Foton BJ3251, repair e-manual (in Russian)

Content

General information

• How to use this manual
• General information
• Vehicle identification plate
• Vehicle identification
• Repair rules
• Preparation
• Repair tips
• Vehicle jacking and supporting positions

Preparatory tools

• Fuel (WP10)
• Preparations
• Fuel (WP12)
• Preparations
• Fuel (WD615)
• Preparations
• Startup
• Preparations
• Exhaust exhaust, turbocharging (WP10)
• Preparations
• Exhaust exhaust, turbocharging (WP12)
• Preparations
• Exhaust Exhaust Turbocharged (WD615)
• Preparations
• Cooling (WP10)
• Preparations
• Cooling (WP12)
• Preparations
• Cooling (WD615)
• Preparations
• Lubrication (WP10)
• Preparations
• Smear (WP12)
• Preparations
• Lubrication (WD615)
• Preparations
• Mechanical engine (WP10)
• Preparations
• Mechanical engine (WP12)
• Preparations
• Mechanical part of the engine (WD615)
• Preparations
• Engine management
• Preparations
• Preheating system (WP10)
• Preparations
• Preheating system (WP12)
• Preparations
• Preheating system (WD615)
• Preparations
• Charging system (WP10)
• Preparations
• Charging system (WP12)
• Preparations
• Charging system (WD615)
• Preparations
• Front suspension
• Preparations
• Rear suspension
• Preparations
• Wheels and tires
• Preparations
• Front axle (ANKAI)
• Preparations
• Front axle (SANHUAN)
• Preparations
• Rear axle
• Preparations
• Service brake
• Preparations
• Parking brake
• Preparations
• Frame
• Preparations
• Intermediate bridge (Steyr)
• Preparations
• Intermediate axle (Mercedes-Benz)
• Preparations
• Checkpoint (RT-11509C)
• Preparations
• Checkpoint (9JS135)
• Preparations
• Checkpoint (12JSD160)
• Preparations
• Clutch
• Preparations
• Drive shaft
• Preparations
• Power take-off
• Preparations
• Steering wheel and steering column
• Preparations
• Power steering gear
• Preparations
• Heater and air conditioner
• Preparations
• Seat belt
• Preparations
• Battery
• Preparations
• Lighting
• Preparations
• Windshield wiper and washer
• Preparations
• Audio System
• Preparations
• Beep
• Preparations
• Power windows / rear view mirrors
• Preparations
• Instrument panel / instrument cluster / lighter
• Preparations
• Seats
• Preparations
• Doors / door locks / door handles
• Preparations
• Interior / exterior components
• Preparations
• Cabin
• Preparations
• Hydraulic self-unloading system
• Preparations

Repair standards

• Fuel (WP10)
• Repair data
• Torque requirements
• Fuel (WP12)
• Repair data
• Torque requirements
• Fuel (WD615)
• Torque requirements
• Startup
• Torque requirements
• Exhaust exhaust, turbocharging (WP10)
• Torque requirements
• Exhaust exhaust, turbocharging (WP12)
• Torque requirements
• Exhaust exhaust, turbocharging (WD615)
• Torque requirements
• Cooling (WP10)
• Repair data
• Torque requirements
• Cooling (WP12)
• Repair data
• Torque requirements
• Cooling (WD615)
• Repair data
• Torque requirements
• Lubrication (WP10)
• Repair data
• Torque requirements
• Smear (WP12)
• Repair data
• Torque requirements
• Lubrication (WD615)
• Repair data
• Torque requirements
• Mechanical engine (WP10)
• Repair data
• Torque requirements
• Mechanical engine (WP12)
• Repair data
• Torque requirements
• Mechanical part of the engine (WD615)
• Repair data
• Torque requirements
• Engine management
• Torque requirements
• Preheating system (WP10)
• Repair data
• Torque requirements
• Preheating system (WP12)
• Repair data
• Torque requirements
• Preheating system (WD615)
• Repair data
• Torque requirements
• Charging system
• Repair data
• Torque requirements
• Charging system
• Repair data
• Torque requirements
• Charging system
• Repair data
• Torque requirements
• Front suspension
• Repair data
• Torque requirements
• Rear suspension
• Repair data
• Torque requirements
• Wheels and tires
• Repair data
• Torque requirements
• Front axle (ANKAI)
• Repair data
• Torque requirements
• Front axle (SANHUAN)
• Torque requirements
• Rear axle
• Repair data
• Torque requirements
• Service brake
• Torque requirements
• Parking brake
• Torque requirements
• Frame
• Torque requirements
• Intermediate bridge (Steyr)
• Repair data
• Torque requirements
• Intermediate axle (Mercedes-Benz)
• Repair data
• Torque requirements
• Checkpoint (RT-11509C)
• Repair data
• Torque requirements
• Checkpoint (9JS135)
• Repair data
• Required torques
• Checkpoint (12JSD160)
• Repair data
• Torque requirements
• Clutch
• Repair data
• Torque requirements
• Drive shaft
• Repair data
• Torque requirements
• Power take-off
• Repair data
• Torque requirements
• Steering wheel and steering column
• Repair data
• Torque requirements
• Power steering gear
• Repair data
• Torque requirements
• Heater and air conditioner
• Repair data
• Torque requirements
• Seat belt
• Torque requirements
• Battery
• Repair data
• Torque requirements
• Lighting
• Torque requirements
• Windshield wiper and washer
• Torque requirements
• Audio system
• Torque requirements
• Beep
• Torque requirements
• Power windows / rear view mirrors
• Torque requirements
• Instrument panel / instrument cluster / lighter
• Torque requirements
• Seats
• Torque requirements
• Doors / door locks / door handles
• Torque requirements
• Interior / exterior components
• Torque requirements
• Cabin
• Torque requirements
• Hydraulic self-unloading system
• Repair data
• Torque requirements

Diagnostics

• Engine management - WP
• Engine management - WP
• Precautions
• Description of functions and controls
• General procedure for diagnostics of malfunctions
• Read and clear flashing trouble codes
• KT600 diagnostic tool operation and troubleshooting
• Reference data table from stream
• Basic electrical diagrams
• Basic checks
• Symptom table
• Flashing fault code table
• Lost scan tool communication
• The indicator of the flashing codes of malfunctions does not light up
• Non-blinking of the indicator of flashing codes of malfunctions (when the diagnostic switch is turned on)
• Failure to start the engine
• Difficulty starting the engine
• Automatic stalling after a successful engine start
• Insufficient engine power
• Excessive black smoke
• Black smoke or blue smoke
• Unstable idling 04-113 1-1-1 Problem with on-board AD converter ECU
• 1-1-2 Signal synchronization problem
• 1-1-3 Signal synchronization problem
• 1-1-4 Signal synchronization problem
• 1-1-5 Problem with built-in ECU output device
• 1-1-6 Internal error in ECU
• 1-2-1 Start relay problem
• 1-2-2 Problem with the ignition switch in the "ON" position (T15)
• 1-2-3 Problem with the ignition switch in the "START" position (T50)
• 1-2-4 Battery problem
• 1-2-5 Scheme of non-monotonic EMTC pulse spectrum
• 1-3-1 ECU Integrated Sensor Power Module
• 1-3-2 Main relay problem
• 1-3-3 Fuel rail pressure sensor
• 1-3-4 Common rail pressure limiting valve problem
• 1-3-5 Problem with fuel metering section
• 1-3-6 Common rail pressure limiting valve
• 1-4-1 Problem with the injector of the 1st cylinder
• 1-4-2 Problem with the injector of the 2nd cylinder
• 1-4-3 Problem with the injector of the 3rd cylinder
• 1-4-4 Problem with the injector of the 4th cylinder
• 1-4-5 Problem with the 5th cylinder injector
• 1-4-6 Problem with the injector of the 6th cylinder
• 1-5-1 Problem with condenser 1 (control of injectors 1, 2, 3)
• 1-5-2 Problem with condenser 2 (control of injectors 4, 5, 6)
• 1-5-3 Problems and with the CY33X injector controller chip
• 1-5-4 Failure to reach the minimum permissible limit of a healthy injector
• 1-5-5 ECU fuel injection limitation
• 2-1-1 Water in fuel
• 2-2-1 Problems with pedal position sensors 1 and 2
• 2-2-2 Problem with clutch switch
• 2-2-3 Problems with brake switch, single brake switch
• 2-2-5 Accelerator and brake reliability problem
• 2-2-6 Diesel engine protection (runaway)
• 2-2-7 Diesel engine protection
• 2-2-8 Diesel engine torque exceeded
• 2-2-9 Remote control accelerator pedal
• 2-3-1 Intake air temperature sensor
• 2-3-2 Barometric pressure sensor
• 2-3-3 Intake air temperature sensor
• 2-4-1 Cooling water temperature sensor
• 2-4-2 High water temperature alarm
• 2-4-3 Oil pressure high / low oil pressure alarm
• 2-4-4 Oil temp sensor failure, high oil temp alarm
• 2-4-5 Problem with water temperature sensor
• 2-5-1 High pressure fuel line / low pressure fuel line problem (fuel leak)
• 2-5-2 High pressure fuel line / low pressure fuel line problem (fuel leak)
• 2-5-3 High pressure fuel line / low pressure fuel line problem (fuel leak)
• 2-5-4 High pressure fuel line / low pressure fuel line problem (fuel leak)
• 2-5-5 High pressure fuel line / low pressure fuel line problem (fuel leak)
• 2-5-6 High pressure fuel line / low pressure fuel line problem (fuel leak)
• 2-5-7 Problem with high pressure fuel line / low pressure fuel line (fuel leak)
• 2-6-1 Recovering ECU System
• 2-6-2 Detecting runaway.
• 2-6-3 ECU CJ940 chip
• 2-6-4 ECU chip and watchdog
• 2-6-5 EEPROM (electrically erasable programmable read-only memory)
• 3-1-1 Exhaust brake solenoid valve
• 3-1-3 A / C compressor relay
• 3-2-1 Intake air heater relay
• 3-2-2 Intake air heater relay
• 3-2-3 Intake air heater relay
• 3-2-4 Speed sensor
• 3-2-7 Multi position switch
• 3-3-1 System status indicator
• 3-3-2 Cold start indicator, alarm indicator
• 3-3-4 Water in fuel indicator, warning indicator
• 3-4-1 Cruise control switch
• 3-4-2 Exhaust brake switch
• 3-4-3 Remote control start switch
• 5-1-1 Cylinder 1 misfire detection
• 5-1-2 Cylinder 2 misfire detection
• 5-1-3 Cylinder 3 misfire detection
• 5-1-4 Cylinder misfire detection
• 5-3-1 Cylinder 4 misfire detection
• 5-3-2 Cylinder 5 misfire detection
• 5-3-3 Cylinder 6 misfire detection
• 5-3-4 External review
• 5-2-1 External review
• 5-2-2 External review
• 5-2-3 External review
• 5-4-1 Signal synchronization problem
• Preheating system
• Precautions
• Basic checks
• Symptom table
• Refusal to stop starter
• Refusal to start the starter
• Starter noise
• Charging system
• Precautions
• Basic checks
• Symptom table
• Charging indicator lights up continuously
• Insufficient battery charge
• Battery recharge
• Unstable charging current
• Extraneous noise in the generator
• Measuring the parasitic load generated by the battery discharge current
• Transient startup procedure
• Anti-lock braking system (ABS)
• Precautions
• Description of ABS diagnostics
• Reading and erasing fault codes
• Basic checks
• Fault code table
• 2-1 Right front wheel solenoid valve malfunction
• 2-2 Left front wheel solenoid valve malfunction
• 2-3 Right rear wheel solenoid valve malfunction
• 2-4 Left rear wheel solenoid valve malfunction
• 3-1 Right front wheel speed sensor wide gap, weak signal
• 3-2 Left front wheel speed sensor large gap, weak signal
• 3-3 Right rear wheel speed ??sensor wide gap, weak signal
• 3-4 Left rear wheel speed sensor large gap, weak signal
• 4-1 Short or open circuit in the right front wheel speed sensor circuit
• 4-2 Short or open in the left front wheel speed sensor circuit
• 4-3 Short or open circuit in the right rear wheel speed sensor
• 4-4 Short or open circuit in the left rear wheel speed sensor
• 5-1 Unstable signal from front right wheel sensor
• 5-2 Unstable signal from the left front wheel sensor
• 5-3 Unstable signal from the right rear wheel sensor
• 5-4 Unstable signal from the left rear wheel sensor
• 6-1 Right front wheel rim malfunction
• 6-2 Left front wheel rim malfunction
• 6-3 Right rear wheel rim malfunction
• 6-4 Left rear wheel rim malfunction
• 7-4 ABS warning indicator failure
• 8-1 ECU diagonal voltage low
• 8-2 Overvoltage in diagonal 1 or diagonal 2 ECU, failure of all valves
• 8-3 Internal ECU Fault
• ABS refusal
• Heater and air conditioner
• Precautions
• Basic checks
• Symptom table
• Insufficient air conditioning
• Insufficient heating by air conditioning
• Blower failure
• Air conditioning compressor clutch failure
• Air conditioner cooling fan failure
• Lighting system
• Precautions
• Basic checks
• Symptom table
• Low beam headlamp not burning on one side
• Non-burning front fog lamps on both sides
• Constant burning of the low beam headlamp on one side
• Constant lighting of low beam headlights on both sides
• High beam headlamp not burning on one side
• High beam headlights not burning on both sides
• Continuous burning of the main beam headlamp on one side
• Continuous burning of high beam headlamps on both sides
• Failure to burn overtaking lights
• Low / high beam headlights not burning on both sides
• Non-burning front fog lamp on one side
• Non-burning front fog lamps on both sides
• Continuous burning of the front fog lamp on one side
• Continuous burning of front fog lamps on both sides
• Non-burning rear fog lamp on one side
• Non-burning rear fog lamps on both sides
• Continuous burning of the rear fog lamp on one side
• Continuous burning of rear fog lamps on both sides
• Failure to burn direction indicators, warning lamp of hazard warning system
• Failure to burn direction indicators on one side
• The warning lamp does not burn out (normal operation of the direction indicators)
• Constant burning of direction indicators on one side
• Constant burning of direction indicators on both sides
• Non-burning brake lights on one side
• Non-burning brake lights on both sides
• Constant burning of brake lights
• Non-burning reversing lights on one side
• Non-burning reversing lights on both sides
• Continuous burning of reversing lights
• Reverse buzzer failure
• Non-burning front lights on one side
• Non-burning side lights on one side
• Non-burning front lights, side lights on both sides
• Diagnostics procedure
• Interior light switch illumination not burning
• Lighter illumination not burning
• Illumination of the center differential switch illumination
• Illumination of the cross-wheel differential switch illumination
• PTO switch backlight not burning
• Auxiliary box neutral position switch illumination not burning
• Non-burning backlight electric / pneumatic horn switch cables
• Non-burning of the backlight of the ABS diagnostic switch
• Rearview mirror heating switch illumination not burning
• Rear light switch illumination not burning
• Rear fog lamp switch illumination not burning
• Cruise control (+/-) switch illumination not burning
• Cruise control recovery switch illumination not burning
• Cruise control cancellation switch illumination not burning
• Remote control accelerator illumination not burning
• Engine diagnostic switch backlight failure
• Airflow switch illumination not burning
• Air conditioner control panel illumination not burning
• The backlighting of the switch combination is not burning
• Non-burning of rear lights, identification lights on both sides
• Failure to burn identification lights, side lights, front / rear lights
• Continuous burning of identification lights, side lights, front / rear lights
• Non-burning footrest illumination on one side
• Non-burning illumination of footrests on both sides
• Steps illuminated continuously
• Internal lighting not burning (when switching on the right internal lighting)
• Non-burning interior lighting (when switching on the left interior lighting)
• Non-burning interior lighting (when opening the left door)
• Continuous burning of internal lighting
• Windshield wiper and washer
• Precautions
• Basic checks
• Symptom Table
• Wiper failure in any operating mode
• Slow wiper action
• Refusal to stop the wiper
• Failure of the wiper in the interrupted position
• Wiper failure in low-speed position
• Wiper failure in high-speed position
• Refusal to return to the original position of the wiper (when the switch is turned off)
• Washer failure, normal wiper operation
• Audio System
• Precautions
• Basic checks
• Symptom table
• Audio section refusal
• No sound from speakers (in any mode)
• Poor speaker sound quality (in any mode)
• Low speaker volume (in any mode)
• Refusal to receive radio broadcasts or poor radio reception
• Refusal to download / play MP3 files
• Sound vibrations while playing MP3 files
• Beep
• Precautions
• Basic checks
• Symptom table
• Electric dial tone failure
• Electric dial tone continuously
• Pneumatic horn failure
• Constant air horn sounding
• Instrument cluster
• Precautions
• Instrument descriptions instrument terminals
• Basic checks
• Symptom table
• Failure of the instrument cluster
• Speedometer failure
• Tachometer failure
• Failure of the fuel level indicator
• Water temperature indicator failure
• Oil pressure gauge failure
• Air pressure gauge failure
• Constant burning / non-burning of the coolant level indicator
• Constant lighting / non-lighting of the warning indicator of the unfastened seat belt
• Exhaust brake indicator on / off continuously
• The parking brake indicator is permanently on / off
• Constant burning / non-burning of the air filter clogged warning indicator
• Permanent burning / non-burning of the warning indicator of the cab lock
• Lighter
• Precautions
• Basic checks
• Symptom table
• Lighter failure

Fuel (WP12)

• Fuel system
• General information
• Precautions
• Detail
• Check and adjust
• Fuel tank
• Detail
• Replacement
• Cleaning
• Water-oil separator
• Detail
• Replacement
• Fine fuel filter
• Replacement

Fuel (WD615)

• Fuel system
• General information
• Precautions
• Detail
• Checking and adjusting
• Fuel tank
• Replacement
• Cleaning
• Water / oil separator
• Detail
• Fine fuel filter
• Replacement
• Fuel pump
• Replacement
• Injector
• Inspection and repair
• Nozzle sleeve
• Replacement

Intake

• Intake system
• General information
• Precautions
• Overlying inlet pipe
• Detail
• Replacement
• Air filter assembly
• Detail
• Replacement

Exhaust exhaust turbocharged (WP12)

• Exhaust system
• General information
• Precautions
• Detail
• Check and adjust
• Turbocharger
• Inspection and repair

Exhaust exhaust turbocharged (WD615)

• Exhaust system
• General information
• Precautions
• Detail
• Check and adjust
• Exhaust pipe
• Inspection and repair
• Turbocharger
• Inspection and repair

Cooling (WP12)

• Cooling system
• General information
• Precautions
• Detail
• Check and adjust
• Expansion vessel
• Inspection and repair
• Coolant
• Replacement
• Radiator
• Inspection and repair
• Cooling fan
• Inspection and repair
• Intercooler
• Inspection and repair
• Water pump
• Inspection and repair
• Thermostat
• Inspection and repair

Cooling (WD615)

• Cooling system
• General information
• Precautions
• Detail
• Checking and adjusting
• Expansion vessel
• Inspection and repair
• Coolant
• Replacement
• Radiator
• Inspection and repair
• Cooling fan
• Inspection and repair
• Intercooler
• Inspection and repair
• Water pump
• Inspection and repair
• Thermostat
• Inspection and repair

Smudge (WP10)

• Lubrication system
• General information
• Precautions
• Detail
• Check and adjust
• Oil sump
• Replacement
• Oil filter
• Replacement
• Oily pump
• Inspection and repair
• Oil cooler
• Inspection and repair
• Oil pressure sensor
• Replacement

Smudge (WP12)

• Lubrication system
• General information
• Precautions
• Detail
• Check and adjust
• Oil sump
• Replacement
• Oil filter
• Replacement
• Oil pump
• Inspection and repair
• Oil cooler
• Inspection and repair

Lubrication (WD615)

• Lubrication system
• General information
• Precautions
• Detail
• Check and adjust
• Oil sump
• Replacement
• Oil filter
• Replacement
• Oil pump
• Inspection and repair
• Oil cooler
• Inspection and repair

Mechanical part of the engine (WP10)

• Engine mechanical
• Detail
• Precautions
• Check and adjust
• Complete engine
• Replacement
• Engine Components
• Replacement
• Cylinder head
• Replacement
• Rocker arms, valves
• Replacement
• Timing gears
• Replacement
• Camshaft
• Replacement
• Flywheel and flywheel housing
• Replacement
• Connecting rod-piston group
• Replacement
• Crankshaft
• Replacement
• Cylinder block
• Replacement

Mechanical part of the engine (WP12)

• Engine mechanical
• Detail
• Precautions
• Check and adjust
• Complete engine
• Replacement
• Engine components
• Replacement
• Cylinder head
• Replacement
• Rocker arms, valves
• Replacement
• Timing gears
• Replacement
• Camshaft
• Replacement
• Flywheel and flywheel housing
• Replacement
• Connecting rod-piston group
• Replacement
• Crankshaft
• Replacement
• Cylinder block
• Replacement

Mechanical part of the engine (WD615)

• Engine mechanical
• Detail
• Precautions
• Check and adjust
• Complete engine
• Replacement
• Engine components
• Replacement
• Cylinder head
• Replacement
• Rocker arms, valves
• Replacement
• Timing gears
• Replacement
• Camshaft
• Replacement
• Flywheel and flywheel housing
• Replacement
• Connecting rod-piston group
• Replacement
• Crankshaft
• Replacement
• Cylinder block
• Replacement

Engine management

• Engine management
• Detail
• Accelerator pedal
• Replacement
• ECU
• Replacement
• Injector (WP10)
• Replacement
• Injector (WP12)
• Inspection and repair
• High pressure pump (WP10)
• Replacement
• High pressure pump (WP12)
• Detail
• Replacement
• Common rail
• Replacement
• Fuel pressure sensor
• Replacement
• Crankshaft position sensor
• Replacement
• Camshaft position sensor
• Replacement
• Water temperature sensor
• Replacement
• Oil pressure sensor
• Replacement
• Intake air pressure sensor
• Replacement
• Intercooler intake air sensor
• Replacement

Preheating system (WP10)

• Preheating system
• General information
• Precautions
• Check and adjust
• Ignition switch
• Replacement
• Auxiliary start switch
• Replacement
• Heater relay
• Replacement
• Starter
• Replacement
• Heater
• Replacement

Preheating system (WD615)

• Preheating system
• General information
• Precautions
• Check and adjust
• Ignition switch
• Replacement
• Auxiliary start switch
• Replacement
• Heater relay
• Replacement
• Starter
• Replacement
• Heater
• Replacement

Charging system (WP12)

• Charging system
• General information
• Precautions
• How it works
• Check and adjust
• Generator
• Inspection and repair

Charging system (WP10)

• Charging system
• General information
• Precautions
• How it works
• Check and adjust
• Generator
• Inspection and repair

Charging system (WD615)

• Charging system
• General information
• Precautions
• How it works
• Check and adjust
• Generator
• Inspection and repair

Front suspension

• Front suspension assembly
• General information
• Precautions
• How the system works
• Symptom Table
• Detail
• Check and adjust
• Front shock absorber
• Inspection and repair
• Front spring
• Inspection and repair
• Front anti-roll bar
• Inspection and repair

Rear suspension

• Rear suspension assembly
• General information
• Precautions
• Symptom table
• Detail
• Check and adjust
• Rear spring
• Inspection and repair
• Rear balancer shaft assembly
• Inspection and repair
• Rear anti-roll bar
• Inspection and repair

Tires and wheels

• Tire and wheel assemblies
• Precautions
• Symptom table
• Check and adjust
• Front tires and wheels
• Detail
• Inspection and repair
• Rear tires and wheels
• Detail
• Inspection and repair

Front axle (ANKAI)

• Front axle assembly
• General information
• Precautions
• Symptom table
• Detail
• Check and adjust
• Front wheel hub
• Inspection and repair
• Steering fist
• Inspection and repair
• Front axle
• Inspection and repair

Front axle (SANHUAN)

• Front axle assembly
• Precautions
• Symptom Table
• Check and adjust
• Front wheel hub
• Detail
• Inspection and repair
• Steering fist
• Detail
• Replacement
• Front axle
• Replacement

Rear axle

• Rear axle assembly
• General brought together ia
• Precautions
• Symptom table
• Detail
• Check and adjust
• Half shaft
• Inspection and repair
• Wheel bearing, oil seal
• Inspection and repair
• Rear axle assembly, rear axle housing
• Inspection and repair
• Final drive reducer
• Inspection and repair
• Pinion and bearing
• Inspection and repair
• Differential housing, components of the driven gear and planetary gear
• Inspection and repair

Service brake

• Service brake system
• General information
• Precautions
• Symptom table
• Check and adjust
• Brake pedal
• Detail
• Replacement
• Brake pedal (RHD)
• Detail
• Replacement
• Main brake valve
• Inspection and repair
• Main brake valve (RHD)
• Detail
• Inspection and repair
• Dryer
• Detail
• Inspection and repair
• Receiver
• Inspection and repair
• 4-way safety valve
• Detail
• Inspection and repair
• Relay valve
• Detail
• Inspection and repair
• Differential valve
• Detail
• Inspection and repair
• Multi-port connection
• Replacement
• Front brake chamber
• Inspection and repair
• Rear brake chamber
• Inspection and repair
• Front brake pad
• Detail
• Inspection and repair
• Rear brake pad
• Detail
• Inspection and repair
• ABS spider
• Replacement
• Wheel speed sensor
• Replacement
• Secondary brake
• Detail
• Exhaust brake butterfly valve
• Inspection and repair

Parking brake

• Parking brake system
• Precautions
• Symptom table
• Function test
• Parking brake control valve
• Detail
• Replacement

Frame

• Frame assembly
• Precautions
• Frame size
• Tipping mechanism assembly
• Precautions
• Detail
• Replacement
• Rear suspension assembly
• Detail
• Replacement

Intermediate bridge (STEYR)

• Intermediate bridge assembly
• General information
• Precautions
• Symptom table
• Detail
• Check and adjust
• Half shaft
• Inspection and repair
• Wheel bearing
• Inspection and repair
• Intermediate axle assembly, intermediate axle housing
• Inspection and repair
• Thru shaft
• Inspection and repair
• Center differential
• Inspection and repair
• Final drive reducer
• Inspection and repair
• Pinion and bearing
• Inspection and repair

Intermediate axle (Mercedes-Benz)

• Intermediate bridge assembly
• General information
• Symptom table
• Detail
• Check and adjust
• Half shaft
• Inspection and repair
• Wheel bearing
• Inspection and repair
• Intermediate axle assembly, intermediate axle housing
• Inspection and repair
• Thru shaft
• Inspection and repair
• Center diffferential
• Inspection and repair
• Final drive reducer
• Inspection and repair
• Pinion and bearing
• Inspection and repair
• Cross-axle differential
• Inspection and repair

Checkpoint (9JS135)

• Transmission
• General information
• Precautions
• The design and principle of the checkpoint
• Symptom table
• Check and adjust
• Gearbox control mechanism
• Detail
• Disassembly and installation
• Gearbox assembly
• Replacement
• Double H control mechanism
• Detail
• Disassembly and installation
• Gearbox upper cover
• Detail
• Disassembly and assembly
• Auxiliary checkpoint
• Detail
• Disassembly and assembly
• Main checkpoint
• Detail
• Disassembly and assembly
• Input shaft assembly
• Detail
• Disassembly and assembly
• Output shaft assembly
• Detail
• Disassembly and assembly
• Intermediate shaft assembly
• Detail
• Disassembly and assembly

Checkpoint (RT-11509C)

• Transmission
• General information
• Precautions
• Design and principle of gearbox operation
• Symptom table
• Check and adjust
• Gearbox control mechanism
• Detail
• Disassembly and installation
• Gearbox assembly
• Replacement
• Double H control mechanism
• Detail
• Disassembly and installation
• Gearbox upper cover
• Detail
• Disassembly and assembly
• Auxiliary checkpoint
• Detail
• Disassembly and assembly
• Main checkpoint
• Detail
• Disassembly and assembly
• Input shaft assembly
• Detail
• Disassembly and assembly
• Output shaft assembly
• Detail
• Disassembly and assembly
• Intermediate shaft assembly
• Detail
• Disassembly and assembly

Checkpoint (12JSD160)

• Transmission
• General information
• Precautions
• The design and principle of the checkpoint
• Symptom table
• Check and adjust
• Gearbox control mechanism
• Detail
• Disassembly and installation
• Gearbox assembly
• Replacement
• Single H control mechanism
• Detail
• Disassembly and installation
• Gearbox upper cover
• Detail
• Disassembly and assembly
• Auxiliary checkpoint
• Detail
• Disassembly and assembly
• Main checkpoint
• Detail
• Disassembly and assembly
• Output shaft assembly
• Detail
• Disassembly and assembly
• Intermediate shaft of the main gearbox
• Detail
• Disassembly and assembly

Clutch

• Clutch assembly
• General information
• How it works
• Precautions
• Symptom table
• Check and adjust
• Clutch oil reservoir assembly
• Inspection and repair
• Clutch master cylinder
• Detail
• Inspection and repair
• Clutch pedal assembly
• Inspection and repair
• Clutch slave cylinder
• Detail
• Inspection and repair
• Building blocks
• Detail
• Inspection and repair

Drive shaft

• Drive shaft
• General information
• Precautions
• Symptom table
• Detail
• Check and adjust
• Intermediate drive shaft
• Inspection and repair
• Center drive shaft
• Inspection and repair
• Kardan
• Inspection and repair

Power take-off

• Power take-off
• General information
• How the power take-off works
• Precautions
• Symptom table
• Detail
• Check and adjust
• QH50 PTO
• Disassembly and installation
• Power take-off solenoid valve
• Inspection and repair

Steering wheel and steering column

• Steering wheel and steering column
• General information
• Precautions
• Symptom table
• Detail
• Check and adjust
• Steering wheel (for left-hand drive vehicles)
• Replacement
• Steering wheel (for right-hand drive vehicles)
• Replacement
• Steering column (for left-hand drive vehicles)
• Disassembly and installation
• Steering column (for right-hand drive vehicles)
• Disassembly and installation

Power steering gear

• Hydraulic steering system
• General information
• Precautions
• Symptom Table
• How it works
• Detail
• Check and adjust
• Steering fluid (LHD)
• Replacement
• Power steering fluid (RHD)
• Replacement
• Steering oil pump assembly
• Replacement
• Steering gear assembly (left-hand drive)
• Inspection and repair
• Steering gear assembly (right hand drive)
• Inspection and repair
• Hydraulic line
• Disassembly and installation
• Steering oil reservoir assembly.
• Disassembly and installation
• Tie rod assembly
• Inspection and repair

Heater and air conditioner

• Heater and air conditioner
• General information
• Precautions
• Engine coolant signs of malfunction
• How it works
• Check and adjust
• Heater plumbing
• Detail
• Inspection and repair
• Heater
• Detail
• Inspection and repair
• Heater (for right-hand drive vehicles)
• Detail
• Inspection and repair
• Refrigerant
• Replacement
• Cooling oil
• Inspection and repair
• Cooling piping
• Detail
• Inspection and repair
• Evaporator
• Detail
• Inspection and repair
• Evaporator (RHD)
• Detail
• Inspection and repair
• Compressor
• Inspection and repair
• Compressor (RHD)
• Inspection and repair
• Blower
• Detail
• Inspection and repair
• Blower (RHD)
• Detail
• Inspection and repair
• Capacitor
• Inspection and repair
• Condenser (RHD)
• Inspection and repair
• Liquid storage tank
• Inspection and repair
• Fluid storage tank (RHD)
• Inspection and repair
• Air conditioner control switch
• Inspection and repair
• A / C control switch (RHD)
• Check and repair ont

Seat belt

• Seat belt assembly
• Detail
• Driver's seat belt
• Inspection and repair
• Driver's seat clasp
• Inspection and repair
• Seat belt buckle, intermediate seat
• Inspection and repair
• Clasp, intermediate seat
• Inspection and repair

Battery

• Battery
• General information
• Precautions
• How it works
• Symptom table
• Check and adjust
• Detail
• Battery
• Replacement
• Maintenance
• Electrolyte
• Refueling
• Battery disconnect switch
• Replacement

Lighting

• Audio system
• Replacement
• Door light switches
• Replacement
• Rear lamp combination
• Replacement
• Interior lighting
• Replacement
• Footrest lighting
• Replacement
• Identification lights
• Replacement
• Side light
• Replacement
• Direction indicators
• Adjustment
• Replacement
• Front lamp combination
• Detail
• Precautions
• Lighting system
• Audio system
• Precautions
• Detail
• Receiver-player
• Replacement
• Speaker
• Replacement
• Antenna
• Replacement

Windows, rear-view mirrors

• Windshield
• Detail
• Replacement
• Rear window
• Detail
• Replacement
• Side windows
• Detail
• Replacement
• Glass doors
• Detail
• Replacement
• Windows
• Detail
• Inspection and repair
• Exterior mirrors
• Detail
• Replacement

Instrument panel, instrument cluster, lighter

• Dashboard
• Precautions
• Detail
• Replacement
• Instrument cluster
• Detail
• Replacement
• Lighter
• Detail
• Replacement

Seats

• Seat assembly
• General information
• Precautions
• Driver's seat
• Detail
• Disassembly and installation
• Disassembly and assembly
• Front passenger seat
• Detail
• Replacement
• Intermediate seat
• Detail
• Replacement
• Sleeping place
• Detail
• Replacement

Doors, door locks, door handles

• Complete doors
• Detail
• Adjustment
• Replacement
• Door locks
• Detail
• Replacement
• Door handles
• Replacement

Interior / exterior components

• Door trims
• Detail
• Replacement
• Visors
• Detail
• Replacement
• Mats
• Detail
• Replacement
• Front bumper
• Detail
• Replacement
• Mudguards
• Detail
• Replacement
• Front bonnet
• Detail
• Replacement

Cab

• Disassembly and installation of the complete cab
• Dismantling the cab
• Cab installation

Self-unloading hydraulic system

• Hydraulic self-unloading system
• General information
• Precautions
• How the system works
• Symptom table
• Detail
• Hydraulic oil (for front lift truck)
• Draining and filling
• Oil pump
• Inspection and repair
• Components of the tipping mechanism
• Inspection and repair
• Hydraulic tank (for dump truck with front lift cylinder)
• Disassembly and installation
• Lift valve (for front dump truck)
• Inspection and repair
• Restrictor valve (front lift truck)
• Inspection and repair
• Air filter (front lift truck)
• Inspection and repair
• Return line oil filter (for front lift truck
• Inspection and repair
• Hydraulic cylinder (for dump truck with front lift cylinder)
• Inspection and repair
• Manual valve (for front lift truck)
• Inspection and repair
• Cargo area (for dump truck with front lift cylinder)
• Disassembly and installation
• Hydraulic cylinder (for dump truck with t-type mid-lift cylinder)
• Disassembly and installation
• Manually controlled flexible shaft (for t-type mid lift truck)
• Inspection and repair
• Swing valve (for mid-lift dump truck)
• Inspection and repair
• Cargo area (for dump truck with a mid-position hydraulic cylinder of a lift type T)
• Disassembly and installation

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