Maintenance Instructions For SINOTRUK |

Assembly

Petroleum Product

Brand

Volume

Fuel tank capacity（L）

Diesel

Diesel which apply to the local temperature

400 or 300

Engine Cooling system（L）

Long-lasting antifreeze anti-corrosion coolant

Heavy duty long-lasting antifreeze anti-corrosion coolant used in four seasons

40

Engine Lubrication system（L）

Engine Oil

CH-4 Grade

23

Transmission（L）

Gear oil of heavy duty vehicles

85W/90 GL-5

13

Clutch（L）

Brake fluid

SAE 116/DOT3

About 1L

Steering（L）

hydraulic liquid

HVN32 Low temperature hydraulic liquid

3.5

Rear-axle final drive and bush bearing（L）

Gear oil of heavy duty vehicles

GL-5EP 80W/90 or GL-5EP 85W/140

23

Tilt-cab assembly

hydraulic liquid

HVN32 Low temperature hydraulic liquid

0.4

Item

Content

Check Period

Every week

Every month

Every two month

Every Quarter

Every Year

Air- conditioning Unit Compressor

Coolant volume

Check coolant level

+

Coolant leakage

Check leakage with halogen checker

+

Check cracks and damage

+

Hose and pipe

Check leakage of connectors and tightening of clamps

–

Replace desiccant and filter

–

Coolant

Refill with specified coolant

+

Oil seal

Check leakage trace with white paper

+

–

Belt

Check tightness of belt pulley and check wear

+

Bolt

Check tightness，check and check change all of them, if necessary

+

Evaporator condenser Electrical Apparatus Element

Evaporator Cartridge

Check dirt, clean, if necessary

+

Wind motor

Check running condition

+

Expansion valve

Check running condition,remove filter gauze and clean

+

Condenser Cartridge

Check dirt, clean, if necessary

+

Wind motor

Check running condition

+

Connector and Plug

Check looseness of wire clamp plug

+

+

Heat Sensitive Resistance Switch

Check action

+

Magnetic Clutch

Check if specified requirements has been met

+

Magnetic Clutch bearing

If it cannot turn steadily,please replace it

+

WG I

WG II

WG III

Mileage per year less than 2x 10 ⁴ km of working duration not more than 600h.

Mileage per year less than 2x 10 ⁴ km and less than 6x 10 ⁴km

Mileage per year mire than 6x 10 ⁴km

Normal condition

Bad Condition

A

B

C

D

E

Good condition and long distance transport, sulfer content of fuel is less than 0.05%

Short distance transport, engineering truck, bus, etc.

Off-road, mountain and rugged road

Hot or cold region(temperature always above 30℃ or below -10°C）

Sulfer content of fuel more than 0.05%

Service Condition Item

WG I

WGII

WGIII

First-time Check

After running1000~1500km After running 30~50h

After running1500~2000km

After running1500~2000km

Routine Check（P）

Every 5000km Every 150h

Every 1x 10 ⁴km

Every 1.5x 10 ⁴km

1^st-Grade Service （WD1）

Every 1x 10 ⁴km Every 300h

Every 2x 10 ⁴km

Every 3x 10 ⁴km

2^st-Grade Service （WD2）

Every 2x 10 ⁴km Every 300h

Every 4x 10 ⁴km

Every 6x 10 ⁴km

1^st-Grade Service （WD3）

Every 4x 10 ⁴km Every 300h

Every 8x 10 ⁴km

Every 12x 10 ⁴km

4^st-Grade Service （WD4）

Every 8x 10 ⁴km Every 300h

Every 16x 10 ⁴km

Every 24x 10 ⁴km

Cab Maintenance instructions

First-time
Check

Routine
Check

1^st-Grade
Service

2^st-Grade
Service

3^st-Grade
Service

4^st-Grade
Service

Check the wiper

·

•

•

•

•

•

Re-tighten locking handle on drive`s cover

•

•

•

•

Re-tighten engine radiator`s cover

•

Check oil level of cab tipping hand pump

•

•

•

Check lifting cylinder

•

•

•

•

Chassis Maintenance instructions

First-time
Check

Routine
Check

1^st-Grade
Service

2^st-Grade
Service

3^st-Grade
Service

4^st-Grade
Service

Check fixation and action of towing hook

•

•

•

•

•

Re-tighten the bolts on cross member of the frame

•

Tighten front and rear leaf spring bolts and brackets

•

•

•

•

Check spare tire fixing device

•

•

•

Check and adjust slide rail clearance of leaf spring

•

•

•

Check the fixation of wheel nuts

•

•

•

•

•

Check the fixation of battery

•

•

•

Check the fixation of fuel tank

•

•

•

Electrical system Maintenance instructions

First-time
Check

Routine
Check

1st-Grade
Service

2st-Grade
Service

3st-Grade
Service

4st-Grade
Service

Check the working condition of electrical system（Instrument, lamp, wiper and air conditioner）

•

•

•

•

•

•

Check electrolyte level and cell voltage

•

•

•

•

•

Check the fixation of battery terminal,
Coat electrode with grease

•

•

•

•

•

Check electric tachometer and speed accuracy

•

•

•

•

•

•

Brake system Maintenance instructions

First-time
Check

Routine
Check

1^st-Grade
Service

2^st-Grade
Service

3^st-Grade
Service

4^st-Grade
Service

Drain water from air reservoir

•

•

•

•

•

•

Check leafproofness of air pressure system（With barometer）

•

•

•

•

•

Check brake lining thickness and adjust brake clearance

•

•

•

Check wheel brake

•

•

Check vulnerability of brake pipeline and hoses

•

•

•

•

Check brake chamber

•

•

•

•

Check footbrake, handbrake and exhaust brake action（when do the trial running）

•

•

•

•

•

Check ABS

•

•

•

•

•

Diesel Engine Maintenance Item

First-time Check

P

WD1

WD2

WD3

WD4

Replace diesel oil

•

CH-4 Oil changing cycle as per different conditions

Replace fuel filter or filter element

•

When changing diesel oil

Check and adjust valve clearance

•

•

•

•

•

Replace fuel filter element

•

•

•

•

Clean fuel pre-filter or replace filter element

•

•

•

•

Check coolant volume and add it to full

•

•

•

•

•

•

Replace coolant

According to 4.4

Fasten cooling pipe clamp

•

Fasten inlet air pipe, soft tube, and flange connection parts

•

•

•

•

•

Check air filter maintenance indicating light or indicator

•

•

•

•

Clean dust cup of air filter（Excluding automatic exhausting type）

•

•

•

•

•

Clean main filter element of air filter

When indicator light or indicates red

Replace safety filter core of air filter

After cleaning main filter core for give times

Check bearing clearance of turbocharger

•

Check，adjust clutch stroke and wire rope conditions

•

•

•

•

•

•

Electric components and electronically controlled system wiring harness

Check it every 250hours

Note：The mark means that the maintenance is needed.

Vehicle Maintenance instructions

First-time
Check

Routine
Check

1st-Grade
Service

2st-Grade
Service

3st-Grade
Service

4st-Grade
Service

Short distance trial running
（Including braking test）

•

•

•

•

•

Visual check for leakage

•

•

•

•

•

•

Check and tighten cargo body

•

•

•

•

•

•

Lubrication Maintenance instructions

First-time
Check

Routine
Check

1^st-Grade
Service

2^st-Grade
Service

3^st-Grade
Service

4^st-Grade
Service

Water pump

•

•

•

•

•

•

Clutch release shaft

•

•

•

•

•

•

Clutch pedal shaft

•

•

•

•

•

•

Check release bearing

•

•

•

•

•

•

Universal joint and intermediate
Support of transmission shaft

•

•

•

•

•

•

Steering knuckle and front axle

•

•

•

•

•

Leaf spring pin

•

At least once every four weeks

Check leaf spring slide rail clearance of suspension

•

•

•

•

•

•

Shock absorber mounting

•

•

•

•

•

•

Gearshift lever bracket

•

•

•

•

•

Brake camshaft and brake arm

•

•

•

•

•

•

Towing hook

•

•

•

•

•

•

Fifth wheel

•

•

•

•

•

•

Cab door hinge

•

•

•

•

Perform rust-proofing treatment of driver`s cab again according to schedule

Once every 12 months

 Service Conditions
Changing interval

WG I

WG II

WG III

A

——————-

15000km

20000km

B

5000km/4 months/service time 200h

10000km/6 months/service time 500h

———————-

C

5000km/4 months/service time 200h

10000km

15000km

D

5000km/4 months/service time 200h

10000km

15000km

E

5000km/4 months/service time 200h

10000km

15000km

1. For vehicles services in various bad condition or always over-loads, interval of oil changing shall be shorten
2. Ensure two times of oil changing in whatever conditions