Foton SUP Series (BJ1027) since 2008, repair e-manual

Content

Main vehicle data and specifications

• SUP series vehicle main parameters and specifications
• Technical specifications for BJ491EQ1 gasoline
• Technical specifications for BJ493Q diesel engine
• Technical specifications for BJ493ZQ diesel engine
• Technical specifications for BJ493QA diesel engine
• Technical specifications for BJ483ZQB diesel engine
• Technical specifications for BJ486ZQ diesel engine
• Technical specifications for BJ491Q Gasoline engine

Vehicle technical maintenance

• Vehicle daily maintenance
• Vehicle 1st level maintenance
• Vehicle 2nd level maintenance
• Vehicle maintenance during break-in period
• Vehicle seasonal maintenance
• Vehicle lubrication

BJ493ZLQ series diesel engine construction and service / adjustment

• Notes to diesel engine maintenance and adjustment
• Cylinder block parts
• Cylinder head parts
• Piston / crank connecting rod mechanism
• Valve train
• Lubrication system
• Crankcase ventilation devices
• Cooling system
• Fuel supply system
• Air intake and exhaust system
• Supercharging system
• Electrical system
• Electric control EGR system
• EGR valve and throttle position sensor

BJ493ZLQ diesel engine operation

• The rules of safe operation
• Fuel / oil and cooling fluids
• Preparations before start up
• Diesel engine start-up procedures
• Check during engine running
• Shutdown
• Keys points to engine operation
• The rules to engine operation
• Use diesel engine in winter
• Diesel engine and environment
• Transportation, installation and storing
• Decide an overhaul

Technical maintenance for BJ493ZLQ diesel engine

• Daily maintenance
• 1st level technical maintenance
• 2nd level technical maintenance
• Technical maintenance of air filter
• Technical maintenance of fuel supply system
• Technical maintenance of lubrication system
• Technical maintenance of cooling system

BJ483ZQB Diesel engine construction and adjustment / service

• Notes to diesel engine maintenance and adjustment
• Diesel engine maintenance and adjustment

Diesel engine faults and troubleshooting

• Hard start-up
• Hard start-up at low temperature
• Insufficient power
• Abnormal noise during operation
• Abnormal exhaust gas color
• Low oil pressure
• Abnormal coolant temperature or insufficient coolant
• Supercharging system fault
• Starter does not run, weak start up or noise
• Alternator does not work, lower or higher charging current
• Lower battery volume, higher self-discharging
• Failure cold-start preheating system
• Water pump electro-magnetic fan clutch faults

Construction, adjustment and maintenance of BJ491EQ1 gasoline engine

• Cylinder head parts
• Cylinder block parts
• Crank-connecting rod mechanism
• Valve train
• Lubrication system
• Cooling system
• Starting system
• Charging system
• Crankcase ventilator
• Clutch

BJ491EQ1 gasoline engine fuel injection system

• Brief introduction of delphi electronic control fuel injection (EFI) system
• Parts and components of Delphi EFI system

Application of BJ491EQ1 gasoline engine

• Safe operating regulations
• Fuel, oil and coolant
• Preparations before startup
• Startup proedures
• Idle Speed and warm-up
• Check during running
• Shutdown
• Component protection
• Limp in
• Application notices

Technical maintenance of BJ491EQ1 gasoline engine

• Technical maintenance period
• Content of technical maintenance
• Technical maintenance for lubrication system
• Technical maintenance for cooling system
• Technical maintenance for fuel system
• Technical maintenance for air intake system

BJ491EQ1 gasoline engine failure and troubleshooting

• General knowledge of gasoline engine troubleshooting
• Fault diagnosis basics for gasoline engine electronic control fuel injection system
• Notes to trouble diagnosis of gasoline engine electronic control fuel injection system
• Troubleshooting method of gasoline engine

Chassis construction and service

• Clutch
• Transmission
• Propeller shaft
• Rear axle
• Front axle
• Steering mechanism
• Suspension
• Brake system
• Frame
• Wheel

Ollin pickup body

• Body main structural parameters
• Construction overview
• Construction, disassembly and repair - body and accessories

Ollin SUP Pickup cargo box

• Cargo box structural parameters
• Construction overview
• Notes to use and repair

Structure and service - SUP pickup electrical devices and instruments

• Summery of electrical system
• Fuse panel
• Faults and repair
• Electrical
• Complex instrument and auxiliary electrical devices
• Vehicle A/C

Appendices

• Electrical elementary diagram for BJ1027V3KD5, BJ1027V2MD5 pickup
• Electrical elementary diagram for BJ1027V2MD5, BJ1027V2MD6 pickup
• Electrical elementary diagram for BJ1027V2MW5, BJ1027V2MW6, BJ5027V2SW5 pickup
• Electrical elementary diagram for BJ1027V2MD6-1, BJ1027V2MD5, BJ1027V2MD6-1（493QA） pickup
• Electrical elementary diagram for BJ2027Y2MDV-01Z006, BJ2027Y2MDV-1 pickup
• Electrical elementary diagram for BJ2027Y2MDV pickup
• Electrical elementary diagram for BJ2027Y2MWV pickup
• Electrical elementary diagram for BJ1027V2MB5 pickup
• Electrical elementary diagram for BJ1027V3KD5, BJ1027V2MD5 pickup
• Electrical elementary diagram for BJ1027V3KB5, BJ1027V2MB5 pickup
• Electrical elementary diagram for BJ1027V2MW5, BJ1027V3KW5, BJ1027V2KW5, BJ1027A pickup
• Electrical elementary diagram for BJ1027V2MW5, BJ1027V2MW6 pickup
• Electrical elementary diagram for BJ1027V3KW5, BJ1027V2MW5, BJ1027V2MW6, BJ5028EC6WA pickup
• Electrical elementary diagram for BJ1027V2MW5-00Z123 pickup

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