CA5083 XXYPK2L1A80 Operation Manua GF-6000l

Operation Manual

Model: CA5083XXYPK2L1A80

Cab-over-engine Diesel Truck

Brief manual

Forward

1

Welcome to choose FAW Truck

FAW model CA5083XXYPK2L1A80, cab-over-engine cabin truck is a new product

developed by FAW, metal and cab-over engine type cabin, CA6-75 mechanical gearbox,

CA4DF2-13 diesel engine, turbo charging, intercooler, Euro-2 emission. The truck has the

advantage of high performance and low fuel consumption.

For better drive and maintenance of this truck, this manual introduces the detail of

operation, maintenance, adjustment and trouble shooting. Please carefully read this book to

master the driving method to operate the truck properly, to prolong the service life to make

maximum profit.

All of the contents of this manual are latest. The reprint version will contain the changed

content.

The copyright of this manual belongs to FAW. Without permit, any person or unit cant

duplicate it.

Wish you a pleasant journey!

China FAW Group Imp. & Exp. Corporation

January, 2006

Brief manual

Content

Vehicle identification1 Brief technical properties2 Fuel, lubricating oil9 Symbol mark12 Operation mechanism13 Indicator lights and instruments15 Switch, button and handle 21 Correct operation28 Correct drive47 New vehicle running-in55 Regular maintenance57 Maintenance and adjustment of main assemblies67 Replacing lubricating oil105 Lubrication table111 Emergency treatment113 Fault causes and solution114 Main bolt and nut tightening torque125 Bearing table128 Oil seal table129

Brief manual

Outline diagram

Brief manual

Forward

1

Vehicle identification

China FAW Group Corporation

Vehicle type CA

Engine type Load kg

Engine power kW TW kg

Chassis number

Engine number

Date of manufacture Y. m. d.

Vehicle model Engine model Loads Gross weight

CA5083XXYPK2L1A80 CA4DF2-13 3570 8200

Vehicle nameplate lie in outside and middle of right longitudinal beam. Engine parameters

Engine model

Max.power/rotation

speed kW/(r/min)

Max. torque/rotation

speed Nm(r/min)

Min.fuel

consumption rate

g/kWh)

CA4DF2-13 96(2500r/min) 390/( 1400-1600r/min) 208

Brief manual

Brief technical properties

2

CA5083XXYPK2LIA80

General parameters

Chassis curb weight kg 3735

Chassis gross weight kg 8200

Front kg 2150 Gross axle weight (chassis)

Rear kg 1585 Front kg 2700 Gross axle weight

(Full-load) Rear kg 5500 Length mm 7557

Width mm 2385 Overall Dimensions

(chassis) Height mm 2725(no load)

wheel base (full-load) mm 4250

front mm 1800 Wheel track

rear mm 1740

Front suspension (full-load) mm 1232

Rear suspension (full-load) mm 2075

Distance between cab back and rear axle

center (full-load) mm 3600

Distance between body geometrical center

and rear axle center (full-load) mm 3200

Length mm 5400

Width mm 2284 Inner body dimensions

Height mm 600

Min. Ground clearance (full-load) mm 220

Vehicle (full-load) Approach angle 22

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Vehicle (full-load)Departure angle 15

Camber 1

Inclination 6 Front wheel alignment

Caster 130

Toe-in mm 26

Min. turning diameter (by front outside

wheel trace center) m 17.8

Max turning angle of front inside wheel 40

dynamic mm 412.5 Wheel radius(full load)

static mm 407

Top speed km/h 90.5

Max. Grade ability % 28

60km/h m 36.7 Brake distance(load)

40km/h m 33.8

Parking brake on slope(5min) % 18

Fuel consumption L/100km 20

Max. continuous running mileage km 700

Max Noise from outside of vehicle when

accelerating running dB(A) 83

Minimum speed (high shifting gear) km/h 28

Capacity parameters

fuel tank L 150

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Cooling system L 25 (no heater)

26 (Include heater)

Lubricating system (including engine oil

filter and engine oil cooler) L 14

Gear box oil volume L 8.3without PTO

9 With PTO

Rear axle oil volume L Around 3.5

Power steering gear and reservoir L Around 3

Shock absorber (each) L 0.74

Clutch hydraulic control mechanism L Around 0.4

Adjustment parameters

intake mm 0.30 Valve clearance (cooling state)

exhaust mm 0.35

Fan belt tension (plus 78N) mm 10-15

Normal temperature of engine coolant 75-95 Free traveling of clutch pedal mm 35-45

Total traveling of clutch pedal mm 180

Air pressure of brake kPa 784-833

front mm 2510 Brake chamber push-rod space

rear mm 3010 Clearance between brake drum and brake

hoof-plate of running brake (measure the middle

shoe plate at brake drum inspect hole)

mm 0.6-0.1

Front wheel kPa 560 Tire pressure

Rear wheel and spare wheel kPa 670

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Brief description of structure

Engine

Model CA4DF2-13

Type In-line six-cylinder, four-stroke, water-cooled,

turbocharger, central-cooled, direct-injection

Compression ratio 16.8

Cylinder replacement 4.751 L

Max. torque 390 Nmat 1400 r/min Max. power 96 kW(at 2300 r/min)

Piston space 125mm

Cylinder diameter 110mm

Min. fuel consumption 208 g/(kWh) Cylinder ignition

sequence 1-3-4-2

Fuel supply advance angle before upper dead-point 91 Cooling system Pipe radiator, centrifugal water pump, wax temperature

regulator, plastic fan and silicon oil fan clutch, with dilator

Fuel injection bump P7100

Fuel injector P model, 6 spouts

Governor Full speed controller

Fuel delivery pump KS plunger model, fuel delivery pressure is156.8kPa

Fuel filter Double-level rotation type, paper filters core (model is

X0710A)

Air cleaner The filter is dry paper filters core with safe filters core

Clutch 350 Transmission CA6-75 mechanical transmission, 6 forward gear, 1 reverse

gear,

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Gears speed rate

Gear 1

Gear 2

Gear 3

Gear 4

Gear 5

Gear 6

Reverse gear

Over speed gear

6.515

3.796

2.284

1.428

1

0.815

6.060

propeller shaft Open, 2 piece, with 3 universal joints

Rear axle deceleration ratio is 5.43

Frame Boundary beam pressing riveted structure. Longitudinal

beam front is variable section, middle and rear are straight

sections, max. section size is (section height wing width

plate thickness) 237mm 75mm 7mm, and longitudinal

beam is infrastructure board connection structure; there are

hooks at front and rear frame.

Suspension Front and rear leaf springs are both longitudinal symmetrical

semi-ellipse leaf spring structure. Rear end is flying rings

structure, front suspension is installed with 50mm bidirectional sleeve shock absorber, and rear suspension with

auxiliary plate spring .

Structure parameters Action length(mm)width(mm)height(mm)

leaf spring number Front spring 13507611-2 13507610-5

Rear spring 14757611-10

Rear auxiliary spring 11707614-3

Plate spring center space

Front spring 830 mm

Rear spring 1004 mm

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Front axle Integral forging forming. Spare tire riser Catenary one gear differential structure, transmission ratio

is 17, it mounted at lower part of frame behind rear axle.

Wheel Rim is 8.25-16 model,

Steering gear Cycle integral power steering gear, gear ratio is 20.48

Braking system Adopt front and rear independent two-way pneumatic brake

system, braking valve is straight-step double-cavity piston

series valve. Equipped with four-loop protection valve,

fast-release valve, relay valve, and exhaust braking valve. Air compressor Single-cylinder water-cooled type Running brake Front and rear brakes are all pneumatic drum ones Parking brake Adopting spring energy-storage braking cylinder,

controlled by manual braking valve, acting on rear driving wheels; Parking braking system is equipped with fast-release valve.

Auxiliary braking Engine exhaust braking, engine exhaust braking valve and control cylinder is equipped in silencer inlet pipe, electromagnetic valve pneumatic control

Air reservoir The main gasholder is integral double-cavity type (the front cavity volume is 17L, it is used for front braking; its rear cavity 23L is used for rear wheel braking. There is a single-cavity gasholder with 20 L, used for separator water.

Electric system 24V, cathode wire tapping Battery 6-QAW-120D, two in series Generator Magnetic field outside wire tapping, silicon rectifier AC

generator, with neutral-point tap, voltage is 28V, electricity is 55A.

Starter Electromagnetism control, max. output power is 6kW

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Other electric equipment Heater motor is 24V permanent magnetism, output power is 85W. Wiper motor is permanent magnetism double-speed DC motor, equipped with combination instrument, combination switch and warning system linking steering wheel. Circuit protection system consists of two pieces of fusible wire and 18-plates fuse box. Circuit control system consists of 8 relays. Combination switch consists of 8 switches, and set the automatic return unit of turning switch, and starting switch has the anti-theft mechanism and stop unit of self-lock steering wheel.

Vehicle body

and accessories

Cab is forward metal closed type, adopts panorama and curving surface windshield; and equipped with torsion bar spring booster switching mechanism and safeguard by safety hook. The interior is equipped with high backrest driver seat with multiple functions, passenger seat with adjustable backrest angle, with safety belt. With three-gear electric wiper; single-arm glass regulator, card type door lock; windshield syringe, plastic carpet, large sphere rear-view mirror, air mixed heating system and multi-point injection defroster, and second-level pedal mechanism, as well as new headlights, front small light and side turning light. Select electric door and window.

Operation manual

Fuel and lubricating oil

9

Fuel and lubricating oil Fuel Must use good quality diesel fuel . The user should select proper diesel fuel according to local temperature condition,

in compliance with following.

Air temperature above 0 0 -10 -10 -20 -20-35

Diesel fuel type No.0 No.-10 No. 20 No.-35

The fuel filled when new vehicle leaves the factory is:

Summer: GB252 grade one No. 0 light diesel Winter: GB252 grade one No. 35 light diesel

If the diesel is mixed with fuel such as gasoline and alcohol, fire may occur, so this case should be avoided absolutely.

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Caution Before filling fuel, stop running first, and pay attention to whether there is open

flame, to prevent unexpected thing occurrence. Diesel fuel must be deposited at least 48 hours before it is filled into fuel tank,

not including any impurity and water. The filling container must be clean, preventing dust and impurity from entering

it. Do not fill diesel when engine is running, not spattered diesel outside.

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Lubricating oil

Lubricating oil can be filled into diesel engine after filtering( see on picture) . The diesel engine series vehicle type is exhaust-driven supercharger and central

refrigeration turbine diesel, must select engine oil above grade CD. Lubricating oil viscosity is influenced greatly by temperature, lubricating oil

should be select according to the stipulation of national standard(GB11122), based on local temperature.

If local temperature overstep the utmost, it only start capability but damaged diesel engine.

Engine oil must keep clean, not be polluted by dust and impurity. The lubricating oil filled when new vehicle leaves the factory is:

General areas whole year: 15W/40 CD(-20 40) grade diesel engine oil. Summer (south areas): 40CD(040) grade diesel engine oil. Winter (cold areas):5W/30CD(-3040) grade diesel engine oil.

Operation manual

Symbol indication

12

Symbol indication

Turning symbol

Battery charge condition

Engine oil pressure warning

Braking system trouble

Parking brake

Master switch for lights

Leg space ventilation

Master power switch

e

Electric and pneumatic horn conversion switch

Fuel

Coolant temperature

Cigar lighter

Exhaust braking

Heating

Cab toplight

Differential lock

Windshield wiper

Working light

Engine preheating

Vehicle door

Cab tilting

Reversing light

Lights and lanterns

Filter block

ABS

ADM

Fog lamp

Danger signal

Parking light

Windshield defrost and defog

Power takeoff indicator light

Contour light

High beam light

Operation manual

Control mechanism

13

Control mechanism 1-steering wheel 2-turning switch, light switch 3-instrument cluster 4-fog light switch 5-starting switch 6-wiper switch, washer switch, exhaust brake switch, danger warning switch 7-air conditioner switch 8- cigar lighter 9- ashtray 10-heating control lever 11-manual valve 12-gear control lever 13-accelerograph pedal 14-braking pedal 15-clutch pedal 16-glass regulator handle 17-door lock inside handle 18-steering wheel lock handle 19-horn button 20-clutch oil tank

Operation manual

Control mechanism

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1-voltage meter 2-air pressure meter 3-fuel gauge 4-water temperature meter 5-oil pressure meter 6-warning indication lamp 7-speedometer 8-engine revolution meter 9-rear fog switch 10-pre-heat button 11-windshiel washer switch 12-wipper switch , exhaust brake switch and danger warning switch 13-lock knob of ignition switch 14-ignition switch 15-lock handle for steering wheel 16-horn button 17-light switch, turning light switch 18-front fog light switch

Operation manual

Indicator lights and instruments

15


Parking braking indicator light The light comes on when parking braking valve (i.e. manual valve) is at braking

position, which remind the driver turn the parking braking valve back the front( ravel parking braking) in time when the vehicle starts to run; and the light goes off when fast-release valve pressure reaches 392kPa.

Power indicator light Indicate the charging state of generator. The light comes on when the engine

begin starting, showing it has been charged; if the light comes on when the vehicle is running, it is necessary to check whether the power supply system trouble occurs.

Check whether V-belt has breakdown and V-belt tension is normal. Check whether high current fuse of charged circuit is blown out; if it has been

blown out, replace it. If there is no abnormal in the above two items of check, which shows the

charging system has trouble, remove it in time.

Braking system trouble warning light After brake warning light comes on, braking effect decline obviously, extremely

danger, the vehicle cannot continue running absolutely. If the braking system has air leakage, the brake shall lose its action.

When pneumatic braking system has trouble or pipe has air leakage, gasholder pressure drops to 441kPa, the warning light comes on. When running if the light is bright, must stop vehicle to check, after the trouble is removed, it can run.

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Run the engine in middle rotary speed, until the warning light goes out. Check whether the match pipes and pipe joint of all sections has air leakage. If the warning light does not go out, or it comes on soon after it goes out, the

braking system should be repaired.

Start preheating indicator light.

When starting engine, after starting switch switching in ON gear, press starting preheating button, the preheating indicator light comes on; release the button, relieve preheating, the indicator light goes out, preheating system finishes work.

Engine oil pressure and engine oil filter warning light

When the key switches in power, oil pressure indicator light comes on. After the engine starts, the indicator light goes out.

When the engine oil pressure drops to 605kPa, the light is comes on. If the light comes on when running, which shows that the engine oil is deficient or engine filter is crammed, at that time, must stop vehicle to check, and drive it after the trouble is removed.

When it is cold, the warning light still comes on temporarily after the engine starts sometimes due to the engine oil viscosity rising, this phenomenon is not abnormal.

If the light comes on when the engine is running, the vehicle should be parked on safe place to check.

Check engine oil level, if it is deficient, complement. Check all section of the engine to see whether there is oil leakage. The oil level is normal and there is no oil leakages, showing that lubricating

system has trouble, remove it.

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Cooling water level/engine over-hot warning light

When engine coolant is deficient or the engine is over-hot, the warning light comes on.

Dont ignore the warning light; Otherwise the engine temperature rises excessively, to lead to sinter.

If the warning light comes on, and water thermometer hand get outside of the red area, showing that the engine is over-hot, the following operation should be done.

Operate the engine at the rotational speed slightly higher than idle speed, to make the engine temperature drop.

If the warning light comes on, but the water thermometer is in normal position, showing that the coolant is deficient, the following check should be carried out.

Stop the engine until the coolant temperature drops. Check whether radiator and its match pipe have water leakage. Open radiator water tank cap, and fill coolant fully. If finding water leakage, go to garage to repair.

Caution

Dilator cap can be reopened until the water temperature drops. When open the cap, cover it with cloth, slowly unscrew to the first stop, after pressure relief, and open the pressure cap, to avoid hot water erupting to cause scald.

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Air pressure meter

Air pressure meter is double-hand type. The upper hand indicates the front cavity air pressure of air holder, the front

cavity air is used for front wheel braking. The lower hand indicates the rear cavity air pressure of air holder, the rear cavity

air is used for rear wheel braking. When vehicle is running, braking air

pressure must keep in the range of 784-833kPa.

Speed odometer aindicate vehicle running speed b indicate vehicle cumulate total

running mileage During the wear away period (2500km), Max. Speed does not exceed 60km/h.

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Fuel gauge

Indicate the fuel level in fuel tank. 0: show no fuel in the fuel tank. 1: show full fuel in the fuel tank.

After close starting switch, the hand still indicates the fuel level in the fuel tank. Fuel tanks volume is 300L, this is equipped with conceived fuel tank. Continuous running mileage of vehicle is 1000km.

Water thermometer

Water thermometer indicates engine coolant temperature, scale 110 expresses high temperature, 50 low temperature, 110-50 expresses normal temperature..

After the engine is cold started each time, it is necessary to run at low speed to preheat rising temperature, until the coolant temperature reaches above 50, it can start to run.

In running, observe carefully water temperature, to make coolant temperature keep 75-95(about at the middle of both scales).

If the hand is outside of scale 110, it shows that the engine is getting over heat, it is necessary to stop to check, remove the trouble.

In normal operation circumstance, radiator curtain is fully open, temperature controller and fan clutch shall automatically adjust coolant temperature, to make it at optimal working temperature. When it is particularly cold, lower the radiator curtain to adjust coolant temperature.

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Voltmeter

Voltmeter reading range is 0-32V. 16-24V and 30-32V are red area, normal voltage is at middle position. Engine oil pressure meter

Indicate the working pressure of lubricating oil in main oil-way of engine. After the engine starts, it is necessary to check engine oil pressure. Scale 6 expresses high pressure, 0 expresses low pressure. In running, often observe engine oil pressure. When the engine runs normally, if

the hand of engine oil pressure meter is 06, the pressure is normal. If the engine oil pressure is over low, the hand does not move or the hand moves suddenly, must be stop vehicle to check, to prevent parts from burning out. When the engine is working, the engine oil pressure does not lower than 100kPa.

Operation manual

Switch, button and handle

21

Switch, button and handle Combination switch

Combination switch includes: light switch, change lights switch, turning signal switch, wiper switch, washer switch and danger warning switch. Left handle (light switch, turning signal switch)

This switches control lever, at left side of turning column High beam and low beam conversion

Overtaking dimming

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Light switch

To turn the knob at the end of left handle, to make the handle be at OFF position, turn off all light.

When the left handle turns to position, front and rear small lamps, instrument light and rear license plate light come on.

Raise the handle, high beam and low beam of headlight comes on simultaneously, giving overtaking signal; after releasing it, headlight goes off.

When the left handle is turned to position, headlight, front and rear dim lamps, instrument light and rear license light come on.

Raise the handle to the top, high beam and low beam of the front light come on simultaneously. Raise the hand to the top again then release, returning low beam.

Repeat rising and releasing, may send the vehicle meeting signal that high beam and low beam alternate conversion. Turning switch

When the left handle is on middle gear position, turning light goes off. Push the left handle forward, right turning light comes on, at the same time,

corresponding turning indicator light on the instrument cluster flash. Pull the left handle backward, left turning light comes on, at the same time,

corresponding turning indicator light on the instrument cluster flash.

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Right handle (wiper switch, windshield washer switch, danger warning switch, exhaust braking switch)

This switch is control lever, at the right side of turning column. Wiper switch

Danger warning

Windshield wash

Operation manual


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When right handle is in the middle position (OFF), the wiper not to work. When right handle is turned to LO position, the wiper works at a low speed. When right handle is turned to HI position, the wiper works at a high speed. When right handle is turned to INT position, the wiper works intermittently.

Windshield washer switch

Windshield washer switch is at the end of wiper switch. Press the switch at right handle end inward, detergent will spray on windshield

glass; When loosening, spray stop. When wiper switch turns to OFF position, press washer switch, the wiper

should automatically wipe twice. Caution

Washer spray cannot exceed 5 seconds for each time; the interval to next spray cannot be less than 25 seconds.

Danger warning switch

This switch can simultaneously turn on and turn off left and right turning light power.

Use it when vehicle in trouble, or parking at danger place. When right handle is raised to the middle position, front, rear, left and right

turning lights flash simultaneously. Raise the right handle to the top, after loosening, the right handle falls

automatically, 4 turning lights go off simultaneously. Exhaust brake switch

Push right handle forward, at OFF position, exhaust brake does not work. Pull right handle backward, at ON position, exhaust brake will work.

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Starting switch

starting switch key and vehicle door key are the same one. LOCK: Shut off electric circuit ACC: Turn the key rightward (clockwise) to

gear 1, switch in accessory gear. When vehicle stop, if want to use some electric equipment (radio cassette, etc), turn the key to this gear, then can operate the corresponding electric equipment.

ON: Continue to turn the key to gear II, switch in electric circuit. S: Continue to turn the key to the bottom, start engine, after loosening, the key

returns automatically.

Key locking When the key is inserted into the starting switch, turned LOCK position to

ACC position, the lock locking button(white button) will spring automatically, to make the key not be pulled out, preventing the key from pulling out from lock hole due to vehicle vibration in running.

Fog light switch

Fog light switch is roller type, at steering wheel jacket. Please use fog light when it is foggy or sight is not good in cloudy day. Press the switch at ON position, the fog light comes on; The switch is returned,

the fog light goes off.

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Electric and pneumatic horn conversion switch

The vehicle is equipped with electric horn and pneumatic horn, and set the conversion switch on the instrument cluster, the user can convert them randomly.

Cigar lighter

Press down the cigar lighter switch, until resistance wire is red and hot, it automatically pops out, at that time, pull out the button to use it.

Dont hold the lighter in to block it pop-up; otherwise, it will overheat to cause danger.

If the lighter doesnt pop out within 30 seconds, which shows the lighter in trouble, remove it to prevent fire.

When the lighter doesnt work well, stop using it. Dont leave the vehicle when the lighter is

pulled. Deformed lighter cannot pop-up, replace it with

right lighter. Dont use the lighter socket for plug-in

accessories. They may damage it or cause electrical accident.

When the ignition switch must be in the ON or ACC position, it can be used. Ashtray

Beside the lighter is equipped an ashtray. Put Cigar end and match into the ashtray after they are completely.

Was put out; then press the ashtray cover well. Dont put things other than cigar end or be full of cigar end; You may bring a

fire.

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Steering wheel locking handle

Steering wheel locking handle is installed on the steering post, release the locking handle can adjust steering wheel and steering post positions. When adjusting, raise the locking handle, make the steering wheel relieve locking, at that time the steering wheel can slide upward and downward or swing forward and backward. The steering wheel can slide upward 40mm, downward 20mm; swing 5 forward and backward respectively.

Parking braking control valve (manual valve for short)

Manual valve is at the right side of driver seat.

When braking, pull the manual valve to the end. When relieve braking, lift the pull button 2 of the manual valve, at the same

time push handle 1 forward to the end. Caution

Use the manual valve only for parking. In running, when running braking fails or other dangers occur, the manual

valve is allowed to use, but dont replace running braking.

Steering wheel

Steering wheel locking handle

Braking position Relieve braking

Operation manual

Correct operation

28

Correct operation Outside unlock of left door:

Insert the key into lock hole, turn 90 clockwise then return, pull out the key, then hold the outside handle, and press strongly press-button with thumb, pull outward, to open the door. Outside locking of left door

Close the door properly, insert the key into lock hole, and turn 90 anticlockwise, the door is locked. The key can be pulled out after it returns.

Right door operation is the same as left

door, but the direction is reverse: Inside unlocking of door

Raise lock button, then pull inside handle, to open the door.

Inside locking of door

Close the door, press the lock button, to lock the door. Note: When the door is not closed completely, the light inside of cab

comes on; after the door is closed properly, the light goes off.

Outside handle Press-button Lock body

Lock button

Inside handle Inside arm

Glass regulator handle

Operation manual

Correct operation

29

Cab ventilation

Natural ventilation is implemented through air ways on interior and upper walls of cab, airflow enter the cab through airways and vent grid, manually trigger grating to adjust airflow.

Forcing ventilation, heating and defrosting are to send fresh air into the cab through floor vents, central vent grating and left and right side defrost nozzle.

Glass regulator operation

Left door: Turn handle clockwise, door glass fall. Turn handle anticlockwise, door glass rise.

Right door: Turn handle anticlockwise, door glass fall. Turn handle clockwise, door glass rise.

Vent grating

Lock button

Inside handle Inside arm

Glass regulator handle

Operation manual

Correct operation

30

Central control door lock (optional)

Press remote device locking button outside of the door, left and right doors can be locked simultaneously.

Press remote device unlocking button, left and right doors can be unlocked simultaneously. Inside locking of door:

Close the door, press the locking button inside of left door, left and right doors can be locked simultaneously; Press the locking button inside of right door, only right door can be locked. Press the front end of door control switch, left and right doors can be locked simultaneously. Inside unlocking of door

Pull the locking button inside of door, or press the rear end of door controls switch, the door is in unlocking state, pull inside handle backward, to open the door.

Operation of electric glass regulator (optional):

Driver side can control left and right door glass regulators. Press the front end of control switch of left door glass regulator, left door

glass rise, release it, glass stop lifting, right door operation is the same as left door.

Press the rear end of control switch of left door glass regulator, left glass fall, but release it, the glass continues falling up to the low stop point.

Press the rear end of control switch of right door glass regulator, right glass fall, release it, the glass stops falling.

Operation manual

Correct operation

31

1 2 3

Left door Right door 1-inside lock button 2-inside handle 3-right door regulator switch 4-left door regulator switch 5-door lock control switch

Operation manual

Correct operation

32

Adjustment of drivers seat Front and back adjustment:

When adjusting front and back positions, step on the floor, pull rightward slide-way regulation handle, to make the regulation board take out toothed plate, use the friction force of the body and seat-bottom to make the seat slide to necessary position, then release the handle, to make the regulation plate and toothed plate fit, restore locking.

The front and back adjustment of the seat can be divided into 8 gears, Max. Adjustment quantity is 140mm.

Backrest angle adjustment:

When adjustment, pull backward the angle regulation handle to relieve locking, the backrest will incline forward automatically due to spring elasticity, use the body backrests pressure to adjust the back to proper angle, then release the handle to restore locking.

The original angle of the back is 1230; it can be adjust forward to 22; backward to 46, divided into 23 gears.

Slide-way handle

Slide-way regulation handle

Operation manual

Correct operation

33

Headrest position adjustment

Must adjust the headrest to correct position, and fix well. When adjusting the drivers seat headrest position, pull the headrest

regulation lock plate, after open the lock plate, press down or raise the headrest, to the position you want, then release your hand to lock.

Passenger seat: except for the front and back adjustment function, other functions are as the same as the drivers.

In running, dont make the backrest incline backward, otherwise, when emergency braking, passengers body will slide off the seat to suffer from serious injury.

Middle seat: The back can tilt forward, behind the back is equipped with a glove box. Height adjustment of selecting drivers seat:

Pull upward height adjustment handle, adjust front handle 3, relieve locking, adjust seat front angle with human body weight, after adjusting to proper position, release handle, then lock it again.

Adjust rear handle 4, relieve locking, adjust seat rear angle with human body weight, after adjusting to proper position, release handle, relock, and finally reach the goal of adjusting seat height.

1-front and rear adjusting handle 2-angle adjusting handle 3-front handle of height adjustment 4-rear handle of height

adjustment 5-rigidity adjusting handle 6-electric heating pad plug

Unlock

Operation manual

Correct operation

34

Front and back adjustment:

Pull upward the front and back adjusting handle 1, relieve locking, adjust seat assembly forward or backward with human body strength, after adjusting to proper position, release the handle, relock. Angle adjustment

Pull upward the angle regulation handle 2, relieve locking, adjust seatback angle forward or backward with human body strength, after adjusting to proper position, release the handle, relock.

Rigidity adjustment:

Turn rigidity adjusting handle 5 forward or backward, adjust to driver weight value according to the scale on the handle, so as to adjust the seat mat rigidity suitable for driver.

Passenger seat adjustment:

The height adjustment, front and back adjustment, angle adjustment of passenger seat is the same as driver seat adjustment, only without rigidity adjustment. Seat electric heating unit:

Turn on the electric heating seat switch on instrument cover, and then the seat can be heated.

Operation manual

Correct operation

35

Seat belts (selection)

In order to reduce the damage occurring in vehicle bumping or emergency braking, it is very important to use seat belt correctly.

Before vehicle start to run, make sure all passengers fastening the seat belts. It is extremely dangerous to remove or fasten the seat belts in running, must

do it when vehicle stops. One seat belt is not allowed to used by tow passengers. Note abraded seat belts, this kind of seat belt is not only non-effective, but

also very dangerous. After fastening seat belts, should sit up on the seat, make the back lean

against the seatback. If sitting posture is not upright that will reduce the protection effect of seat belts.

When vehicle is running, dont over-tilt the seatback, otherwise, when vehicle bumps, passengers body will pull out from the seat belts, to cause passengers neck hanging, suffering from unexpected injury such as cervical vertebra wreckage.

In order to avoid abdomen crush in vehicle bumping, must fasten the seat belt on bones, also note the shoulder belt position.

When fastening seat belts, make sure the seat belts are not twisted up. The area of the twisted section, which will bring over large pressure on human body, causing danger.

If the seat belts have broken, and burst at the seam, or the belt buckle effect is abnormal, replace them immediately.

When vehicle bumping accident occurs and the seat belts receive impact force, although the seat belts are not found damage, the seat belts should be also replaced.

Dont insert impurity into the belt buckle of the seat belts, dont transform or take off the seat belts either.

Seat belt cleaning: When the seat belts are dirty, they should be cleaned with neutral detergent, dont use bleacher, dye or dry cleaning agent, which can seriously damage their strength.

Fastening seat belts: sit upright on seat, make the back against the seatback comfortably, slowly pull out tongue and insert it into buckle until you hear a click, make sure the seat belts have not twisted section; loin belt is fastened on bone, the lower the better.

Releasing seat belts: press red button, the belt will automatically wrap, when the belt is wrapping, hold the tongue until it wraps.

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Sundries box

Dont put the things that may fall down or roll, or they may roll out to block safe running when vehicle starts or stops.

Before vehicle starts, must close the cover. Outside rear view mirror

Outside rear view mirror can be adjusted manually to the desired angle, to reach satisfactory effect.

Rear view mirror should be wiped to keep mirror cleanness. Adumbral board

When driving, if the sun irradiate directly, lower the adumbral board. Adjust the adumbral board to proper angle, to guarantee both the drivers

sight and effective visual field. Pull out the adumbral board from the fixed clip, swing to door side, to keep

out sidelight.

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Radio/cassette player

Dual-track, AM/FM stereo radio cassette tape player, it has LED frequency and clock display function, high tone and low tone compensation function, remote and local reception control function, automatic reverse function, etc.

Power supply (SW), volume (VOL) button: Turning clockwise until you hear click, showing switch in power, may adjust volume.

TUNE button: Turn this button, display frequency on LED screen correspondingly change, may select corresponding broadcasting station.

Volume output balance (BAL) button: Adjust left and right track volume balance. Tone control button: Adjust high tone and low tone to make tone quality optimal. Frequency/clock selection button: Change the selection of reception

frequency and clock display on LED screen. Band (BAND)button: AM and FM switch Stereo control button(ST): Normal / Stereo selection. Remote/near control button(DX): Remote broadcasting station and near

broadcasting station switch. Clock set button(SET): Hour set button (H), minute set button (M): press (H)

button or (M) button, LED will display clock. If the adjustment is need, adjust hour or minute.

When vehicle stops, if using the radio, first turn the starting switch key to switch in accessories gear.

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Emblem mark 1-TUNE knob (for radio channel selection) 2-power, volume knob 3-tone control knob 4-clock set button 5-LED display screen 6-cassette holder

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Cab tilting forward and return Cab tilting forward:

Cab locking control mechanism is at the left side of cab back. Pull out safety pin 6 from the pinhole, pull control handle 7 down to the end,

make main hook detach from lock latch assembly 2 (see the right figure in next page).

Pull outward pull-rod 5, make safety hook detach from lock latch fixed rack 3, at that time, the cab can spring upward to one balance position.

Push upward handrail 12, make cab 11 lift, so as to make support rod assembly 10 strengthen out, at that time, the cab is balanced, push upward lock hook, insert linchpin 8 into lock hole, lock the support rod, see the left figure in next page. Caution

Support rod linchpin must be inserted into the hole actually, to avoid the cab fall to cause personal injury. Cab return

Stand outside of left front wheel, pull out linchpin 8(see the left figure in next page), turn downward lock hook, at the same time hold handrail 12, pull downward, to make the can fall.

When the cab fall, safety hook 4 (the right figure in next page) will lock the lock latch fixed rack 3, the cab will be advance locked.

Push upward control handle 7(as the position in the right figure in next page), to make main hook 1 lock the lock latch assembly 3.

Insert safety pin 6 into pin hole, at that time the cab is locked.

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1-main hook 2-lock latch assembly 3-lock latch fixed rack 4-safety hook 5-pull-rod 6-safety pin 7-control handle 8-slip-pin 9-lock hook 10-support rod assembly 11- cab 12-armrest

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Operation of air conditioner (heating, cooling)

1: A/C switch: A/C switch is cooling switch. Cooling equipment is a selection. When wanting to operate cooling equipment, press this switch, compressor begins operation; Want to stop, please press this switch again.

2: Cooling outlet shift control rod Air blows toward selected direction from the central or left and right outlets.

Air blows out from the center, left, right or floor.

All air blows from floor.

All air blow toward front glass window (frost prevention device).

Air blows toward the center, left, right and front glass window.

Air blows toward the center, left, right and front glass window. 3: Interior and exterior air shift control rod

Interior circulation: make the air within the cab circulate.

Exterior circulation: input exterior fresh air.

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4: Fan switch OFF stop

Gentle breeze

Mild wind

Normal wind

Strong wind

5: Temperature regulation control lever

Left side (COOL)blow cool wind Right side (WARM)blow warm wind

Operation tips Heating: When wanting the cab interior become warm, place control lever 3 in interior circulation position

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Ventilation: Place control lever 3 in exterior circulation position, other control lever positions are as shown in the figure.

Defrost: All control lever positions are as shown in the figure. Caution

When using heating, the engine coolant temperature should be above 75. When using heating in winter, the heating outlet switch on engine cylinder

head should be opened first. Antifreeze is required to use in cold areas. If antifreeze is not used, when

vehicle stops for a long time, it is necessary to open discharge valve, to prevent generating ice block in pipeline or freeze heating radiator.

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Using tire chain in winter Tire chain installation

Tire chain should be installed firmly, to avoid to take off or collide and interfere other parts in running.

The tire chain suitable for tire size should be mounted. Dont mount tire chain on front wheel. When installing, check whether tire chain and it spring drawstring have abrasion. After running 5-15 minutes, check whether tire chain has looseness or dropout. After install tire chain, driving speed should not exceed 30km/h. On the road without ice and snow, dont use tire chain; Otherwise chain is

easily damaged. The bending section of cross chain should be at outboard.

Cross chain

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Inside chain is all used to make it become non-residual state and link hook,

pull the cross chain of inside tire outward, to eliminate inside chain looseness.

Outside chain Middle chain Inside chain

Hook

Cross catena The hook that temporary fix outside chain is as shown as the figure. Strain the middle chain as far as possible and connect hook.

Hook Strain both ends of outside chain and connect hook.

Hook

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Make sure all hooks and tire side-wall become parallel state, at the same time,

make sure all chain has no twisted section. Fix residual chain with wire, to prevent contact other parts. Fasten spring clamp, all sections of spring clamp should face the outside and

evenly installation.

Spring clamp

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Correct drive

General starting of engine Place gearlever in the neutral position, strain manual valve, then switch in

power with key(turn the key clockwise to ACC position). Step on clutch pedal, continue to turn the key to start engine, as soon as the

engine starts, release the key immediately. After the engine works smoothly, uniformly release clutch pedal. After starting, check engine oil pressure and coolant temperature.

Caution for starting: Make sure whether there are people or barriers in the under part, front, left and

right of the vehicle with eyes or rear view mirror. Make sure whether there are bright warning lights. Make sure manual valve is in relieving braking state. When starting, dont step on accelerograph suddenly, to prevent the engine oil

pressure from rising suddenly, while the engine oil is over viscous, which cannot reach the friction surface of all parts in time, to accelerate part abrasion.

Starter is not used for more than 5-7 seconds each time, after each failure, restarting must be after 2 seconds. If three successive starting fails, check whether oil pipeline and circuit have trouble, restart after finding the cause and removing it, and dont start forcedly.

After engine starts, dont step on gas pedal suddenly, to avoid engine running at high speed.

After engine starts, first work for several minutes at low speed, until water temperature reaches 50, begin to run, but dont idle work over long.

For the vehicles that dont drive for a long time, or the engine oil and engine oil filter cylinder are replaced, must start motor first, to make lubricating oil get on all lubricating surface, then start the engine.

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Caution for winter

When the temperature is lower than 5, must particularly maintain the diesel. Must use the engine oil and diesel for winter, dont mix diesel with water, to

avoid block oil-way. When replacing low-temperature engine oil, discharge the engine oil in the

original disc and oil injection pump of the diesel completely, and clean engine oil filter, engine oil disc and engine oil receiver, then fill low-temperature engine oil into the engine disc and oil injection pump. When diesel working environment temperature is below -10, the replacing oil cycle should be shortened.

Before starting, pull down radiator curtain. When starting the engine, first the starting preheating button, then start the

engine with key. After the vehicle stops in winter, discharge water until the waters temperature

drops to 40-50. In cold areas, it would be better if the vehicle would not stop in the open,

otherwise, when starting, must warm engine oil disc to make engine oil not over dense. If the vehicle does not use antifreeze, the water tank must be filled boiled water, and use heater so as to start easily.

When starting engine below -35 temperature in winter, if using hot-water heater, the water temperature should not be over high, to avoid cylinder body crazing.

Documents

CA5083 XXYPK2L1A80 Operation Manua GF-6000l