten the connector clamp.
air leakage.
The solenoid valve can’t be turned on. Inspect and eliminate the fault.
The heater can’t be
The combustion –supporting air vent is blocked. Elimination
heated.
Charging or Accumulator
The terminal voltage of the accumulator is too low.
Replacement
The ignition sensor has the fault or the positive electrode
and the negative electrode of the ignition sensor are Replacement or Adjustment
connected reversely.

86
 The combustion-supporting air volume is too small. Adjustment
The heater is ignited The pumped oil volume of the oil pump is large. Adjust the quenching resister.
but emits the black Increase the
The altitude is too high and the oxygen content of the
smoke. combustion-supporting air
combustion-supporting air is too low.
volume.
The coolant in the heater circulating system is not
Add the water volume.
adequate (<10 liters).
将气体由放气螺塞放出
The heater is There is the air stored inside the heat exchange body of
Release the air via the air
overheated. the heater and the coolant does not circulate.
release plug screw.
Inspect and eliminate the
The flow of the water pump is too low.
cause.
Adjust the
The combustion-supporting air volume is too large. combustion-supporting air port
too make it smaller.
The heater has the Add the low-temperature
abnormal sound. The motor bearing has the problem. lubricating grease or conduct
the replacement.
Dismantle the heater for the
Mechanical Scratching or Bumping
elimination.
The water pump has Dismantle the heater for the
The mechanical sealant cover has the crack.
the water leakage. replacement.
Thermostatic Control The controller has the fault. Repair or Replacement
of Heater The water temperature sensor has the fault. Replacement
76℃：OFF， The coolant inside the heat exchanger do not circuit with Release the air and fill it with
65℃: ON Fault the overheating condition. the coolant.
The control procedure
of the heater does not The controller has the fault. Repair or Replacement
work.

87
 The green lamp The heater plug is broken. Replacement
flashes after the The oil pump has the fault. Repair or Replacement
normal starting for a Fill the oil tank with the fuel
There is no oil inside the oil tank.
period of time. oil.
There is the alarm
when the starting is
conducted; the heater
The solenoid valve element is dirty or has the fault. Cleaning or Replacement
is not shut down when
the shutdown is
conducted.

For the heater with the fault indicator, after the starting, the indicator lamp (HL2) is on. Detect all the elements of the controller. If there is
the fault, the indicator lamp will flash (see the table below); if there is no fault, the indicator lamp will be on all the time. Then, follow the
standard heater control procedures.

Flash Signal Sheet of YJ/H Heater Fault Lamp

Short Pulse Flash of Indicator Lamp: 0.2s Pulse Interval: short pulse – 0.2s
Long Pulse Flash of Indicator Lamp: 0.5 Pulse Interval: long pulse – 0.5s
The interval between the long pulse circulation and short pulse circulation is 1s.

88
Maintenance and Servicing:
a. After the heater runs for a period of time (according to the use conditions), it is necessary to unscrew the heater plug for accumulated carbon
cleaning. If the heating wire burns out, it is necessary to replace the old heater plug with the new one.

89
b: When the heat efficiency is reduced due to too much accumulated carbon, it is necessary to clean the cooling fin on the inner wall of the water
jacket body and the accumulated carbon inside the combustion chamber.
c. It is necessary to keep the oil tank, oil pipeline and oil filtering device clean and unblocked. Conduct the cleaning periodically according to
actual conditions.
d. The heater circulating system shall use the anti-freezing solution or anti-freezing mixture matching with the environment temperature as the
coolant media.
e. Inspect periodically the forced circulation pump of the heater according to the use conditions. If it is detected that the sealing surface has the
water leakage or the running is difficult during the starting or other faults, it is necessary to conduct the overhaul.
f. Maintain the automatic controller, solenoid valve and other electrical elements of the heater according to the general low-voltage electrical
appliance maintenance methods. Since all the performance parameters of the automatic controller are adjusted seriously by the manufacturer, the
user shall not make the change arbitrarily.
g. The motor used by the heater needs no maintenance within the use of 3,000hours under normal conditions. If the motor work abnormally due
to the too-long use time or other causes, it is necessary to conduct the overhaul. Inspect the carbon brush wear or the bearing lubrication
conditions and add the lubricating grease or replace the carbon brush with pre-running-in when necessary.
h. In the season when the heater is not used for warming, it needs to start the heater for 3-4 times with the running time of each time as 5
minutes.
① Schematic Diagram of Hydraulic System

90
 1- Tank 2- Gear Pump 3- PT-lift Valve 4- Cylinder 5 –Limit Valve 6 –Pneumantic Control Valve
(1) Operation of PTO
①First place transmission control lever in the neutral position of low gear zone;
②Turn on PTO switch so that auxiliary transmission is in neutral position and PTO is engaged;

91
③According to particular conditions, turn transmission control lever to required gear; at this time, PTO will operate.
Operation of HY7S-130DQ PTO:
①Start engine and confirm normal operation of engine.
②With gear lever at neutral position and brake barometer indicating brake system air pressure higher than 0.4MPa, disengage the clutch. A few
seconds after disconnection of power, press PTO switch self-locking button to turn on the PTO switch.
③After this step, closely engage the clutch. At this time, PTO output shaft will drive oil pump to start operation. ④To stop oil pump, disengage
Lifting
the clutch, and press PTO switch self-locking button to turn off PTO switch. PTO power will be cut off and the oil pump operation will stop.
Self-lock
(2) Lifting of Cargo Body Button

With oil pump operating, press lifting control switch lock button (Fig.2-31) and move handle from “Ｏ” to “Lift” position. At this time, the cargo
body will be lifted. When maximum height is reached, the system will automatically discharge oil and stop lifting. Cargo body lifting speed
increases with increase of engine rotation speed. During use, cargo body lifting speed should not be too high. Normally, middle throttle of engine
shall be used for lifting. Engine rotation speed must not exceed the highest permitted value, to avoid oil pump over speed.
(3) Lowering and Restoring of Cargo Body
After unloading of cargo, lower and restore cargo body at once. To lower Lowerin Pause Lifting the cargo body, press lifting switch
lock button and move handle from “Lift” via “Ｏ” to “Lower” position. g Self-lock The cargo body will be lowered
ing Button
gradually. When the cargo body is fully restored to its original position, press lifting switch lock button and
move handle to position “Ｏ”. Only when the cargo body is fully restored and both lifting switch handle

92 Lifting Control
Switch
and POT handle are in position “Ｏ” can you run the vehicle.
(4) Pause of Cargo Body
During lifting or lowering of cargo body, if you need to temporarily stop the cargo body at certain angle (0～50°), just turn lifting switch to
position “Ｏ” (handle self-lock position). If this will be short, PTO power needs not be interrupted. If this will be long, disconnect PTO power
and stop the oil pump.
(5) Heating System
The exhaust system has a total of two channels of exhaust. A channel has a direct access to the muffler and another one leads to the floor heating
system. Turn off the exhaust valve leading to the muffler exhaust pipe and open the exhaust valve leading to the heating system exhaust pipe at
the same time when the backplane heating is needed. Lead the heat from the exhaust pipe into the compartment heating system, playing the role
of backplane heating. Turn on the exhaust valve leading to the muffler exhaust pipe and close the exhaust valve leading to the heating system
exhaust pipe at the same time when the backplane heating is not needed.
(6) Precautions
①For early stage of use, the vehicle shall be loaded according to early stage operation requirements to avoid damage of parts.
②In case machinery is used for loading, pour cargo into cargo body from a position as low as possible to avoid excessive impact resulting in
damage of parts.
③During lifting operation, the vehicle shall be in horizontal position to avoid excessive inclination resulting in accident.
④During lifting and lowering of cargo body, never let anyone standing or object placed under cargo body.

93
⑤For maintenance of the vehicle with cargo body in lifted status, make sure to erect and support auxiliary frame rear safety support assembly
inside cargo body cross member and allow extinction of engine.
⑥To check oil level in hydraulic oil tank, first lift and lower the cargo body a few times and vent gas in the hydraulic system. The oil level shall
be between upper and lower scale lines of dip stick (effective volume of hydraulic system not exceeding 44L).
② To clean the vehicle, prevent water from entering hydraulic oil tank.
③ Before running, the lifting switch must be in middle position “Ｏ” and PTO switch must be disconnected, to avoid the accidental lifting of
cargo body during running.
⑨To fill hydraulic oil, let oil enter the oil tank via filter. For filling of oil, do not remove the filter, to ensure clean oil.
⑩During lifting operation, do not step down throttle hard, use even force instead. Normally, the cargo body can be lifted (with load) at idling
speed. When certain lifting angle (about 10°) is reached, slightly increase the throttle.
⑩Upon restart of the vehicle after long period of no use or replacement of oil pump, run the oil pump at no load for no less than 10min and run
it with load for a short time. During operation of oil pump, oil leak, sound of impact, excessive heating, and noise shall not occur.
⑩To unload large rock, heavy pieces, or similar, remove rear board of cargo body.
⑩No person is permitted to stand in the cargo body.
⑩During running of vehicle, lifting and lowering of cargo body is not permitted.
(7) Maintenance
① Hydraulic oil should be replaced after 300 times of lifting in the running-in period of new automobile. Then hydraulic oil should be replaced

94
every 1500 times of lifting.
② Hydraulic oil must be kept clean, and can not contain moisture and impurities. Timely replace regularly hydraulic oil, and remove sediment.
Hydraulic oil should finish 48 hours of precipitation before being injected into tank and the filtration accuracy of hydraulic oil is 25μm.
③High-pressure hose should be replaced every two years. If cracking and damaged hose or local expansion is found, the hose must be replaced.
Regularly check for the interference and leakage of hydraulic system hose, give timely maintenance, and replace sealers. For the specifications of
seals, refer to the list of fragile items. Regularly check and replace the filter, to avoid the ingress of impurities, blocked or strained hydraulic parts.
④ Each part of the vehicle should be filled with grease. 2# Li-base grease is chosen as grease. Clean the lubrication nozzle and the required
lubrication parts before filling, and inject grease until the new grease is squeezed out. Clean excessive grease after filling and place the nozzle cover
in the original way.
(8) Oils
Add enough the stipulated hydraulic oil according to the ambient temperature and requirements.
Hydraulic system oil: When the outside ambient temperature is above-10℃, HL or HV32 ordinary hydraulic oil should be used. When the
outside ambient temperature is below -10℃ and the solidifying point of synthesis spindle oil is below -40℃, HR32 low pour hydraulic oil
should be used.
(9) Common Faults and Disposal Route
① Working Device
Faults Cause Disposal Route

95
 ① Loose control valve ① Check or replace control valve
② Too low set pressure or failure of ② Check, increase the rated pressure of
Unlifte overflow valve system, or replace overflow valve
d ③ Damaged or badly worn hydraulic ③ Repair or replace hydraulic pump
compa pump ④ Repair or replace hydraulic cylinder
rtment ④ Damaged hydraulic cylinder ⑤ Clean
⑤ Blocked hydraulic pipeline or the
input pickup port
Compa ① Lack of hydraulic oil ① Fill hydraulic oil to the specified height
rtment ② Air in the hydraulic system ② Exclude air
can ③ Limit valve opened prematurely ③ Adjust
not be
lifted
to the
maxim
um
lifting
angle
Long ① Too dirty hydraulic oil ① Replace hydraulic oil
landing ② Control valve working poor ② Clean
time of ③ Repair or replace
compa
rtment
Landin ① Leak of one-way valve ① Check or repair
g of ② Leak of control valve ② Check or repair
compa ③ Damaged hydraulic cylinder piston ③ Replace seal ring

96
 rtment seal ring

②Hydraulic System
Faults Cause Disposal Route
High ① Too large pressure and loss caused by ① Clean
oil partial blockage ② Replace seal ring
tempe ② Too large friction loss of hydraulic ③ Adjust or repair
rature components ④ Adjust
of ③ Disordered pressure control valve
hydrau
lic
system
Noises ① Air mixed with hydraulic oil ① Exclude air
produc ② Throttling noises caused by blocked ② Clean
ed by pipeline ③ Replace qualified hydraulic oil
hydrau ③ Used hydraulic oil incompatible with ④ Fasten or repair
lic specifications
system ④ Noises caused by mechanical faults

Use of Towing Hook

On your XCMG automobile, the chance to use towing hook is extremely small. However, understanding correct use of

towing hook will do you good and no harm.

97
In the tools box supplied along with the vehicle, 2 sets of towing hook assemblies (including front towing hook, lock pin,

flat washer, and split pin) and 2 sets of front towing hook pull rod.
 3. Vehicle Maintenance

Careful maintenance of vehicles is extremely important for extended service life and normal operation. For details of diesel engine maintenance,
refer to diesel engine maintenance and operation instructions.
(I) Routine maintenance (before and after running each day)
Routine maintenance mainly includes cleaning and basic inspections. Contents are as follows:
1. Check for sufficient oil and water, and for any leakage.
2. Check tire pressure.
3. After start of engine, listen to check normal operation.
4. Check for normal and reliable instruments, horns, signal indications, and lights etc.
5. Check for normal clutch and brakes.
6. Check for flexible and reliable steering gear, drop arm, track rod, and drag link; check for sufficient hydraulic oil.
7. Check tightening of tire bolts and nuts.

98
8. At end of use of vehicle, properly clean the vehicle. In particular, wipe to remove accumulated dust and oily dirt on exterior of engine, and for
vehicle in which anti-freezing solution is not used in winter, at end of use of vehicle, completely drain cooling water from cooling system.
9. Drain water from air storage cylinders.
10. Check for damage and cracking of tires; remove stones and impurities trapped in tire tread.
(II) Level 1 maintenance (at interval 1500～2000km or accumulated operation of 50 hours)
1. Cleaning
(1) Clean exterior of vehicle and each assembly.
(2) Clean air filter air inlet and dust bag; clean engine oil strainer and filter, as well as fuel filter and fuel transfer pump strainer.
(3) Clean vent plugs on transmission and middle/rear axle, and check their oil level; add oil if low.
(4) Clean exterior of batteries and check and add distilled water.
2. Tightening
(1) Check tightening of U bolts of front and rear leaf springs and propeller shaft connection bolts.
(2) Check for loose connection and poor contact of power cables.
(3) Check tightening of tire bolts and half axle bolts.
(4) Check tightening of connection bolts between exhaust pipe and exhaust manifold, and exhaust pipe and silencer.
(5) Check and tighten brake pipeline connectors and eliminate gas leakage (pay special attention to prevent gas leakage in parking brake).
(6) Check spin scribed mark of crankshaft torsional vibration damper.

99
3. Adjust degree of tightness of generator belt.
4. Carry out lubrication of level 1 lubricating items according to lubrication chart.
(III) Level 2 maintenance (at interval 5000～6000km or accumulated operation of 150 hours)
1. All items of level 1 maintenance
2. Cleaning
(1) Clean fuel pump strainer and fuel filter element.
(2) Clean air filter element; replace every 3 mileages of level 2 maintenance.
(3) Clean to remove dirt on inner wall of rotor of engine oil centrifugal rotor type filter; replace engine oil coarse filter element.
3. Tightening
(1) Check for loose rivets on frame, loose connection bolts between engine front/rear suspension and support, and loose cab suspension bolts;
timely tighten if yes.
(2) Check clamping of hanging pinch bolts and remove clearance.
(3) Check and tighten connection bolts tightening each part of cab.
(4) Check connection bolts at each part of steering gear.
(5) Check tightening of cab lifting device and tilting stopper.
(6) Check for loose spider bearing and midship mounting of propeller shaft; check tightening of each yoked flange nut.
4. Adjustments

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(1) Check and adjust clutch pedal free travel.
(2) Check and adjust toe-in.
(3) Check and adjust operation of parking brake.
(4) Check steering wheel play; adjust when necessary.
(5) Check brake air chamber push rod travel; adjust if necessary.
5. Lubrication
(1) Check, replace, or add lubricating oil in engine, transmission, and middle/rear axle (replace according to specified mileage).
(2) Check and add steering system hydraulic oil.
(3) Dismantle and check wheel brakes, clean, lubricate and adjust hub bearings, lubricate brake shoe support pin, adjust clearance between brake
disc and brake drum, and swap tires.
(4) Carry out lubrication and maintenance of starter.
(5) Carry out lubrication items of level 1 and level2 maintenance according to lubrication chart.
6. Other
(1) Check battery electrolyte density; charge if necessary.
(2) Check damper performance. Dismantle for inspection, cleaning, and oil replacement every 3 mileages of level2 maintenance.
(IV) Level 3 maintenance (at interval of 30000～40000km or accumulated operation of 1000～1500 hours)
1. All items of level 1 and level 2 maintenance.

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2. Dismantle engine assembly for inspection, cleaning, grinding, replacement, adjustment, and refitting.
3. Dismantle axles for inspection, adjustment, and oil replacement.
4. Check and adjust steering gear and transmission, and clean them and replace oil.
5. Check dual chamber brake valve, relay valve, manual valve, spring brake chamber, load sensing valve, air drier, and spare tire riser.
6. Dismantle and inspect steering knuckle, track rod, and drag link.
7. Check for firm connection at each rivet on frame and hanging part; check and lubricate hanging device.
8. Dismantle and check each spider of propeller shaft; clean and lubricate steering propeller shaft spider.
9. Check crankcase ventilator.
10. Clean air storage cylinders and 4-circuit protection valve.
11. Clean and check braking chamber membrane.
12. Dismantle, inspect, and clean clutch control hydraulic system, and replace oil.
(V) Lubrication
Lubrication is an extremely important factor affecting operation performance of each part of the vehicle and service life of vehicle. During
operation, in combination with maintenance, lubrication shall be carried out for specified parts at specified periods. Before filling lubricating oil,
clean positions of lubrication and avoid mixing of dirt and dust.
For positions of lubrications, number of lubrication points, and lubricants used, refer to Annexed Table 1 “Lubrication chart”.
(VI) Maintenance of Axles

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Operation and Maintenance of Front Axle:
1. After 1500km break-in of entire automobile, readjust brake clearance, recheck lubricating grease and bearing clearance, and recheck tightness
of fasteners at each part, before formally putting the automobile into operation;
2. For every 2000km, fill 2＃ Li-base grease into each grease nozzle;
3. For every 5000km, check brake clearance;
4. For every 8000-10000km, check tightness of brake back plate, looseness of hub bearings, and wear of break disc. If wear of brake disc
exceeds the limit pit, replace brake disc at once.
Operation and Maintenance of Rear Axle:
1. Periodically replace hypoid gear oil in heavy truck. Replace this oil after first break-in of new automobile or after gear replacement. Later,
replace this oil each time during winter and summer respectively in combination with level 2 maintenance.
2. Frequently check gear oil in speed reducer housing. Too large or too small amount of gear oil does not favor normal operation. Capacity of
heavy truck hypoid gear oil is about 10L.
3. During running of automobile, temperature of lubricating oil in rear axle housing shall not exceed ambient air temperature by 60℃.
4. Ensure free ventilating plug, and prevent too high air pressure in axle housing, which will result in leakage.
5. Frequently check external bolts, to prevent loosening.
6. Periodically check half axle housing for bending and crack etc.
(VII) Maintenance of Supercharging System

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 Connection of supercharger with gas intake pipe and exhaust pipe must be tight and free of leakage. In case of gas leakage between exhaust
pipe and waste gas turbine, efficiency of supercharger will be greatly lowered, and diesel engine exhaust temperature will rise sharply, damaging
gas valve and supercharger.
Before starting a new machine, it is necessary to fill clean engine oil in supercharger and supercharger filter via the supercharger oil intake
pipe, to ensure lubrication of supercharger once the diesel engine is started. After 8000～10000km, replace supercharger engine oil filter
element.
Before shutdown of diesel engine, idle for 3～5min, so that supercharger rotation speed declines and temperature is lowered. Also, listen to
operation of supercharger. If abnormal noise is heard, stop the machine for inspection at once. If rotation of supercharger rotor is not free and
jamming or friction occurs, send the automobile to a maintenance station capable of repair.
For every 500h or 30000km, check clearance of supercharger rotor shaft and remove dust and carbon deposit on air pump turbine housing
and rotor blades. At this time, remove turbocharger from diesel engine and replace metal gaskets between supercharger and exhaust pipe. Never
use mechanical method to remove dirt deposit on rotor parts. Instead, use gasoline or cleaning solution suitable for cleaning of Al air pump parts.
Attention: Avoid damage or deform (due to force) of rotating parts of removed turbocharger; otherwise turbo balance will be affected.
Do not damage any rubber seals.
(VIII) Method of Maintenance of Air Conditioning System
1. Maintenance of Air Heating System
S/N Item Period Contents

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 Check water pipeline for crack, aging, brittleness, dinky, collapsing and
1 Pipeline, connector, drain valve Monthly damage. Check for water leakage at engine drain valve, engine radiator drain
valve, and pipe connectors.
Remove dust on inner/outer circulating air admission net
Blower inner/outer circulating air
2 Monthly
admission net

Open middle cover plate. Unscrew 3 tapping screws fixing water tank on air
3 Water tank Yearly heater assembly, to remove the water tank and clean its cooling fins of dust or
impurities.
Remove glove box and apply 2# industrial Li base grease on moving parts
Air damper link drive
4 Yearly such as guide plate slipway and locking sleeve.
mechanism

2．Maintenance of Air Cooling System

S/N Item Period Content
Check pipeline connectors for leakage and oily dirt; check each hose and pipeline for crack,
Pipeline, aging, brittleness, dinky, collapsing, and damage.
1 Monthly
connector

Weekly (in Check compressor shaft seal for leakage and oily dirt. Check wire of EM clutch for damage.
2 Compressor season of Check for mud and impurities on compressor EM clutch sheave and suction cup. In particular,
use of AC) check impurities at clearance between suction cup and sheave.

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 Check for loose bolts fixing compressor support and compressor. Check for loose or abnormally
worn belt. Without staring the engine, turn on power to check if EM clutch can quickly engage
Monthly
and disengage, and for slipping and jamming. Run compressor for a few minutes to listen for
normal sound.
Check for intact radiating fins and flat pipes of condenser. Check for clogging of channels.
3 Condenser Monthly Ensure free flow of cooling air. Remove mud, leaves, insects, plastic bags and other trash on
radiating fins.

Adjust wind power to maximum. Turn on air conditioning unit. Set temperature to lowest value.
Start engine and view from sight glass. If in 1min, coolant gradually changes from gas bubble to
Coolant
4 Seasonally clear, then the coolant is normal. If gas bubbles always exist, amount of coolant is not enough
quantity
and coolant shall be filled. If coolant is always clear and cooling air is strong, excessive coolant
has been filled and part of coolant shall be drained.

4. Troubleshooting

Possible fault Analysis of causes Measures

Low battery voltage Remove for charging
Difficult start of engine Ablation of head gasket Note water tank water consumption
Clogging of oil path Check oil path
Check water leak at connection between
Engine water temperature too high Lack of water in radiator
radiator and hose

106
 Thermostat failed; valve cannot open Replace
Fan belt slipping Adjust belt degree of tightness
Oily dirt on friction disc Remove oily dirt
Slipping clutch
Thinning of driven friction disk due to serious wear Replace
Pedal free travel too large Adjust as specified
Clutch disengagement not complete
Clutch release lever improperly adjusted Correct the lever and adjust as specified
Incomplete clutch release Adjust clutch control system
Synchronizator failed Replace synchronizator
Difficult gear shift
Control mechanism detuned; each moving
Replace and adjust
connector worn and loose
Disorderly gears Interlock device excessively worn or damaged Replace
Tire pressure too high or too low Charge as per specified pressure
Vehicle overload or unbalanced load Avoid
Abnormal wear of tires
Incorrect front wheel alignment angle Adjust
Sudden start or forced braking Drive smoothly
Excessive clearance between friction disk and
Readjust
brake drum
Loss of brake drum roundness Bore and grind
Low braking force Brake valve improperly adjusted; max. air pressure
Adjust max. air pressure
too low
Brake block oily, muddy or sintering Clean and remove carbon deposit layer
Rusting of brake block or cam support Lubricate; replace if necessary
Leaf spring broken along center
Vehicle overload for long periods Load normally
hole
Possible fault Analysis of causes Measures

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 Steering link ball head loose Tighten as per specified torque
Steering propeller shaft spline and spider bearing loose Readjust
Steering knuckle thrust plate clearance too large Readjust
Steering wheel shimmy,
Front leaf spring U bolt loose
unstable control Tighten as per specified torque
Left/right steering knuckle lower arm fastening bolt loose
Clearance between knuckle king pin and liner too large Replace liner or king pin
Load unevenly distributed; fore axle load too small Pay attention to even loading
Generator not generating Generator field winding circuit disconnection or poor
Carry out maintenance of generator
power or charging current too contact
small Voltage regulator damaged Replace
Voltage regulator adjustment voltage too high Suitably reduce adjustment resistance
Charging current too large
Voltage regulator damaged Replace
Excessive sway of ammeter Slipping generator belt Adjust
pointer Generator brush poor contact Repair
Fan not working Check fan and control circuit
Check radiator water inlet/outlet pipelines to
Radiator water circulation fault
No air heating determine leakage; repair leaking part
Check action of commutator, control circuit,
Wind direction control damper not working
and air damper driving mechanism
Check compressor clutch control circuit. For
Compressor not working compressor internal fault, replace with a new
No cooling
compressor
Coolant leakage Check leaking position, repair, and fill coolant

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 V. Operating Instructions for Natural Gas Vehicle Model
1. Cautions & scope
1.1 Application scope
The Operating Instructions applies to the use and servicing of special devices of the vehicle model related to LNG natural gas manufactured by the Company.
1.2 Cautions for use
1. First, be sure to read seriously “the Operating Instructions” and execute the use and servicing according to the requirements of “the
Operating Instructions”.
2. If you want to repair the Truck, please call the Company.
3. When the liquidometer displays the alarm, it is necessary to fill the liquid timely, or else, it may cause the breaking down of the Truck.
4. Part of LNG inside the cylinder is residual and the residual liquid volume is about 1-5L.
5. The speed scope applicable to the Truck (unit: km/h):

Expresswa Class I Class II Class III Mine Road, Factory Road,

y Highway Highway Highway Country Road

Inter-city ≤110 ≤90 ≤80 ≤60 ≤30

Bus

Freight ≤90 ≤80 ≤60 ≤40 ≤30

Truck
≤110 ≤90 ≤80 ≤60 ≤30
Sedan

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1.3 No-warranty scope
1. Incidents caused by the operations not conforming to the Operating Instructions.
2. Bumping, turnover, impact, damage, burning, etc. caused by the accident.
3. Changed installation, additional installation and part change for the final state.
4. Speeding not conforming to the specified speed.
5. Damage or corrosion caused by the environment or chemical treatment such as the chemical corrosion, flood, etc.
6. Failure of regular inspection: Fail to fasten corresponding fasteners periodically; fail to verify the pressure meter and safety valve
according to the provisions; fail to replace the vulnerable parts of the door periodically.
7. Damage conducted by human.

Caution:
All the problems caused by the above reasons do not lie in the warranty scope and the service department will provide the paid service.

2. Safety summary
2.1 For the safety problems caused by the characteristics of natural gas and the handling methods, please follow Article 3.2.
2.2 During the repair or replacement of the parts and pipeline joints on the cylinder body, it is necessary to discharge all the LNG liquid and air in the container
via safe methods. During the operation, the working staff shall dress according to corresponding provisions of Article 3.1.
2.3 During the filling or use of LNG liquid, it is necessary to prevent the liquid splashing or overflowing; during the operation, there shall have the anti-freezing
measures. In case of the frostbite, handle it according to the methods stated in Article 3.2.
2.4 During the filling or use, the turning on/off of the valve may not be easy due to the frosting. Under such condition, the user shall not screw the valve by force

110
but unfreeze the valve with warm water first before the turning on/off.
2.5 For the liquid-containing cylinder with the storage period exceeding 5 days, it is necessary to drain all the liquid, release the pressure until 0MPa is achieved
and turn off all the valves. In addition, such cylinder shall be placed in the open place or ventilated space and the electrical appliance in such space shall be the
anti-explosion type. During the draining, select the location according to the provisions of Article 3.1.
2.6 The cylinder containing LNG is forbidden to stored in the airtight space.

Warning: The screwing by force may cause the damaged valve and lead to the personal injury.

3. Safety protection
3.1 Safety protective equipment and measures
When working on the site with the natural gas or LNG, relevant staffs need to have the following common safety knowledge:
1. Make the LNG equipment stay far away from the flame or electric spark. There shall not have the inflammable or burnable objects in surrounding areas.
2. Fireworks are forbidden to enter the LNG equipment maintenance, filling and storage areas.
3. During the working in the area with LNG, it needs to wear the safety goggles, face mask, heat-insulting gloves and protective clothing. The protective
clothing shall adopt the cotton materials. It needs to wear the pants for the operation rather than the skirt and shorts. There shall not have the iron nail on the shoe sole.
The leg bottom of the pant can’t be rolled up. The pants must over the open mouth of the shoe upper. The gloves shall adopt the cotton or leather materials and large
enough to be taken off easily. The gloves shall be intact and dry without any breakage and humidity.
4. During dismantling and maintenance of the parts, it needs to conduct the draining and release the pressure for the LNG cylinder.
5. Provide the dry powder extinguisher with the proper quantity.
6. There shall be sufficient water sources in surrounding areas. The water source is used for the temperature reducing rather than the extinguishing.
7. Before entering the natural gas area, it is necessary to measure first the oxygen concentration and natural gas concentration in such area.

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 Warning:
Protect the eyes and exposed skin; make the equipment area stay in the good ventilation condition; during the equipment maintenance or servicing,
guarantee that the pressure release has been conducted for the system and the system is far away from inflammable materials, electric sparks and fire
sources.
3.2 Basic handling methods for injuries
3.2.1 Handling methods for cold burn
1. When the skin sticks to the low-temperature surface, adopt the hot water heating method to unfreeze the skin and flesh and then move the frostbitten position
away. In addition, move the wounded to the warm place (about 20℃).
2. Remove all the clothes hindering the blood circulation of the frostbitten part.
3. Conduct the water bath for the frostbitten part immediately. The water temperature is required to be 40-45℃ and the drying or direct heating method is not
allowed; if the water temperature exceeds 45℃, it will intensify the injury to the body tissue in the frostbitten area.
4. Send immediately the wounded to the hospital for further treatment.
5. If the wounded has the large-area frostbite and the body temperature has dropped, it needs to soak the wounded in the water of 40-45℃ and then send the
wounded to the hospital as soon as possible.
6. The frostbitten body part will start paining and swelling after the heating. If the injury condition is not serious, it is necessary to conduct the slow continuous
heating for the frostbitten part until the skin turns from grey white into pink red or red.
7. The wounded is not allowed to smoke or drink, for smoking or drinking will reduce the blood volume flowing to the frostbitten tissue. Give the tetanus shot to
prevent the infection.

3.2.2 Handling methods for leakage

1. The apace with possible leakage is required to be satisfy the requirement that the ventilation rate is not less than 1/12 of airtight space volume per minute

112
(equivalent to not less than 5 times of replacement within 1 hour).
2. The airtight space shall be equipped with the inflammable gas alarm. The lowest limit of the alarm is that the alarm shall gives out the alarm when the natural
gas content in the air of the space reaches the volume content of 1%; the alarm signal shall be able to send out the sound and light and the driver can see the alarm
display.
3. Equip necessary fire extinguishers. For the selection of extinguishing methods, please refer to “LNG Extinguishing Mode & Its Level”.
LNG Extinguishing Method & Its Level:

Extinguishing
Level Use Method
Mode Instructions

Chemical Dry Conduct the extinguishing via

Powder It shall be used onto the fire root chemical reaction. It needs the
Extinguishing 1 and definitely shall not be sprayed skilled operations. In case of any
Agent onto the flame. obstacle, the extinguishing is
(Postassium impossible.
Carbonate)
Chemical Dry
Conduct the extinguishing via
Powder
It shall be used onto the fire root chemical reaction. It needs the
Extinguishing
2 and definitely shall not be sprayed skilled operations. In case of any
Agent
onto the flame. obstacle, the extinguishing is
(Sodium
impossible.
Carbonate)
（Hi - Ex） Spray it onto the flame and
Boiling Foam unburned LNG so as to reduce the Isolate LNG from the flame and
3
with High LNG overflowing and the ignition reduce the flame size, thus
Expansion Rate chances. decreasing the evaporation

113
 Extinguishing
Level Use Method
Mode Instructions
(Hi - Ex) volume.
It can control but not extinguish
the fire. Spraying it onto LNG
（CO2） Use it onto the part above the
directly will increase the height of
Carbon Dioxide 3 flame and do not spray it onto the
the steam and flame, thus it is
(CO2) flame directly.
more suitable for the flame
without gases.
It can’t be sprayed onto the LNG
gas but can be sprayed onto the
Control the flame without gases
Water 3 natural gas steam in the water mist
and cool down adjacent
form to make the steam cloud
equipment.
cluster shrink.

Instructions: Level 1 is the best while Level 3 is the worst.

Caution:
The user can conduct the configurating according to the capacity of the fire extinguisher. A 30L dry power extinguisher can extinguish the flames
within the scope of 2m2 while a 350L dry power extinguisher can extinguish the flames within the scope of 14m2.

Warning:

114
 It is not allowed to spray the water onto LNG liquid, which will cause the evaporation of enormous LNG and consequently intensify the fire
behavior.
3.2.3 Handling methods for choking:
1. The excessive accumulation of natural gas may make the oxygen concentration in the air become thin and people in such environment may have the
symptoms including coma, injury and even choking.
The physiological features of choking is listed below (also known as hypoxia effect):

Oxygen (Volume
Phase
Concentration) Symptoms
The breathing rate and pulse rate increase and the muscular movement
1 21% - 14%
coordination will be slightly disordered.
Agitated emotion, fatigue action, difficulty in breathing and wrong judgment
2 14% - 10%
and pain anesthesia.
3 10% - 6% Nausea, emesis, non-free action, collapse, anesthesia, permanent brain damage.

4 ＜6%
Spasm, faint breathing, dying in minutes.

2. When the staff loses the consciousness, it is necessary to evacuate him/her from the site and conduct the artificial respiration. When the operator stops
breathing, it is necessary to conduct the artificial respiration and send him/her to the hospital for the treatment.
3. When the oxygen concentration in the environment is <19%, blow the area with natural gas of high concentration with the air to keep the oxygen
concentration stay >19%. However, it needs to control the natural gas concentration as <1%.

Warning:
When the oxygen concentration in the air is <10% or the natural gas concentration in the air is >50%, the working staffs can not enter the LNG
area.

115
 4. Brief introduction on cylinder

4.1 Brief introduction on cylinder

LNG is the English abbreviation of liquefied natural gas with the boiling point as about -163℃ under the barometric pressure. Natural gas can’t be liquefied via
pressurizing under normal temperature. It can liquefied under a certain pressure when the temperature drops to the value below -80℃ around. Normally, LNG (liquid)
of one volume will generate the gas (standard status) of 625 volumes. Under the atmospheric environment, when it is mixed with the air, its volume is flammable
under the conditions of 5%-5%. LNG steam does not have the smell while natural gas a choking agent. When there is the natural gas of high concentration in the air,
people will have the nausea and dizziness symptoms due to the oxygen deficit.
Cylinder is a low-temperature thermal-insulating pressure container which can substitute the oil tank of the Truck to contain, store and supply the fuel (LNG)
with the function of multiple repeated filling. It is the dual-layered container. The liner can bear certain pressure and is used for storing and supplying the
low-temperature liquid LNG. Twin the outer wall of the liner with the multi-layered thermal-insulting material composed of the glass fiber paper and clean aluminum
foil. The multi-layered material has the features of low thermal conductivity, high thermal-insulting performance and light weight under the high vacuum condition.
The shell is mainly used for forming the interlayer space (space between two layers of containers) together the liner and supporting the liner.
The interlayer space is vacuumized as the high vacuum space and forms the good thermal-insulting system together with the multi-layered thermal-insulting
material. Such system is used for lengthening the storage time of LNG.
The supporting system is set up between the shell and the liner to fix reasonably the liner and the shell. The design of the supporting system can bear the
vibrations generated during the speeding up, speed reducing and operating of the Truck during the driving.
All the external pipelines and valves of the cylinder are set up at one end of the cylinder and protected with the protective ring or protective cover. The setting up
of the valve system can satisfy the LNG filling an supply.
The liner is set up with the two-stage relief valve (in the pipeline system), which can protect the liner when the liner bears the excessive pressure. Under the
excessive pressure condition, the main relief valve (Svp) (the turning-on pressure is 1. 75MPa, 250psi) will be turned on first. Its function is to release the pressure
rise caused due to the normal thermal leakage loss of the thermal-insulting layer and support or the pressure rise caused due to the speeding-up thermal leakage when

116
a fire is started. The pressure set for the auxiliary relief valve (Svs) (the turning-on pressure is 2. 9MPa, 410psi) is higher than that of the main relief valve. The
auxiliary relief valve will be started when the main relief valve does not work or is blocked.
When the interlay has the excessive pressure, the shell protection is achieved via a circular vacuum plug. Under normal conditions, the vacuum plug is pressed
tightly in the vacuum plug base by the barometric pressure to isolate the atmosphere from the interlayer space and guarantee the vacuum degree of the interlayer.
Since that the low-temperature liquid or steam will have a relatively large volume after being heated, the interlayer pressure will rise rapidly even when a small
number of low-temperature or steam leaks into the interlayer. When the interlayer pressure exceeds around 0.17MPa (gage pressure), the vacuum plug will be opened
for the pressure release.
The economic valve (Er) is set up. During the use (except for the long-time driving), the economic valve can use preferentially the natural gas steam formed by
the evaporation due to the natural evaporation at the top of the cylinder liner so as to reduce the internal pressure of the cylinder, enabling that the cylinder pressure
will not rise to the turning-on pressure of the relieve valve as long as the Truck is used and there is no need to conduct the emptying.
The excess flow valve (Ef) is also set up. When the external pipeline breaks and the pipeline flow is larger than the set value, the excess flow valve will turn off
automatically; when the liquid valve before the excess flow valve is turned off, the excess flow valve will return to its original position automatically. The automatic
turning off of the excess flow valve can effectively avoid the occurrence of secondary hazards.
The specific characteristic of the whole set of system is the setting up of the self-pressurizing system. The self-pressurizing system includes: Pressurizing stop
valve (Pv), pressure rise regulating valve (PBr), self-pressurizing coil pipe (Pr) and corresponding pipelines. Such system can satisfy the requirement of guaranteeing
the normal steady liquid supply pressure and flow of the cylinder merely by the thermal exchange with the air without additional energy. The steady pressure is
controlled via the regulating of the pressure rise regulating valve. When the pressure at the cylinder top is lower than the pressure set by the pressure rise regulating
valve (i.e. the pressured needed by the system), LNG will enter the self-pressurizing coil pipe via the pressurizing stop valve and pressure rise regulating valve to
conduct the thermal exchange with the air and the liquid will turn into the steam and return to the cylinder top. Since that the liquid gas of LNG is relatively large, the
pressure will rise consequently. When the pressure equals to the pressure of the pressure rise regulating valve, the pressure rise regulating valve will turn off
automatically and the cylinder pressure will not rise continuously
4.2 Brief introduction on flow
4.2.1 Flow chart & symbol
The LNG truck fuel system is composed of the cylinder, carburetor, pipeline pressure reduction regulating valve and the engine system.

117
 The carburetor mainly utilizes the circulating cooling water of the engine to heat and carburet LNG, enabling the natural gas to satisfy the use temperature and
flow requirements of the engine.
The main function of the pipeline pressure reduction regulating valve is to reduce the pressure of the natural gas carbureted by the carburetor, enabling such
natural gas satisfy the use pressure requirement of the engine with the stable pressure maintained.
The function of the buffer tank is to reserve the gas of a certain volume. When the power of the Truck is relatively large and relatively more natural gas is
needed during the starting, a buffer tank can be equipped behind the pipeline pressure reduction regulating valve. If this is limited by the installation space of the
Truck and the power of the Truck is not large and the length of the gas supply pipeline (equivalent to the buffer tank) can satisfy the needs, this container may not be
equipped. The system needs to be equipped with the relief valve (prepared by the user) and the turning off pressure of the relief valve needs to be not more than that
of the equipment with the minimum working pressure in the system shown in Figure 1.
The function of the solenoid valve is to prevent the natural gas from flowing towards the engine and avoid the natural gas leakage by lying in the “OFF” state
when the ignition switch of the engine is switched off or lies in the secondary position and the flameout ignition switch is still in the “ON” state.

Caution: The component in the dashed frame shown in the flow schematic diagram is configured correspondingly according to the needs of the
user and is not the standard configuration.

118
 Figure 1 System Flow Schematic Diagram
Symbol Name Symbol Name Symbol Name
C1 Low-temperature Liquid Inlet FCv Liquid Inlet Check Valve P2 Pipeline Pressure Meter
C2 Emptying (Gas Return) Joint DCv Outlet Check Valve PBr Pressure Rise Regulating Valve
Vv Emptying (Stop) Valve Er Economic Valve Pr Self-pressurizing Coil Pipe
Vu Use (Stop) Valve Ef Excess Flow Valve Pt Pressure Transmitter
Va Carburetor P1 Cylinder Pressure Meter Pv Pressurizing (Stop) Valve
LG Liquidometer Svp Main Relief Valve Svs Auxiliary Relief Valve
LSv Pipeline Relief Valve LRe Pipeline Pressure Reduction Cb Switch Controller
Regulating Valve
SV Solenoid Valve

4.2.2 Flow introduction

119
4.2.2.1 Liquid inlet pipeline
The liquid inlet pipeline is composed of the low-temperature liquid inlet (C1), liquid inlet check valve (FCV) and connecting pipeline.

Figure 2 Liquid Inlet Schematic Diagram

The gas filling station pushes away the low-temperature liquid inlet (C1) with the mechanical force of the gas filling gun and LNG is pumped into the gas filling
pipeline by the low-temperature pump equipped for the gas filling station. The liquid inlet check valve (FCV) is turned on due to the pump pressure. At this time, the
whole liquid inlet pipeline is in the “ON” state.
During the liquid entering, the steam at the cylinder top phase space will be liquefied and cycled again due to the spraying effect so as to avoid the emptying loss
and make the cylinder pressure stay unchanged and even decrease.
When the cylinder inside is almost filled, the pressure inside the cylinder will rise rapidly due to the liquid incompressibility. When such pressure reaches the
shutdown pressure set by the gas filling device, the gas filling device will stop the filling and the gas filling is completed.
Since that both the low-temperature liquid inlet (C1) and liquid inlet check valve (FCV) only allow the single phase flow of the liquid (the liquid can only
flowing into the cylinder and can’t flow out of the cylinder), LNG staying in the pipeline between the low-temperature liquid inlet (C1) and liquid inlet check valve
(FCV) will flow into the cylinder after being carbureted without causing the overpressure fracture of the pipeline.

Caution: For the structure of the low-temperature liquid inlet, please refer to Article 4.3.3; for the structure of the liquid inlet check

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 valve, please refer to Article 4.3.4.

4.2.2.2 Self-pressurizing pipeline

The self-pressurizing pipeline is composed of the pressurizing stop valve (Pv), pressure rise regulating valve (PBr) and self-pressurizing coil pipe (Pr)

Figure 3 Self-pressurizing Schematic Diagram

When the cylinder inside is almost filled, the pressure inside the cylinder will rise rapidly due to the liquid incompressibility. When such pressure reaches the
shutdown pressure set by the gas filling device, the gas filling device will stop the filling and the gas filling is completed.
Since that both the low-temperature liquid inlet (C1) and liquid inlet check valve (FCV) only allow the single phase flow of the liquid (the liquid can only
flowing into the cylinder and can’t flow out of the cylinder), LNG staying in the pipeline between the low-temperature liquid inlet (C1) and liquid inlet check valve
(FCV) will flow into the cylinder after being carbureted without causing the overpressure fracture of the pipeline.

Caution: For the structure of the low-temperature liquid inlet, please refer to Article 4.3.3;
for the structure of the liquid inlet check valve, please refer to Article 4.3.4.

4.2.2.2 Self-pressurizing pipeline

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 The self-pressurizing pipeline is composed of the pressurizing stop valve (Pv), pressure rise regulating valve (PBr) and self-pressurizing coil pipe (Pr).

Figure 3 Self-pressurizing Schematic Diagram

During the self-pressurizing, it needs to guarantee that all the stop valves except the pressurizing stop valve (PV) are in the “OFF” state. Thus, the cylinder and
self-pressurizing pipeline can form a airtight circulating space.
Turn on the pressurizing stop valve. Then, the low-temperature liquid will pass through the pressure rise regulating valve (PBr) and then the self-pressurizing
coil pipe (Pr) and will be heated as the saturated steam, entering the cylinder gas phase space (top). Since the liquid gas of LNG is relatively large, the relatively less
output liquid will turn into enormous steam. In the meantime, this is an airtight circulating space, i.e. the increased gas volume is much larger than the exported liquid
volume and the gas has the compressibility, thus enabling the pressure rise of the cylinder.
When the cylinder pressure rises to the needed pressure (set pressure of the pressure rise regulating valve), the pressure rise regulating valve (PBr) will turn off
automatically and the cylinder pressure will not rise any longer but stay stable.
Caution: For the structure of the stop valve, please refer to Article 4.3.2; for the structure of the pressure rise regulating valve, please refer to Article 4.3.8.

4.2.2.3 Liquid outlet pipeline

The liquid outlet pipeline is composed of the outlet check valve (DCv), liquid outlet stop valve (Vu) and excess flow valve (Ef).

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 Figure 4 Liquid Outlet Schematic Diagram
When the liquid outlet stop valve (Vu) is not used, it shall be in the “OFF” state.
When the Truck conducts the fuel gas supply, the liquid outlet stop valve (Vu) will be turned on. LNG will pass through the outlet check valve (DCV) and then
enter the power supply system via the liquid outlet stop valve (Vu) and excess flow valve (Ef).
When the difference value between the inlet pressure and outlet pressure of the excess flow valve (Ef) is larger than the design value, the excess flow valve (Ef)
will turn off rapidly and stop the external liquid supply. When the liquid outlet stop valve (Vu) is turned off, the excess flow valve will return to the “ON” state soon.
Caution: For the structure of the stop valve, please refer to Article 4.3.1; for the structure of the outlet check valve, please refer to Article 4.3.2; for the structure
of the excess flow valve, please refer to Article 4.3.

4.2.2.4 Economic circuit

The economic circuit is composed of the economic valve (Er), liquid outlet stop valve (Vu) and excess flow valve (Ef).

Figure 5 Economic Circuit Schematic Diagram

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 When the pressure inside the cylinder is higher than the set pressure set of the economic valve and if it is in the gas supply process, the economic valve (Er) will
turn on and the saturated steam in the gas phase space at the cylinder top will enter the gas supply pipeline via the economic valve (Er). At this time, the outlet check
valve (DCV) is basically in the “ON” state. There is the gas-liquid mixture in the gas supply pipeline. Along with the constant use of the gas, the pressure inside the
cylinder will gradually reduce to the set pressure of the economic valve (Er). At this time, the economic valve will turn off, returning to the liquid supply state.

Caution: For the structure of the economic valve, please refer to Article 4.3.9. When it is not in the gas supply process, the economic valve (Er) can’t
reduce the pressure inside the cylinder.

4.2.2.5 Gas supply system

The gas supply system is composed of the carburetor (Va), pipeline pressure reduction & regulating valve (LRe), buffer tank, pipeline relief valve (LSv),
solenoid valve (SV) and pipeline pressure meter (P2).

Figure 6 Schematic Diagram of Gas Supply System

After entering the carburetor (Va), LNG will be heated by the cooling water of the engine and turn into the gas. Then, it will pass through the pipeline pressure
reduction & regulating valve (LRe) and reduce the pressure until the pressure meets the needs of the engine. Then, it will pass through the buffer tank and solenoid
valve (SV) and go to the engine.

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4.2.2.6 Safety system
The safety system is mainly composed of the main relief valve (Svp), auxiliary relief valve (Svs), cylinder pressure meter (P1), liquidometer (LG) and manual
vent nozzle (Vv).

图7 安全系统示意图

Caution: The pressure sensor (Pt) is optional.

4.3 Valve structure and maintenance

4.3.1 Low-temperature stop valve

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 Figure 8 Flow Diagram Figure 9 Sectional View

Figure 10 Exploded Assembly Drawing

Part name:
①Gasket ②Screw ③Spring Shield ④Lining ⑤Spring ⑥Hand Wheel ⑦Washer ⑧Thread Jacket ⑨Valve Rod ⑽Sealing Gasket ⑾Valve Clack ⑿
Valve Body
Leakage handling:
If the valve has the leakage, firstly, unscrew ②, dismantle S.N. ①, S.N. ③, S.N. ④, S.N. ⑤, S.N. ⑥ and S.N. ⑦ in sequence and screw down S.N. ⑧
with the wrench; then, conduct the assembly in the reversed sequence for the restoration.
If the stop valve can’t be turned off securely, it only needs to replace the vulnerable part and there is no need to replace the rest parts.
Vulnerable part:
The vulnerable parts are marked with A in Figure 9: ⑽Sealing Gasket ⑾Valve Clack.

4.3.2 Outlet check valve

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 Figure 11 Sectional View Figure 12 ON State Diagram
Part name:
①Valve Body ②Gland ③Spring ④Steel Ball
Vulnerable part:
This valve is in the integral replacement type.
。

4.3.3 Low-temperature liquid Inlet

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 Figure 13 Sectional View and Exploded Assembly Drawing

Figure 14 On State
Part name:
①Upper Cover ②Screw ③Seal Ring A ④Spring ⑤Spring Seat ⑥Seal Ring B ⑦Seal Ring Gland ⑧Elastic Check Ring ⑨Connector ⑩Protective Cap
泄漏处理：

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 Leakage handling:
If the vulnerable part (marked with A in Figure 13) or vulnerable surface (marked with B in Figure 13) is damaged, there will have the leakage; when the spring
(S.N. ④) has the fault, there will also have the fault. However, this condition is not common.
If there is the leakage between S.N. ① and S.N. ⑨, screw down S.N. ② (it is necessary to adopt the diagonal screwing down mode); if screwing down S.N.
② can not solve the problem, replace S.N. ③.

The main cause for the leakage at the inlet is that S.N. ⑥ is damaged or the sealing surface of S.N. ⑨ (the position marked with C in Figure 14) is blocked or
scratched by the debris (fine sand, ice cube, etc.).
For the condition that S.N. ⑥ is damaged:
Unscrew all the S.N. ② and then take out S.N. ③, S.N. ④ and S.N. ⑤ (S.N. ⑥-⑧ have been installed in ⑤) successively. Then, take out S.N. ⑧, S.N.
⑦ and S.N. ⑥ successively; replace S.N. ⑥ and then conduct the assembly in the reversed sequence for the restoration.
For the blocking condition:
If the blocking is caused by the solids such as the fine sand, etc. and the sealing surface is not scratched, unscrew all the S.N. ② and then take out S.N. ③, S.N.
④ and S.N. ⑤ (S.N. ⑥-⑧ have been installed in ⑤) successively. Then, remove the debris and conduct the assembly in the reversed sequence for the
restoration.
When the blocking is caused by the ice cube, take out the parts according to the above steps and dry the parts (the flame shall not be used during the drying).
Finally, conduct the assembly in the reversed sequence for the restoration.
For the scratching condition: Dismantle the valve according to the steps for the condition when S.N. ⑥ is damaged and then grind the internal sealing surface
of S.N. ⑨ or replace S.N. ⑨ and S.N. ⑥. Finally, conduct the assembly in the reversed sequence for the restoration.
The reason for the leakage at the contact surface between the gas filling gun and liquid inlet is that the sealing surface of S.N. ⑨ or gas filling gun is
damaged.If S.N. ⑨ is damaged, dismantle the valve according to the steps for the condition when S.N. ⑥ is damaged and replace S.N. ⑨. Finally, conduct the

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assembly in the reversed sequence for the restoration.
Vulnerable part:
The vulnerable parts are marked with A in Figure 13: ③Seal Ring A, ⑥Seal Ring B

4.3.4 Liquid Inlet check valve

Figure 15 Sectional View, Exploded Assembly Drawing and ON State

Part name:

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 ①Gland Nut ②Gasket I ③Spring Pressing Cap ④Spring ⑤Check Valve ⑥Gasket II ⑦Valve Body ⑧Hose Spherical Connector
Leakage handling:
If S.N. ⑥ and sealing line are damaged or there is the debris between them (the position marked with C in Figure 16), there will have the sealing failure.
If the conical surface of S.N. ⑦ or spherical surface of S.N. ⑧ has the penetrating crack or scratch, the connecting position between them will have the
leakage.
If the leakage occurs at the position between S.N. ① and S.N. ⑦: Firstly, screw down S.N. ⑦; if the leakage still continues, unscrew S.N. ⑦ (unscrew
S.N. ④-⑥ simultaneously), replace S.N. ② and then screw down S.N. ⑦.
For the condition that S.N. ⑥ is damaged:
Unscrew S.N. ① and S.N. ③ and then take out S.N. ②, S.N. ④ and S.N. ⑤ (S.N. ⑥ has been installed on ⑤) successively. Replace S.N. ⑤ (S.N. ⑥
has been installed on ⑤) and then conduct the assembly in the reversed sequence for the restoration.
For the blocking condition:
If the blocking is caused by the solids such as the fine sand, etc. and the sealing surface is not scratched, unscrew S.N. ① and S.N. ③ and then take out S.N.
②, S.N. ④ and S.N. ⑤ (S.N. ⑥ has been installed on ⑤) successively. Then, remove the debris and conduct the assembly in the reversed sequence for the
restoration.
When the blocking is caused by the ice cube, take out the parts according to the above steps and dry the parts (the flame shall not be used during the drying).
Finally, conduct the assembly in the reversed sequence for the restoration.
For the scratching condition:
Dismantle the valve according to the steps for the condition when S.N. ⑥ is damaged and then grind the internal sealing surface (B position of the enlarged
view in Figure 8) of S.N. ⑦ or replace S.N. ⑦. Next, replace S.N. ⑤ (S.N. ⑥ has been installed on ⑤). Finally, conduct the assembly in the reversed sequence
for the restoration.
If the leakage occurs at the position between S.N. ⑦ and S.N. ⑧: Firstly, unscrew S.N. ⑧ and find out the damaged sealing surface. Then, grind the

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damaged surface or replace the corresponding component of the damaged surface.
Vulnerable part:
The vulnerable parts are marked with A in Figure 15: ②Gasket I, ⑥Gasket II

4.3.5 Relief valve

Figure 16 Sectional View and Exploded Assembly Drawing

Part name:
①Adjusting Nut ②Spring ③Valve Clack ④Sealing Gasket ⑤Valve Body
Leakage handling:
For the leakage caused by the main body of the relief valve or that the relief valve can’t be turned off, the only solution is to replace the valve with the new valve
with the same model and turning-on pressure.
If the leakage of the relief valve occurs at the position between the valve body and connecting part, twine the thread of S.N. ⑤ with the PTFE thread seal tape
(note that do not make the PTFE thread seal tape enter the pipeline and cause the blocking) and then screw it down.

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 Vulnerable part:
This valve is the integral replacement type.

4.3.6 Restrictor valves

Figure 17.Cross-section drawing Figure 18 Axonometric drawing Figure 19 State drawing

Parts name:
①Clamp nut②Cutting sleeve 1③Cutting sleeve 2④Valve body⑤Steel ball⑥Bumper pin⑦Valve body
Leakage treatment:
If the leakage occurs at the outlet, the SN ② and ③ shall be replaced. But under lack of spares, raw tape shall be used to wrap at outside, and the ① need be
tightened. During replacing the SN ② and ③, the ends of tube need be smooth otherwise the leakage could not be fixed (under the condition while the tubes need
to be cut).
If the leakage occurs at the inlet, raw tape shall be used to wrap the thread of ⑦(but the raw tape must not blocking the tube), and the valve need be tightened.
Damageable parts:
As shown in figure 17 A: ②cutting sleeve 1, ③cutting sleeve 2

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 In general, the valve does not need to be repaired as long as the ball does not wear out and the valve is not removed.

4.3.7 Vent valve

Figure 20 Exploded assembly drawing.

Figure 21 the open state Figure 22 Axonometric drawing

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 Parts name:
①Circlip②Gland nut③Spring plate④Spring⑤Split washer⑥Guide shaft (valve core)⑦Sealing gasket⑧Valve body⑨Protection cap
Leakage treatment:
If the leakage occurs at the inlet, use the raw tape to wrap the thread connected with the SN⑧ (be careful not to allow the raw tape to enter the tube to cause a
blockage), and then tighten the part.
If the leakage occurs at the outlet, the general situation is: The sealing surface is damaged and there is debris between the sealing surface (fine sand, ice, etc.)
If the sealing surface is damaged, first remove the SN ①and ②, the other SN ③-⑦ then can be all removed, then replace the SN⑦, and then assemble the
parts in the reverse order to the original state.
If there is debris between the sealing surface, disassemble the valve in the above order, clean the debris; if there there is ice, clean and dry treatment shall be
taken (not flame is allowed), and then assemble the parts in the reverse order to the original state.
Damageable parts:
As shown in figure 21A: ⑦Sealing gasket

4.3.8 Pressurization regulating valve

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 Figure 23 Cross-section and Exploded assembly drawing.

Parts name:
①Adjusting screw rod ② Locknut ③ Nameplate ④ Valve deck ⑤ Spring upper bracket ⑥ Spring A ⑦Compression ring ⑧ Spring lower bracket
assembly ⑨ Gasket A ⑩ Valve body ⑾ Sealing assembly ⑿ Spring B⒀Washer ⒁ Plug screw
Leakage treatment:
If leakage occurs at connection between ④ and ⑩, tighten the ④ and if leakage keep going, then remove the ④ and the other parts that could be removed,
then replace the ⑨, and then assemble the parts in the reverse order to the original state(in the repairing, do not adjust the ①, otherwise the pressure could be
changed).
If leakage occurs at connection between ⑩ and ⒁, tighten the ⒁ and if leakage keep going, then remove the ⒁ and the other parts that could be removed,
then replace the ⒀, and then assemble the parts in the reverse order to the original state.
In the condition there is air leakage at the hole on the ④, it means that mebrane of ⑧ is damaged, remove the ④ and all the other parts that could be removed,
replace the mebrane, and then assemble the parts in the reverse order to the original state (in the repairing, do not adjust the ①, otherwise the pressure could be

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changed).
If the leakage occurs at the outlet or inlet, use the raw tape to wrap the thread connected with the ⑩ (the raw tape shall not block the tube), and then tighten the
part.
Damageable parts:
As shown in figure 23A: ⑧ Spring lower bracket assembly (and the mebrane), ⑨Gasket A, ⒀Washer.

4.3.9 Reducing valve

Figure 24 Cross-section and Exploded assembly drawing.

Parts name:
①Adjusting screw rod ② Locknut ③ Nameplate ④ Valve deck ⑤ Spring upper bracket⑥ Spring A ⑦ Compression ring ⑧ Spring lower bracket
assembly ⑨ Gasket A ⑩ Valve body
Leakage treatment:
If leakage occurs at connection between ④ and ⑩, tighten the ④ and if leakage keep going, then remove the ④ and the other parts that could be removed,
then replace the ⑨, and then assemble the parts in the reverse order to the original state(in the repairing, do not adjust the ①, otherwise the pressure could be

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changed).
In the condition there is air leakage at the hole on the ④, it means that mebrane of ⑧ is damaged, remove the ④ and all the other parts that could be removed,
replace the mebrane, and then assemble the parts in the reverse order to the original state (in the repairing, do not adjust the ①, otherwise the pressure could be
changed).
If the leakage occurs at the outlet or inlet, use the raw tape to wrap the thread connected with the ⑩ (the raw Damageable parts:
As shown in figure 24A: ⑧ Spring lower bracket assembly(and the mebrane), ⑨Gasket A.

4.4 Carburettor introduction

Carburetor is a kind of water bath tube heat exchanger. It use the engine cooling water to heat the liquefied natural gas. The liquefied natural gas and cooling
water have the same flow direction.
There is a tube coil working as heat exchanger, it heats up the liquefied natural gas to a appropriate temperature for the engine.
There is a drive pipe at outside of the heat exchanger, it forms a closed loop with the cooling water system. And the shell keeps the cooling water from leakage.

4.5 Liquidometer introduction

Liquid level measurement system adopts capacitor liquidometer, the systems contains three subsystem: Capacitor electrode, Capacitance transmitter and Liquid
level display table (It's equivalent to the car oil scale). The principle is: because the dielectric constants of the liquid and the vapor are different, and when the liquid
surface changes, the capacitance of the capacitive sensor (capacitance transmitter) changes. And the changing indication could display on the liquid level display
table, in this way the level of the liquid could be calculated.
As a part of cylinder, the capacitor electrode is welded to the inside of the cylinder. It contains inside and outside electrode whose purpose is to generate a linear
proportional capacitance signal according to the fuel level in the cylinder and transmit it to the capacitance transmitter. The capacitor transmitter converts the
capacitance signal into an electrical signal and pass it to the liquid level display table.
The electrical signal is not affected by fuel state (liquid phase or gas phase) and pressure, and it could reflect the volume of internal fuel. Similar to gasoline and
diesel (oil level measurement system), the system is able to adapt to the instantaneous impact of changes in driving conditions such as acceleration, braking, climbing

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and turning.
The capacitance electrode conductor and external contact should be kept dry. If there is water here, it will cause a short circuit, the liquid level display meter
readings will appear as full scale whatever the level in the container is.
For specific principles and instructions, please refer to the instruction manual of the liquid level meter.

5. Operation method

5.1 Initial charging

Usually the initial charging cylinder, cylinder that has not been used for more than two weeks, and the cylinder finished with maintenance are called a "hot
cylinder". The inner tank of hot cylinder must be cooled to the temperature of the liquefied natural gas before charging. The following procedures shall be followed:
1．Confirm that the gas station or the vehicle fitted with the cylinder has been well grounded;
2．Open the cryogenic inlet(C1)(see 4.3.3) and the protection cap of vent connection(C2)(see 4.3.7);
3．Visually inspect the valves, joints and tubes of the cylinders to ensure that there is no leakage or missing parts;
4．Use dry nitrogen (or use a clean, dry cotton) to purge the cryogenic inlet (C1) and the vent connection (C2) to ensure that there is no moisture and
impurities.
5．If necessary, connect vent nozzle and vent connection(C2), and turn the vent gun 90 °;
6．Confirm that the fuel nozzle and the cryogenic inlet (C1) match, connect the fuel nozzle and low temperature inlet.
7．Turn on the gas station pump, fill the cylinder with liquid, when the gas dispenser shows 30L, stop adding liquid;
8．Open the cylinder vent valve (VV) to reduce the pressure to 0.3MPa, then close the vent valve (VV);

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 Warning:

Note in the venting: the vented gas shall go back to the gas station or to the safe place.

9．Cool the cylinder for about 10 minutes, during which pressure will rise;
10．Observe the cylinder pressure gauge (P1), if the cylinder pressure is high, it may be necessary to vent the cylinder before charging, and the steps shall
be according to the provisions of section 8 of this article;
11．Restart the gas station pump for charging until the gas dispenser stops automatically;
12．Confirm that the vent valve (VV) has been closed, remove the fuel nozzle and vent nozzle;
13．Cover the protection cap of cryogenic inlet (C1) and vent connection (C2).

5.2 Routine charging

Routine charging refers to the normal use of a gas cylinder, which is in a low temperature and there is a part of the liquid in the cylinder when charging.
1．Confirm that the gas station or the vehicle fitted with the cylinder has been well grounded;
2．Open the cryogenic inlet(C1)(see 4.3.3) and the protection cap of vent connection(C2)(see 6.3.7);
3．Visually inspect the valves, joints and tubes of the cylinders to ensure that there is no leakage or missing parts;

4．Use dry nitrogen (or use a clean, dry cotton) to purge the cryogenic inlet (C1) and the vent connection (C2) to ensure that there is no moisture and
impurities.

5．If necessary, connect vent nozzle and vent connection(C2), and turn the vent gun 90°;

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 6．Confirm that the fuel nozzle and the cryogenic inlet (C1) match, connect the fuel nozzle and low temperature inlet.

7．Observe the cylinder pressure gauge (P1), if the cylinder pressure is high, it may be necessary to vent the cylinder before charging, open the cylinder vent
valve (VV) to reduce the pressure, then close the vent valve (VV) (The vented gas shall go back to the gas station or to the safe place);

8．Turn on the gas station pump to charge until the gas dispenser stops automatically;
9．Confirm that the vent valve (VV) has been closed, remove the fuel nozzle and vent nozzle;
10．Cover the protection cap of cryogenic inlet (C1) and vent connection (C2).

Caution:
1，Before charging, you should check out whether there is a condensation or frosting phenomenon on the surface of the cylinder, it
is suggested that the cylinder that appears the phenomenon should not be charged, and should be sent back to the manufacturer for
repair.
2，Check whether the cylinder is under pressure. If the pressure is zero, the gas cylinder should be blown and tightness test. After
passing the test, charge it again.
3，The pressure of a fully charged cylinder is rising very rapidly, which may lead to the opening of the relief valve; therefore fully
charged cylinders should be used as soon as possible and prohibit long storage.

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 Warning:
Check if there is liquid water and impurities in the hypothermia inlet before charging, and the water and impurities should be
completely cleaned before charging.
If there is water, the water will freeze rapidly during charging. And frozen ice will block the valve and inlet resulting the leakage
of inlet and valve, it even could lead to damage of the surface of sealing. If the ice went to the cylinder, it may block the check
valve during using resulting to insufficient liquid, and it may make the engine underpowered or even unable to start the engine.
If there is impurities, the impurities may enter the check valve and inlet and making it not totally closed, it even may lead to
damage of the surface of sealing. At the same time, engine could be damaged if not filter is setting before the upper end of engine.
When venting to the atmosphere, the vent gas shall be lead to a safe place, otherwise, it may lead to fire or explosion.

5.3 Fuel supply

5.3.1 Pressurization

The following situation requires pressurization of the cylinder:

1．Cylinders that are used for the first time and whose pressure is lower than the requirement of engine;
2．Cylinders that go through checking by check valve and pressure gauge;
3．Cylinders that repaired after venting;
4．Or when the setting pressure of pressurization regulating valve is lower than the requirement of engine.

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5.3.2 Pressurization process

1．Confirm the application valve (Vu) and vent valve (Vv) are in closed state;
2．Open the pressurization valve (Pv), and then the charging line begins to frosting;
3．When the pressure stabilizes, the frosting ice on pressurization line begins to melt.
If the pressure is not high enough to satisfy the engine, the pressurization regulating valve (PBr) shall be adjusted according to the method of 8.3.3.
When providing fuel, the pressurization valve of cylinder is not required to be closed.

5.3.3 Online regulation of pressurization regulating valve

1. Judgement of setting value of pressurization regulating valve

1) If the pressurization tube coil is not frosted and cylinder gauge (P1) reading is not changing; as usage goes on, when the pressure reduces to a stable value, the
reading of cylinder gauge (P1) is the setting value of reducing valve. It means that at the time, the setting value of pressurization regulating valve is lower than the
reading of cylinder gauge (P1).
2) If the pressurization tube coil is frosted, and the cylinder gauge (P1) reading keeps increasing，it means that the setting value of pressurization regulating
valve is higher than the reading of cylinder gauge (P1). As the usage goes on, the when the pressure goes to a stable value, the reading of cylinder gauge (P1) is the
setting value of reducing valve.

2. Adjustment of pressurization regulating valve (see the 4.3.8 for the structure)

1）If pressure need to be set higher

（1）Determine the setting value of the pressurization regulating valve;
（2）Loosen the ② locknut, then spin the adjusting screw rod clockwise, and the spin number shall be according to the difference of setting value and
the actual value;

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 （3）After the spin, the self pressurization tube coil will frost, and the pressure of cylinder will increase; when the reading pressure is stable or the frost on
the self pressurization tube coil starts to melt, the reading value of cylinder gauge (P1) is the setting value of pressurization regulating valve;
（4）If the pressure is not high enough for the setting value, repeat the above steps;
（5）When the pressure is high enough, tighten the locknut ②.
2）If pressure need to be set lower
（1）Determine the setting value of the pressurization regulating valve;
（2）Close the pressurization stop valve,then reduce the pressure to the setting value by usage of venting;
（3）Loosen the locknut ②, and then spin the adjusting screw rod anticlockwise;
（4）Open the pressurization stop valve, check out if the pressure increase;
（5）If it increases, repeat the above steps until the pressure meet the requirement;
（6）Tighten the locknut ②.
Tips: 1) one spin of the adjusting screw rod equivalent to about 0.2MPa.
2) The pressurization regulating valve is set 0.8mpa when it is out of the factory.
Note: 1) It is recommended spin 1/4~1/2 circle for each time;
3）If the setting value after adjustment is higher than the requirement, please adjust it according to the steps of above, do not spin it back.

5.3.4 Liquid output

1．Confirm the setting value of the pressurization stop valve and the pressure of the cylinder meet the requirement of engine or not ;
2．If the pressure of the cylinder is 0.3mpa higher than the engine pressure, the gas cylinder should be vented;
3．When the pressure of the cylinder is 0.1mpa higher than the engine pressure, slowly open the application valve (Vu);
4．When the engine is working normally, the opening of the application valve can be increased.

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 Caution: The high cylinder pressure or if the valve is opened too quickly, it may cause the restrictor valve to close and cause the engine to stall.

5.4 Gas output

In normal use, if the pressure of the cylinder is higher than that of the reducing valve, the reducing valve will open automatically.

Caution: In normal supply, the carburetor is supplied with liquid fuel; However, when the reducing valve is opened, the gas-liquid two-phase mixture
will flow through it, and the proportion of gas is larger.

5.5 Adjustment of reducing valve

5.5.1 Off-line adjustment

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 Figure 25 Adjustment of reducing valve

Parts name:
①High pressure nitrogen cylinder②Relief regulating valve (common control valves for high pressure gas cylinders)③stop valve④pressure gauge⑤Standby
reducing valve
1）Connect all valves according to flow chart;
2）Confirm that all valves are closed and confirm that the adjustment screw rod of the reducing valve is in full loosen condition;
3）Slowly open the high-pressure nitrogen cylinder valve, then open the test stop valve ③, check out if there is leakage on pipeline;
4）Open high pressure nitrogen cylinder valve, adjust the relief valve making outlet pressure equal to the setting reducing valve pressure value ;
5）Spin the adjustment screw rod of the reducing valve clockwise until there is gas coming out from the reducing valve, at the time, the reading value of
pressure gauge is the setting value of reducing valve.

Tip: the pressure of reducing valve shall be 0.05MPa~0.1MPa higher than that of pressurization regulating valve.

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5.5.2 On-line adjustment

When adjusting online, first judge the setting value of reducing valve. Then adjust the adjusting screw rod according to the pressure needed.
（1）Loosen the locknut ②, then spin the adjusting screw rod ;
（2）It is recommended spin 1/4-1/2 circle for each time;
（3）Tighten the locknut ②.

Caution:
1.One spin of the adjusting screw rod equivalent to about 0.2MPa.
2.The pressurization regulating valve is set 0.86mpa when it is out of the factory.
3.It is suggested to use off-line regulation when adjusting.

6. Common faults and treatment methods

6.1 常见故障

147
 The appearance of the gas Treatment
Phenomenon Check items
cylinder system. methods

1.If inlet and outlet of carburettor are

Shaping
crushed

2.Leakage of Inlet and outlet of Leakage

carburettor treatment
汽化器表面结霜 Leakage
3. Leakage of supply pipeline
The surface of carburettor treatment
frost
Repair of
4.Idle cylinder of engine
manufacturer
Engine
5.Too thin cooling water tube coil Reconfiguration
underpowered
6.Water pump is not appropriate Reconfiguration

7.Carburettor is not appropriate Reconfiguration

Pressure of cylinder keeps 1.Pressurization regulating valve Replacement of
reducing, and the failure failure parts
pressurization tube coil does
2.Blocking of pressurization tube See 6.2.1
not frost

148
 The appearance of the gas Treatment
Phenomenon Check items
cylinder system. methods

Pressure of cylinder keeps Setting value of reducing valve is

reducing, and the lower than that of pressurization
pressurization tube coil See 5.3.3 and 5.5
frost regulating valve, and also lower than
requirement of engine
1.Pressurization regulating valve
The engine need high See 5.3.3
failure
pressure,and the
Engine
pressurization tube coil frost 2.Blocking of pressurization tube Wash with water
underpowered
Pressure of cylinder is
normal, and the
Setting value of tube regulating
pressurization tube coil does
valve is lower than the requirement
not frost, the pressure at See 5.3.3
of engine
outlet of regulating valve is
lower than engine
P1 is stable, P2 is not Tube regulating valve failure
Engine power is
Cylinder pressurization regulating Setting value of
not steady P1 is not stable
valve failure reducing valve is

149
 The appearance of the gas Treatment
Phenomenon Check items
cylinder system. methods
too high
1.Setting value of reducing valve is
See 5.3.3,5.3,and
Engine start lower than pressurization regulating
6.2.2
failure or sudden Restrictor valve blocked valve
stalling 2.Application valve open too rapidly See 5.3.4 and
during starting 6.2.2
Cylinder pressurization regulating
P1 pressure is too low See 5.3.3
valve failure or wrong setting value
Cylinder surface frost or Repair of
Vacuum deterioration
Cylinder pressure condensation manufacturer
increase too high Small check valve failure Replacement
or too rapidly Normal surface of cylinder Setting value of reducing valve is
See 5.3.3
too high
Sealing failure of
Relief valve failure Replacement
open relief valve
Venting of Matter of gas
Flexible pipe of fuel nozzle is not
cylinder when vacuum tube station

150
 The appearance of the gas Treatment
Phenomenon Check items
cylinder system. methods
charging
Hypothermia
Valve leakage Repair
valve freezing

6.2 Repair method

6.2.1 Tube blocking

1．Discharge all the liquid in the cylinder and make the pressure released to 0MPa at the same time;

2．Charge the gas cylinder with dry nitrogen to ensure natural gas concentration is lower than 1%;

3．Purge gas cylinders with 0.3 - 0.4 MPa nitrogen until detection of dew point is lower than - 40 ℃.

Tip: See Security Summaryand Safety Protection for safety measures.

.2.2 Restrictor valve blocking

151
 1．Close the application valve;

2．Wait for a while or knock the restrictor valve lightly.

7. Routine maintenance

The cylinder user shall prepare a detailed overhaul plan and follow the plan to ensure the safety of the cylinder.

7.1 Requirement of routine maintenance

Maintenance
Maintenance content Maintenance method Maintainer 日期
interval
Connection nut for
15 days Tighten the nuts
cylinder and bracket.
Connection nut on the Before each Visual observation if there
cylinder pipe trip is a leakage
Clean the incrustation on
Carburettor 6 months
the coil
Check if it is totally closed
Valves Often and leaking

Send it to local technical

Relief valve 12 months
supervision department to

152
 check
Send it to local technical
Pressure gauge 12 months supervision department to
check
Cylinder vacuum
12 months Pressure test
degree
Airtight test or leakage
Leakage detection Often
detection

7.2 Leakage detection

A portable methane detector can be used to inspect the gas leakage points of the vehicle's gas system (in accordance with the detector manufacturer's
instructions). In order to ensure the normal operation of the vehicle, the system should be inspected regularly, if there is the leakage point detected, it should be
repaired immediately.
Under some special conditions, it is difficult to judge the leakage point accurately with the detector, liquid soap shall be used to ascertain the leakage point.

7.3 Replacement of parts

Any fuel leakage must be repaired immediately upon discovery:

If the leakage occurs at the pipe thread, the connection surface should be disassembled, cleaned and sealed with raw tape.
If the leakage occurs on the pipe, it shall be disintegrated and strictly checked, if the nut and the cutting sleeve are not damaged, they can continue to be used,

153
reinstall the pipeline and tighten the nut, and finally conduct pressure leakage detection.
If the leakage occurs at valves, repair shall be conducted according to the section 4.3 of Valve Structure and Maintenance.

Warning:
In the maintenance and replacement of valves, pipe threads and fittings, safety measures must meet the requirements of Safety Summary and
Safety Protection, otherwise it may cause personal injury.

7.4 Vacuum failure

Usually, there will be a cylinder body frosting or a pressure sharp increase inside the cylinder when vacuum failure takes place. However, for a new cylinder or a
long unused gas cylinder, the pressure rises rapidly in charging liquid due to its high internal temperature, the phenomenon is normal.
Excessive pressure rise can be judged as a basis of the vacuum failure of gas cylinders. The outer shell of the cylinder is equipped with a vacuum plug which
will loosen when the cylinder vacuum fails(normally, the vacuum plug is compressed by atmospheric pressure). Normally, a plastic cap is placed outside the vacuum
plug. Do not open the cap or vacuum plug. If the vacuum failure of the cylinder is found, please send it back to the manufacturer for repair.
In short, vacuum failure is a rare phenomenon. Usually the vacuum of the cylinder can be kept for several years, even longer than the life of the cylinder. And
during this period the vacuum of the cylinder gradually decreases (at a very slow rate). The so-called "soft" vacuum on stationary cylinders can be judged by the
rapid rise of pressure.
If the vacuum plug of the cylinder is not abnormal, but the vacuum failure is suspected, it is necessary to judge by the time of the pressure rise.
When testing the time of pressure rise on the cylinder, first charge the cylinder then start the engine until the fuel is reduced to 3/4 or 1/2. And at the time, the
pressure of cylinder shall be normal working level. Stop the vehicle, the pressure increasing rate shall below 0.27MPa/d. It is important to note that the initial
charging or over charging of the cylinder can also cause a sharp increase in pressure.
The pressure of a vacuum failure cylinder will rise at a rate of approximately 0.007MPa/min, and the change in pressure is very obvious. The temperature of
cylinder shell, especially the part where the pipe is more concentrated and the parts near the support is lower than that of the other parts. Whether the shell is frosted

154
or condensed depends on the temperature and humidity of the surrounding environment. The existence of this condensation phenomenon can not be used as a reliable
indicator to judge the existence of a cylinder vacuum. The test of the pressure increase rate of gas cylinder is the most reliable and effective method.
A vacuum failure cylinder must be evacuated again through a dedicated device. This operation can be done in the vehicle or can be done after the cylinder is
removed from the vehicle.

155
Annex table 1 Lubrication Table

Lubricatio
SN Lubrication part Lubricant Remark
n points

Check the engine oil

According to engine oil number in the
surface of oil pan
Driving and Operation and the temperature,
1 Engine every day and add
properly select the appropriate number of
engine oil according
engine oil.
to regulations.
2 Steering drive shaft Cross Axle 2

3 Straight pull rod ball pin 4

4 Achszapfen 2

5 Tie rod ball head pin 4

2# Industrial lithium base grease
6 Front plate spring pin 12

Drive shaft middle bearing According

7 to the

vehicle

156
 Lubricatio
SN Lubrication part Lubricant Remark
n points

Transmission shaft cross bearings According

8 and sliding forks to the

vehicle

9 Rear plate spring pin 6

10 Front and rear brake camshaft 6

The gearbox control system each 4

11
ball head pin

Steering shaft transmission shaft 1

12
spline pair

13 Gearbox 1 885W/90 Medium load vehicle gear oil

85W/90 Medium load vehicle gear oil or

14 Rear axle 1
Heavy load vehicle gear oil or

15 Steering 1 CD 15W/40 Diesel engine oil

16 Water pump bearing 1

2# Industrial lithium base grease
17 Cab support pin 2

157
 Lubricatio
SN Lubrication part Lubricant Remark
n points

18 Cab locking mechanism 2

19 Front wheel bearing 4

20 Front wheel bearing 2

21 Starter bearing 1

22 Clutch release bearing 1

23 Slack adjuster Arm 6

24 Door glass elevator, door lock 4

25 Shock absorber 4 Special shock absorber oil

26 Clutch hydraulic oil 1 Synthetic brake fluid JG3

158
Annex Table 2 The Accessory Tools

序号 名称 规格型号 数量
1 NXG39WLAM111-01011 Socket head (10) 1
2 NXG39WLAM111-01012 Socket head (11) 1
3 NXG39WLAM111-01013 Socket head (13) 1
4 NXG39WLAM111-01016 Socket head (16) 1
5 NXG39WLAM111-01018 Socket head (18) 1
6 NXG39WLAM111-01021 Socket head (21) 1
7 NXG39WLAM111-01024 Socket head (24) 1
8 NXG39WLAM111-01027 Socket head (27) 1
9 NXG39WLAM111-01029 Socket head (30) 1
10 NXG39WLAM111-01031 Ratchet wrench 1
11 NXG39WLAM111-01032 Extension rod 1
12 NXG39WLAM111-01067 Allen key 1
13 NXG39WLAM111-01100 Cross screw driver assembly 1
14 NXG39WLAM111-01120 Screw driver assembly 1
15 NXG39WLAM111-01125 Hammer assembly 1
16 NXG39WLAM111-01140 Slip Joint Pliers Slip Joint Pliers (8") 1
17 NXG39WLAM111-01146 Tire lever and jack rocker 1
18 NXG3911WLAM111-010 Grease gun assembly 1
19 NXG3912WLAM111-010 Tire gauge and case assembly. 1
Small adjustable wrench assembly
20
NXG39WLAM111-15010 (200X24) 1

159
序号 名称 规格型号 数量
Large adjustable wrench assembly
21
NXG39WLAM111-15020 (300X36) 1
22 NXG37WLAM111-15010 Working light assembly (24V) 1
23 NXG3926WLAM111-010 Triangle warning board assembly 1
24 NXG3919WLAM111-010 Vehicle kit assembly 1

Annex Table 3 Tightening Torque of Main Bolts and Nuts

SN Name of parts Number Torque (N.m)

1 Main bolts and nuts for diesel engines See engine instructions

2 Gearbox biaxial flange fastening nut 1 340-560

160
SN Name of parts Number Torque (N.m)

According
Connection bolts and nuts on the flange of the
3 to the 160-220
transmission shaft
vehicle

According
4 Transmission shaft flange fastening nut to the 400-540
vehicle

According
5 Suspension bolts and nuts in the center to the 160-220
vehicle

6 Wheel nuts 40 450-500

7 Front suspension U bolts 8 350-400

8 Rear suspension U bolts 8 400-450

9 Straightening lever arm fastening nuts 2 185-270

10 Steering knuckle arm fastening nuts 4 280-350

11 Horizontal pull rod pin nuts 4 250-310

12 Front wheel bearing adjustment nuts 2 200

161
SN Name of parts Number Torque (N.m)

13 Horizontal pull rod clamp nuts 2 45-50

14 Rear wheel bearing adjusting nuts 2 500

15 Fixed bolt nut of steering machine 3 397-457

16 Steering wheel lock nuts 1 140-170

162
Annex Table 4 Tightening Torque of Common Bolts and Nuts

Thread dimensions Tightening torque N.m Thread dimensions Tightening torque N.m

M6 9～11 M18 284～319

M8 22～25 M18×1.5 328～357

M8×1 25～30 M20 417～451

Annex Table 5
M10 40～54 M20×1.5 451～495 Technical
M10×1 54～64 M22×1.5 530～642
Information of
M12 88～93 M24×1.5 789～838
the Vehicle
M12×1.5 88～98 M14×1.5 147～162

M12×1.25 93～108 M16 211～230 1.Product

M14 132～152 M16×1.5 225～250 instruction manual
2.Engine instruction manual One piece
3.Certificate of Approval One piece

163
XuZhou Construction Machinery Group Non-highway wide-body auto dumper product manual
The second edition in October 2017
The company reserve the right to further improve our products without notice.

164