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3. Service data
3.1 Vehicles bolt torque table
3.2 Amount of various oil and coolant
Type
Project Name
HKL6540
538018802285
Wheel Tread(mm)
1655/1650
Wheelbase(mm)
Type
Rated Output(kw)
Max. Torque(N. m)
Displacement(L)
Transmission type
Engin
e
Fuel
Approach/Departure angle
Min. turning radius (m)
Bodywork mass (kg)
Max. mass (kg)
3110
4G69S4N
100/5250
217/2600-3200
2.378
ZM001AD
93#
4RB2
102/4600-5000
217/2600-3200
2.438
ZM001AG
93#
14/ 14.5
6.25
2130
3300
70
DK4B1
75/3600
235/1600-2400
2.498
038T
0#
125
125
125
10/12.3
10.2/12.7
9.3/10.9
2105
3300
2208
3450
30
Brake system
Steering system
Suspension system
Tire
Atten. this manual only introduces the parameter of HKL6540. For the information of other types, please
contact sales department of our company.
Name plate
Engine
number
Transmission number
Frame
disassembly.
7 Dealing method after vehicle collided
a When using electrical welder, operation should be conducted after airbag strainer is
dismantled.
b Under the condition that airbag may be collided, operator should dismantle airbag sensor
first, then airbag.
2.2.3 Basic items
1 Maintenance attention
1 Cloth requirement Keep cloth clean, wear helmet and safety shoes
Install fence hood, anti-dirt hood, seat covering and
2
Body protection
carpet covering before maintenance
Fix vehicle with block before maintenance
When there are two or more operators, they should
confirm safety each other before next operation
Keep air ventilating when operation is conducted with
3
Safe operation
engine running.
Take care for those positions of high temperature,
rotation and vibration.
Take measure to confirm safety when vehicle is lefted
Project tool, special tool, measuring equipments,
4 Maintenance tool
lubrication oil, dish cloth and new parts.
Diagnose after error is confirmed, then repair according
to realistic condition
Confirm the deformation of error part and record.
Maintenance
5
Record and mark the complex parts on condition that it
operation
will not influence the performance of vehicle
Reinstall the dismantled parts after cleaning and
inspected to be qualified.
Array the dismantled parts in order in case of polluted
again.
Replace gasket, o-type ring and bolts according to
6
Error part
requirements.
Notice customer in time after package error parts in box.
2 Glued bolts
a Glued bolts mean those bolts painted sealing glue on bolt trace
b Paint new sealing glue when screw bolts again
c After screwing glued bolts, leave it until harden the glue.
3 Gasket
a When install gasket, use sealing glue to avoid leaking if necessary
4 Bolt and sleeve
a Confirm the torque of bolts and sleeves and use wrench with the same specification.
5 Replace fuse
a Use fuse with the same capacity; if use different fuse, the current of new one should be
lower than old one.
6 Claw
a Old claws cannot be used again.
7 Vacuum pipe
a Hold the end of vacuum pipe and pull it out
b Show how to connect with label after pulling vacuum pipe out.
c When use vacuum inspector, do not connect hose if pipe is relatively big.
8Disassembly of electric system
1Disconnection of accumulator cathode wire
a
During maintenance of electric system, operator should disconnect cathode wire of
accumulator in case of short circuit.
b
Turn the key to OFF.
c
After cathode wire of accumulator is disconnected, operator should confirm the
content of some memory parts for it may get lose.
2Disassembly and installation of electric parts
a Do not dismantle ECU
b Do not hit computer, sensor, relay and so on. Replace these parts when they are hit.
c Avoid high temperature and water
d Electric unit, air filter and exhaust relevant parts shall not get water when clean engine
with steam.
9Disassembly of fuel system
1)
Operation place of fuel system
a Good air ventilating, no welder, grinding wheel and drilling machine around
b Cannot fill with fuel gas
2)
Disassembly of fuel system parts
a Prepare fire existing equipment
b Leak out the fuel in pipe
c Connect the ground wire and watering
d Do not use electric pump and operation lamp.
e Separate fueled rags from other rags.
10Disassembly and installation of engine intake system
1 The metal sheet in intake system will influence engine and turbine.
2 When dismantle intake system, operator shall protect the connecting part with plastic bag.
3 When install intake system parts, operator shall confirm no metal sheet mixed in.
11Attention about hoops
1 In order for convenient operation, the position of hoops must be confirmed before hose is
dismantled
2 Replace the deformed hoops
3 Install the hoop on the same place
4 Intensify hoop after installation
12 Vehicle with catalytic converter
It will get lose to catalytic converter once large amount of gasoline get through catalytic converter.
a Only use gasoline without lead. (gasoline vehicle)
b When inspect spark plug, operator should dismantle injector connecting wire in case of
fuel injecting.
c When measure compression pressure of engine, operator should dismantle injector
connecting wire in case of fuel injecting.
d Do not run engine when fuel tank is empty.
2.2.4 Lift of vehicle
1Lift
Rubber
pads
Shall not be used to support
here
Centre of gravity
positiion
Explanation
if dismantle very heavy parts from rear of vehicle, for example, suspension or fuel
tank, operator should first locate the front part of vehicle on safety bracket, for the center of gravity
will change and vehicle will incline forwards.
1Two-pillar lifter
a)
b)
c)
d)
Put rubber block or safety bracket of lifter under the supporting points of vehicle
Lift up a little, then shake the vehicle to confirm whether it is steady.
Lift the vehicle and inspect the supporting point to confirm whether it is fixed.
Put supporting bracket under the vehicle.
2Four-pillar lifter
Drive vehicle on the bracket of lifter, fix four wheels with block.
2Traction
1) Carrying truck tractionPlace the vehicle on a
flatbed trailer. Adopt this kind of traction when chassis
and drive wheel fail to work.As Fig.
If the vehicle must be pulled with front wheel off the ground or four wheel on ground, it should be
done as follows:
aRelease the parking brake.
bShift the gearbox into neutral.
Diametermm
6
8
8
10
Level 4.6
12
14
16
6
8
8
10
Level 5.6
12
14
16
6
8
8
Level 8.8
10
Intensity
Diametermm
Level 8.8
12
Level10.9
14
16
10
12
14
16
Screw
Pitchmm
1
1.25
1
1.5
1.25
1
1.5
1.25
1.5
1.5
1
1.25
1
1.5
1.25
1
1.5
1.25
1.5
1.5
1
1.25
1
1.5
1.25
1
Screw
Pitchmm
1.5
1.25
1.5
1.5
1.5
1.25
1
1.5
1.25
1.5
1.5
NormalN.m
Max.N.m
Min.N.m
4
8
8.5
19.7
20.8
21.8
38.5
39.6
74.6
105
4.5
10.6
11
26
28
29
47
50
90
132
9
23
25
59
63
64
5.5
11
11.5
24.7
25.8
26.5
45
48
92
133
6
14
15
33
34
35
56
60
105
160
12
26
28
75
79
80
2.5
5
5.5
14.3
16.7
17
29
30
56
76
3
7
8
19
22
23
38
40
68
101
6
16
16
37
45
46
NormalN.m
Max.N.m
Min.N.m
97
99
180
240
74
78
80
142
145
210
305
113
115
205
270
90
93
95
158
161
235
335
75
78
146
199
52
63
65
106
108
178
240
93#
diesel
4RB2 engine oil
DK4 engine oil
4G69 engine oil
Transmission box oil
Rear axle gear oil
Booster steering oil
Braking oil
refrigerant
Washing liquid
coolant
0#
SG 15W-40
CF-4 15W-40
SG 15W-40
GL-5 85W-90
GL-5 85W-90
Liquid drive oil 46#Kunlun6#
DOT4
R134a
Glass waer
Glycol-25
93#
0#
SG 15W-40
CF-4 15W-40
SG 15W-40
GL-5 85W-90
GL-5 85W-90
Liquid drive oil 32#Kunlun6#
DOT3
R134a
Glycol-45