Sinotruk Maintenance Manual-SINOTRUK-China National Heavy Duty Truck Group Co., LTD
Sinotruk Maintenance Manual-SINOTRUK-China National Heavy Duty Truck Group Co., LTD
Sinotruk Maintenance Manual-SINOTRUK-China National Heavy Duty Truck Group Co., LTD
[email protected] 0086-531-58052907
To ensure the normal life of vehicles and obtain the good economic benefit, all the instructions of the operation Procurement Manual
and maintenance requirements mentioned in this manual need strictly to be followed.
Operation Manual
Pure fule in accordance with the quality requirement is required to be used during the vehicle's running. All
choosen oil, lubricating oil, hydraulic oil, etc . for vehicles shall be consistent with the provided grades of this Maintenance Manual
manual .
WGⅠ WGⅡ WG Ⅲ
Poor conditions (Severe cold or hot climate, high dust Vehicle with annual mileage less than Vehicles with annual mileage over Global Sales Hotline
content, used in construction site or bus, municipal 60,000km, medium-short distance 60,000km, long distance transportation
Tel: 0086-531-58052907
engineering vehicle, snow sweeper, fire-fighting engine) transportation
Fax: 0086-531-58062767
or vehicles with annual mileage less than 20,000km or (For cargo delivery)
Email: [email protected]
with running hours less than 600h.
INQUIRY
Table 2 Cycle of Maintenance
Service Conditions Items WGⅠ WGⅡ WGⅢ
After running 1000~1500km
First-time Check After running 1500~2000km After running 1500~2000km
After running 30~50h
Related Products
Routine Check (P) Every 5000km Every 150h 4 4
Every 1×10 km Every 1.5×10 km
st
1 -Grade Service 4 4 4
Every 1×10 km Every 300h Every 2×10 km Every 3×10 km
(WD1)
nd
2 -Grade Service 4 4 4
Every 2×10 km Every 600h Every 4×10 km Every 6×10 km
(WD2)
rd
3 -Grade Service 4 4 4
Every 4×10 km Every 1200h Every 8×10 km Every 12×10 km
(WD3)
th SINOTRUK HOWO Dump
4 -Grade Service 4 4 4
Every 8×10 km Every 2400h Every 16×10 km Every 24×10 km Driving Type: 6x4 / 8x4
(WD4)
Horse Power: 290HP / 336HP
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Transmission: HW19710, 10F
Dump Body: 18CBM / 20CBM
Maintenance Items
1. Regular Maintenance Items
1.1Check hand brake and service brake;
1.2Check illuminating lamps, signal lamps and indication lamps (oil pressure, pressure in air reservoir, air filter maintenance indicator and
battery charge indicator, etc.);
1.3Check the working mode of starter, alternator and battery;
1.4Check tire pressure and condition;
1.5Check the level of engine oil, coolant and steering hydraulic oil;
1.6Drain water from air reservoir.
2. Graded Maintenance Tasks
Please refer to the second part for the checking and maintenance of the engine, transmission, front and rear axles, steering gear.
First-time Routine st nd rd th
1 -grade 2 -grade 3 -grade 4 -grade
Cab
Check Check Service Service Service Service
Check the wiper · · · · · ·
First-time Routine st nd rd th
1 -grade 2 -grade 3 -grade 4 -grade
Chassis
Check Check Service Service Service Service
Check fixation and action of towing hook · · · · ·
First-time Routine st nd rd th
1 -grade 2 -grade 3 -grade 4 -grade
Electrical System
Check Check Service Service Service Service
Check the working condition of electrical system
· · · · · ·
(Instrument, lamps, wiper, and air conditioner).
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Check ABS · · · · ·
First-time Routine 1st-grade 2nd-grade 3rd-grade 4th-grade
Vehicle
Check Check Service Service Service Service
Water pump · · · · · ·
Clutch release shaft · · · · · ·
Clutch pedal shaft · · · · · ·
Clutch release bearing · · · · · ·
Universal joint and intermediate support of
· · · · · ·
transmission shaft
Note: After cleaning the vehicle, re-lubricate all the parts which need lubricant at once, once a week for the vehicle operated on construction
site.
Mandatory Maintenance
1.Purpose
Remove and clean the particles, burrs and other harmful impurities caused during the initial operation of vehicle, solve the connections
loosening problems resulting from the initial operation, carrying out a mandatory running-in maintenance, to improve the reliability, so that
make the vehicle in the best working condition to extend the service life of vehicle.
2.Implementation
Special service stations authorized by CNHTC can implement the mandatory service.
3.Mileage Requirement
The vehicle can enjoy a mandatory maintenance with the Warranty and Maintenance Manual of CNHTC, if the mileage is between 2000 to
4000 kilometers and within six months.
4.Content
Please refer to the First-time Check of Table 2 for the details of checking.
Engine Maintenance
1. Operation Attentions and Maintenance
For driving safety, the engine must be carried out routine inspections of each component. If somewhere is abnormal, the vehicle should be
sent to the repairing service station for maintenance.
Before running the diesel engine, the height of cooling level, fuel and oil level, and diesel level will be checked.
When the diesel engine is started, if it doesn’t work within 15 seconds, restart it after 2 minutes.
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After diesel engine is started, idle speed running will last for 2-3 minutes. Fuel pressure will exceed 100,000Pa. When cooling water
temperature is lower than 600C, do not run the engine at high-speed and heavy load at once, otherwise its wear resistance and reliability will
be affected.
In the case that the engine working with load, load and speed must be reduced before shutdown. Idle speed running must last for no less
than 5 minutes.
During running-in period (within 3000km), it is suitable for diesel engine to run only under medium load.
2. Routine Inspection and Maintenance
2.1 Oil Level Check
Check must be carried out after engine shuts down for 5 minutes with the vehicle parked on level ground. When the engine is running or the
vehicle is tilting, the oil level could not be measured accuratly.
Checking Methods:
1. Pull out the oil rule, clean the oil.
2. Re-insert the oil gauge completely, and then pull it out again, check the oil level. If the oil level in the grid within the region , it indicates
that it is normal.
3. If it lacks of the oil, please fill oil. When refueling, do not exceed the "maximum" of oil gauge.
4. After using, re-insert the oil gauge correctly. Do not let the oil spill all around during refueling. Prevent the oil spills on other components of
the engine to avoid danger.
2.2 Coolant Level
Check whether the coolant water level is adequate or not.
Check the coolant level and add the coolant after the engine is cool.
The reason of sudden dropping in coolant level may be the leak of cooling system, please go to service station for maintenance.
Annual mileage less than Annual mileage less than Annual mileage less than
20,000km 60,000km 60,000km
First-time Check After running 1000~1500km After running 1500~2000km After running 1500~2000km
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Fuel Oil, Lubricating Oil, Coolant and Auxiliary Materials Used in Engine:
1. Fuel Oil
Summer: diesel which apply to the local market in summer.
Winter: diesel which apply to the local market in winter.
2. Lubricating Oil
2.1 Grade CF-4 15W/40 engine oil is recommended.
2.2 High-grade oil is allowed to replace lower-grade oil.
Before starting the engine, check the height of the oil within the oil pan.
As the multi-grade oil with a flat viscosity curve, between the range of lubricating low temperature and high temperature, it has good
lubricating characteristic, so we recommend use multi-level lubricant.
Changing Engine Oil:
Check whether the oil color is normal and extraneous matter is mixed in oil or not when discharging the oil, so as to detect hidden errors.
After the oil is to be drained completely, clean the drain plug and then tighten it; replace with new oil filter element, the new oil should be
added into the engine to the upper limit of oil ruler. In order to prevent the case that starting the engine without lubrication, turn the key
switch to the starting position (Position 4) when the high-pressure oil pump is in the off position, empty running for a while, and then start the
engine and operate in low speed. Check oil filter if there is any leaks, shut down five minutes later, check and add oil to the upper limit.
3. Grease
Inject the general lithium grease into the oil cup of water pump in line with the requirements of the local market.
4. Coolant
Cooling system should be added with the long-acting cooling fluid, this fluid has capability of antifreeze rust. Please refer to the ratio of long-
acting coolant antifreeze instructions.
Warning:
1. When temperature is below 0℃, you should check the antifreeze concentration regularly.
2. Vehicles perennial running at areas above 0℃, water which has been treated with anti-rust and
anti-scaling could be used as the coolant; it is prohibited using untreated water as the engine coolant.
Transmission Maintenance
1. Usage Requirements
Operate the transmission properly, and implement regular servicing and maintenance, which is crucial for vehicle’s reliable driving and the
transmission’s long life expectancy. Please comply with the following requirements for use:
1.1 Lubricant Brand
Please fill and inject 85W/91GL-5 vehicle gear oil in the transmission.
1.2 Proper Oil Level
Please make sure that the oil level is abreast with the observation slit of oil level. Check the oil level through the observation slit on box flank
until the oil level reached the slit and spillage happens. The oil injection volume is about 12L for HW18710 transmission (12.5L with power
take-off added).
1.3 Inspection of Oil Level
Regular inspection should be made to the oil level. The car should be parked on flat road when checking the oil level. Considering the
inflation of hot oil, do not immediately check the vehicle that is just parked, and only when the oil level is stabilized and the oil temperature
comes close to the ambient temperature can we check the oil level, to prevent the inaccurate measurement.
1.4 Re-supply of Lubricant
To prevent the chemical reaction of different kinds of lubricants, the re-supplied lubricant should be identical with the former lubricant brand
and specifications.
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2. Precautions
2.1 The clutch must be completely released and the gear shaft lever should be moved into relevant positions when shifting.
2.2 When parking, the gear shaft lever should be moved into neutral position in low gears area.
2.3 When shift into low gear (Creeping gear) or reverse gear, it must be stopped first and then shift into relevant gear to prevent the parts
inside the transmission from being damaged.
2.4 When the transmission shifts from low gears to high gears (vice versa), do not skip gears, or it will influence the lifetime of auxiliary
gearbox’s synchronizer.
2.5 When driving downhill, shifting between high and low gears is prohibited.
2.6 Shift to first gear or second gear to move in accordance with the road conditions.
2.7 Release the brake before the vehicle starts. For the vehicles that equipped with air cut-off brake, do not shift to relevant gear and start
until their brake valves are connected and the air pressure reaches the level required to release the brake.
2.8 On the event of any unusual phenomenon, such as abnormal sound or heavy operation during the use of transmission, the vehicle must
be parked immediately to check for any failure. Do not continue driving until the failure is eliminated.
2.9 The transmission is featured with interlocked mechanism for main and auxiliary transmission. The gear shifting for main transmission is
locked up before the auxiliary transmission shifts into relevant gear. In the event any failed shifting, it may be affected by the interlock of
main and auxiliary transmission. Check the sequential gear shifting cylinder and its gas pipeline to ensure that auxiliary transmission has
shifted into relevant gear.
2.10 Privately disassembly/knock down or assemble the transmission is strictly prohibited within warranty period.
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3.1 Volume of grease for each wheel: at a total of about 0.6kg for wheel hub cavity and two bearings;
3.2 Each brake camshaft and the kingpin of the grease volume: approximately 0.2kg, adding to the bracket with the oil gun until
overflow from the holes;
3.3 Tie rod ball pins, brake lash adjuster arm should be filled with grease.
Clutch Maintenance
Running Parameter:
1. Working medium: air and brake fluid;
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2. The largest working pressure: 4 MPa for brake fluid, 0.85 Mpa for air;
3. Working temperature: - 40℃~+ 80℃;
4. Brake fluid: complying with DOT3, DOT4 or JG3, JG4 standard;
5. Pedal travel: Max stroke 200mm; free stroke, 25mm for pull, 40mm for push;
6. Pedal force: not more than 190N with assistance.
Adjustment of Clutch Operation System
1. Check and Adjust the Clearance between Master Cylinder Pushrod and Piston:
When adjusting, push the pedal with hand smoothly till the main cylinder pushrod contacts against the piston, then adjust the limit bracket
until the clearance between limit bracket and pedal is about 1mm. Tighten the limit bracket nut. Ensure there is 0.5mm~1mm clearance
between the pushrod and piston, this clearance should not exceed 1mm, or it will reduce the effective travel and influent the effect of clutch.
2. Adjust Clutch Brake Control Valve:
Step on the clutch pedal fully, at this time the working travel of main cylinder pushrod should not be less than 32mm, and the clutch pedal
should have control valve to move 3~5mm. Fix the brake control valve, tighten the bolt, and then adjust the limit screw of the pedal bracket,
making the screw cap contact against the clutch against the clutch pedal (when the clutch pedal is stepped down fully). This can prevent the
brake control valve from coming off the pedal bracket.
3. Release the Air in Hydraulic System Thoroughly:
Air in hydraulic system can reduce the effective travel of booster cylinder pushrod, and the clutch can’t be released thoroughly, thus shifting
becomes difficult.
When assembling and disassembling oil tube, be sure to release the exhaust valve of booster cylinder first. Fill the specified oil to the
reservoir. At the same time step on the clutch pedal and release air from the exhaust valve, then tighten it. After stepping on the clutch pedal
rapidly for several times, hold the pedal tightly, release the exhaust valve till no air comes out, then tighten the exhaust valve.
Repeat the afore-mentioned steps for 2~3 times, air in hydraulic system will be released completely.
Attentions:
1. During the exhaust process, relax the pedal after the exhaust valve or an associated tube nut is tightened, so as to avoid inhalation of air,
lifting the pedal to the maximum height in order to add the brake fluid inside the tank to the master cylinder fluid anvil cell.
2. Re-adjust the clearance when you maintain the new vehicle for the first time. Check the vehicle for second grade maintenance every
12,000km and for first grade maintenance every 4,000km. Push the clutch rocker arm with hand, there should be gap in the head of limit
bolt.
3. You must adopt DOT3 or DOT4 brake fluid as actuating medium in hydraulic system. When mounting and dismounting the pipeline, you
can use the Loctite572 to seal the union nut and connector.
4. When changing brake fluid, drain the remaining fluid out of the system thoroughly, and change to the specified brand fluid manufactured in
the same batch.
5. Brake fluid is corrosive. Avoid brake fluid splashed on the human body and the paint surface of the vehicle during the exhaust process.
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Battery
Check the surface and proportion of liquid electrolyte every three months. The surface is 10~15mm higher than the electrode plate; the
proportion is more than 1.24 g per cm3.
Take off the battery into the warmer room when the vehicle does not run for a long period and the temperature is low.
Check whether the battery electrode pile and wire connection clip is loose and the battery conditions are normal or not when the vehicle runs
for each 500 km.
Volume Data
Assembly Petroleum Product Brand Volume
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Rear-axle final drive and bush Gear oil of heavy duty vehicles GL-5EP 80W/90 or GL-5EP 85W/140 23
bearing
(STR Rear axle)(L)
Adjusting Data
Travel of clutch pedal (Free travel)(mm) Pedal 40
Air pressure of tyres (kpa) Single tyre 700 740 740 740
Copyright: China National Heavy Duty Truck Group Co., Ltd. All rights reserved.
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