NOVUS TRUCK

maintenance training
Maintenance training 2012 . 6
 Contents

1. Vehicl introduction ---------- 5 page

2. V.I.N & Vehicle code ---------- 27 page

3. Interior & Exterior ---------- 33 page

5. How to operate the vehicle---------- 41 page

6. Main function & How to operate -----------57 Page

6. Clutch ---------- 65 page

7. Troubleshooting ---------- 83 page

8. Maintenance ---------- 99 page

Vehicle introduction
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 Production line up - Medium Truck

4X2

Model : 4.5T, 5T, 7T

Engine : IVECO NEF

240ps/82kg·m
Electronic Control Fuel Injection System
▶ Common Rail Fuel Injection

T/M : S&T

Forward 6 shifts / Reverse 1step

7 Customer Service Team

 Production line up - Heavy Truck(Cargo)

Model : 8T, 8.5T

ƒ ENGINE : DL08 250ps, T/M : 6th
4X2
ƒ ENGINE : DL08 300ps, T/M : 6th

ƒ ENGINE : DL08 320ps, T/M : 6th(AUTO)

Model : 11T`~17T
ƒ ENGINE : DL08 320ps, T/M : 6th

6X4 ƒ ENGINE : DV11 345ps, T/M : 6th(6X2 Cargo)

ƒ ENGINE : DV11 380ps, T/M : 6th

ƒ ENGINE : DV11 420ps, T/M : 16th(Pull Cargo), 6th AUTO

차종 : 19T, 19.5T

ƒ ENGINE : DV11 420ps, T/M : 16th(6th AUTO,M9ASF)

8X4
ƒ ENGINE : CUMMINS 415ps, T/M : 16th(12th AUTO)

8 Customer Service Team

 Production line up - Heavy Truck(Cargo)

Model : 21T`~24T

ƒ ENGINE : DV11 345ps, T/M : 10th

8X4 ƒ ENGINE : DV11 420ps, T/M : 16th

Three rear axles

Model : 25T

ƒ ENGINE : DV11 420ps, T/M : 16th(6th AUTO,M9ASF)

10X4
ƒ ENGINE : CUMMINS 415ps, T/M : 16th(12th AUTO)

9 Customer Service Team

 Production line up - Heavy Tractor(Cargo)

Model : 40T

ƒ ENGINE : DV11 420ps, T/M : 16th

4X2
ƒ ENGINE : CUMMINS 415ps, T/M : 16th

Model : 40T
ƒ ENGINE : DV11 420ps, T/M : 16th, 12th AUTO
6X2
ƒ ENGINE : CUMMINS 415ps, T/M : 16th, 12th AUTO

차종 : 40 톤

6X4 ƒ ENGINE : DV11 420ps, T/M : 16th, 12th AUTO

ƒ ENGINE : CUMMINS 415ps, T/M : 16th, 12th AUTO

10 Customer Service Team

 Production line up - Heavy Tractor(Dump)

Model : 8T, 8.5T

4X2 ƒ ENGINE : DL08 250ps, T/M : 6th

6X4
Model : 15T

ƒ ENGINE : DL08 320ps, T/M : 6th

ƒ ENGINE : DV11 380ps, T/M : 6th

11 Customer Service Team

 Production line up - Heavy Tractor (Dump)

Model : 24T
ƒ ENGINE : DV11 420ps, T/M : 16th
8X4
(Three ƒ ENGINE : CUMMINS 415ps, T/M : 16th
rear axles)

Model : 24T
ƒ ENGINE : DV11 420ps, T/M : 16th
8X4
ƒ ENGINE : CUMMINS 415ps, T/M : 16th

Model : 25.5T
ƒ ENGINE : DV11 420ps, T/M : 16th
8X4
ƒ ENGINE : CUMMINS 415ps, T/M : 16th

12 Customer Service Team

 Power Train - engine

‹ Doosan - DE12TIS (Semi Electronic)

Applied export vehicle
EURO 2

4 Cycle, Water cooling system, 290ps/2100rpm

Direct 6 cylinder, Turbo intercooler Torque (max) : 115kg·m / 1,260rpm
Displacement : 11,051cc

310ps/2100rpm
Torque (max) : 125kg·m / 1,260rpm
Displacement : 11,051cc

320ps/2100rpm
Torque (max) : 135kg·m / 1,260rpm
Displacement : 11,051cc

340ps/2100rpm
Torque (max) : 145kg·m / 1,260rpm
Displacement : 11,051cc

13 Customer Service Team

 Power Train - engine

‹ Doosan - DV15TIS (Mechanical type)

Applied export vehicle
EURO2

4 Cycle, Water cooling system,

V type 8 cylinder, Turbo intercooler

390ps/2100rpm
Torque (max) : 160 kg·m / 1,200rpm
Displacement : 14,618cc

420ps/2100rpm
Torque (max) : 177 kg·m / 1,200rpm
Displacement : 14,618cc

14 Customer Service Team

 Power Train - engine

‹ IVECO - NEF Engine ( Electronic )

EURO 3

4 Cycle, Water cooling system,

Direct in line 6 cylinder, Turbo intercooler, CDRI system

240ps/2700rpm
Torque (max) : 82.6 kg·m / 1,250rpm
Displacement : 5,880cc
Model : NOVUS 4.5/5/7 Ton

15 Customer Service Team

 Power Train - engine

‹ Doosan – DL08 Engine( Electronic control )

EURO3
4 Cycle, Water cooling system,
Direct in line 6 cylinder, Turbo intercooler, CDRI system

250ps/2200rpm
Torque (max) : 90 kg·m / 1,200rpm
Displacement : 7,640cc
Model : 4X2 Cargo / Dump

300ps/2200rpm
Torque (max) : 115 kg·m / 1,200rpm
Displacement : 7,640cc
Model : 4X2 Cargo

320ps/2200rpm
Torque (max) : 135 kg·m / 1,200rpm
Displacement : 7,640cc
Model : 4X2 ,6X4 Cargo / Dump

16 Customer Service Team

 Power Train - engine

‹ Doosan – DV11 Engine ( Electronic control )

EURO 3
4 Cycle, Water cooling system,
V-type 6 cylinder, Turbo intercooler, CDRI system

345ps/1800rpm
Torque (max) : 145 kg·m / 1,200rpm
Displacement : 10,964cc
Model : 6X2 Cargo

380ps/1800rpm
Torque (max) : 173 kg·m / 1,200rpm
Displacement : 10,964cc
Model : 6X4 Cargo / Dump

420ps/1800rpm
Torque (max) : 187 kg·m / 1,200rpm
Displacement : 10,964cc
Model : 10(8)X4 Cargo /Dump/Tractor

17 Customer Service Team

 Power Train - engine

‹ CUMMINS – ISM Engine( Electronic control )

EURO 3
4 Cycle, Water cooling system, In line 6 cylinder
Turbo intercooler, Direct injector fuel system

415ps/1900rpm
Torque (max) : 187 kg·m / 1,200rpm
Displacement : 10,964cc
Model : Cargo / Dump / Tractor

415ps/1900rpm
Torque (max) : 205 kg·m / 1,200rpm
Displacement : 10,964cc
Model : Cargo / Dump / Tractor

18 Customer Service Team

 Power train - Gear box

‹ T/M - ZF

Part name : ZF16S151 / ZF16S1820 / ZF16S221

(MANUAL TYPE)
th
Gear shift : Forward 16 , Reverse 2th

Model : Cargo, Tractor, Dump

Part name : ZF 12AS2301 (AUTO)

th
Gear shift : Forward 12 , Reverse 2th

Model : Cargo, Tractor

19 Customer Service Team

 Power train - Gear box

‹ T/M - General
S/T Model : T-8S6 (MANUAL TYPE)
T-9S6
T-10S6
T-14S10
T-15S6
T-16S6
th
Gear shift : Forward 6 , Reverse 1th

Model : Cargo, Dump,Tractor

HYUNDAI DYMOS
MODEL : K-1406 (MANUAL)
th
Gear shift : Forward 6 , Reverse 1th
Model : Cargo

20 Customer Service Team

 Power train - Gear box

‹ ALLISON – AUTO T/M

MODEL : MD3060P (AUTO)

MD3066P
HD4560P
S 2500
th
Gear shift : Forward 6 , Reverse 1th
Model : Cargo

21 Customer Service Team

 Power train - Axle

‹ REAR AXLE

MODEL : T- 8H MODEL : R- 145H

T-10H R- 165H
T-12H R- 178H/T
T-13H/T R- 185H/T
T-14H/T R- S26-163
T-15H/T R- S26-185
T-16H/T
T-18H/T
T-19H
T-HR20S/T

Gear ration : Choose by each option

MODEL : ALL

22 Customer Service Team

 Power train - Axle

‹ FRONT AXLE

MODEL : 6.5 TON

7.5 TON
9.0 TON

MODEL : ALL

23 Customer Service Team

 SUSPENSION - FRONT

‹ Front spring

SPEC : M.L.S
(MULTI LEAF SPLING)

MODEL : ALL

SPEC : T.L.S
(TAPER LEAF SPLING)

MODEL : ALL

24 Customer Service Team

 SUSPENSION - REAR

‹ Rear spring

SPEC : M.L.S
(MULTI LEAF SPLING)

MODEL : ALL

SPECL : T.L.S
(TAPER LEAF SPLING)

MODEL : DUMP (25.5T)

25 Customer Service Team

 SUSPENSION - REAR

‹ REAR SPRING

SPEC : 2 Step M.L.S

(MULTI LEAF SPLING)

MODEL : Single axle for driving

SPEC : Air spring

MODEL : Vehicle for bogie lift

SPEC : AIR SPRING

MODEL : ALL for Pusher axle

26 Customer Service Team

V.I.N & VEHIVLE CODE
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 COMPOSITION OF VIN
V.I.N have including for vehicle production information so this is important reference data for spare parts order.

Ex : K L 3 K 7 C E F 1 A K 0 0 0 0 0 1

K L 3 K

Kor e a T AT A DAEW OO 3,4: Euro 3 ↓ Euro 3 ↓ : GVW Euro 4 ↑

3: Cargo/Dump/Mixer A: 1~5 TON(4X2) B: NOVUS 4

4: Tractor E: 15~16 TON(4X2) E: Prima Sleeper E4

F: 17~18 TON(4X2) F: Prima Semi-Sleeper E4

T,U,S: Euro 4↑ G: 19~20 TON(6X4) G: Prima Sleeper E5

T:Cargo/Dump/Mixer H: 21~22 TON(6X4) H: Prima Semi Sleeper E5

U: Tractor
J: 23~25 TON(6X4)
Special unit
S: Bus K: 26~30 TON(6X4)

L: 31~35 TON(6X4)

M: 36~40 TON(4X2,6X4,8X4)

N: 41~43 TON(8X4)

P: 44~45 TON(10X4)

U: 46~50 TON

V: 51~55 TON

29 Customer Service Team

 COMPOSITION OF VIN
Ex : K L 3 K 7 C E F 1 A K 0 0 0 0 0 1
7 C E

Euro 3↓ : Wheel base Euro 4↑: Driving type Euro 3↓ : Application Euro 4↑ : Wheel base Euro 3↓ : Engine Euro 4↓ : Application

1: ＜WB≤2500 C: 4X2 (MCV) A: CARGO VAR1 1: ＜WB≤3500 4: D1146TI C: STD CARGO

2: 2500＜WB≤3800 D: 4X4 (MCV) B: CARGO VAR2 2: 3500＜WB≤4400 5: DE12 A: CARGO VAR1

3: 3800＜WB≤4500 H: 4X2 (HCV) C: STD CARGO 3: 4400＜WB≤4570 6: DE12TI B: CARGO VAR2

4: 4500＜WB≤4650 J: 4X4 (HCV) D: STD DUMP 4: 4570＜WB≤4900 7: DV15T(340/132) K: CARGO VAR3

5: 4650＜WB≤5250 K: 6X2 (HCV) E: DUMP VAR1 5: 4900＜WB≤5735 8: DV15T(370/145) L: CARGO VAR4

6: 5250＜WB≤5750 L: 6X4 (HCV) F: DUMP VAR1 6: 5735＜WB≤6000 9: DV15TI D: STD DUMP

7: 5750＜WB≤6000 M: 6X6 (HCV) M: MIXER 7: 6000＜WB≤6400 B: DE08TIS E: DUMP VAR1

8: 6000＜WB≤6900 N: 8X2 (HCV) P: PULL CARGO 8: 6400＜WB≤7600 E: DE12TIS F: DUMP VAR1

9: 6900＜WB P: 8X4 (HCV, Rear 3axle) T: 6X4 TRACTOR 9: 7600＜WB V: DV15TIS M: MIXER

R: 8X4 (HCV) R: 4X2 TRACTOR D: DDC T: 6X4 TRACTOR

S: 8X8 (HCV) Q: 4X2 TRACTOR 1 C: DDC 480 R: 4X2 TRACTOR

T: 10X4 (HCV) S: 4X2 TRACTOR 2 G: GE12TI S: 4X2 TRACTOR 2

K: CARGO VAR3 J: DL08(250/90) P: PULL CARGO

L: CARGO VAR4 K: DL08(300/115)

L: DL08(320/135)

M: ISM 350

N: ISM 425

P: DV11(345/145)

R: DV11(370/160)

S: DV11(420/187)

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 COMPOSITION OF VIN
Ex : K L 3 K 7 C E F 1 A K 0 0 0 0 0 1
F 1 9 K 000001

Homor o Production Ku n s an
Euro 3↓ : Bra ke Euro 4↓: Engine Se ria l No.
gati on ye a r Pla nt

F: FULL AIR J: DL08(250/90) E4 3: 2003Y

A: A.O.H. K: DL08(320/115) 4: 2004Y

G: BOGIE LIFT L: DL08(320/135) 5: 2005Y

F: DL08(340/145) 6: 2006Y

R: DV11(390/160) 7: 2007Y

Y: DV11(410/178) 8: 2008Y

S: DV11(420/188) 9: 2009Y

C: DV11(440/205) A: 2010Y

G: GE12TI(340/140)E4 B: 2011Y

GL11K(340/140)E5 C: 2012Y

W : ISM 390/178 E4 .

ISM 410/178 E5 .

N: ISM 410/189 E4 .

ISM 410/188 E5

M: ISM 430/205 E4

ISM 440/212 E5

H: NEF 251/82 E4

NEF 260/107 E5

U: GE08TI 230/82 E4

GL08K 230/82 E5

T: DL06 270/82 E4

DL06K 270/100 E5

A: DL06K 280/100 E5

D: Cursor 13 500/234

X: Cursor 13 560/255

31 Customer Service Team

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Interior & Exterior
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 Exterior

Roof airhorn
Mirror of
Assistance
Deck

Rear combi.
lamp

Rear
protector

Front Lid
Front
bumper Side protector
Lamp (Head/Fog/Combi)

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 Exterior

Front Glass Sun visor Mirror (Assistance)

Mirror(Driver) Wiper Door and Front handle

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 Exterior

Cornering lamp Corner vane Front Bumper

Door open lamp Cab step Rear combi. lamp

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 Exterior

Dump Body

Muffler (Side mounted type)

Mixer

Fuel tank (aluminum)

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 Interior

Steering and Meter cluster Radio and A/C switch Fuse box & Center consol

Relay box Overhead locker and Speaker Fluorescent lamp

39 Customer Service Team

 Interior

Rear view mirror Bed Driver seat

Power window switch Door lock Air gun port (Located passenger seat)

40 Customer Service Team

How to operate the vehicle
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How to open Front Lid

◆ How to open
1. Pull forward the front lid lever located at lower left-hand
side of the instrument panel.
2. Put your hand between the front lid and radiator grille to
pull forward the hook located in the middle of the front
part, and then the front lid becomes unlocked
3. Pull the front lid to open

◆ How to close
1. Push the front lid slowly to close. Keep pushing it until a
“Click” is heard from its lower part.
2. Make sure that it is locked securely.

43 Customer Service Team

How to open Front Lid

◆ Preparation for cab tilting

1. Place the vehicle on the level ground and ensure that
there is a sufficient space in front of and above the cab.
And then, position starter switch “ON”
2. Set the parking brake firmly.
3. Set the gearshift lever to neutral position.
4. keep interior of the cab free from fragile articles.
Close the doors securely.
5. All the wheels should be choked.
6. Re-check if there is any person in the cab.
7. Open the cab according to the following instructions.

44 Customer Service Team

 How to operate cab tilt
◆ How to lift the cab
1. To “ON” position located in the key box
2. Pull forward lock lever located at the lower right-hand side of
the rear of the cab while lifting the hook, and then the lock
will be released.
3. Push cab tilt enable switch to “ON” position located in instrument
panel inside the cab in case of the hydraulic cab lock option
system is applied in the vehicle.
4. Turn the direction change lever installed onto the pump located
at the rear lower right-hand side of the cab to set it to “U” position.
5. Press the switch as shown, and then the pump works and the cab
starts to ascend

◆ How to lower the cab

1. Position the direction change lever
descending position.
2. Press the switch as shown, and then
the pump works and the cab starts to descend.
3. Once the cab descended completely,
stop pushing the switch.

45 Customer Service Team

How to operate cab tilt
◆ How to lift the cab (Hydraulic cab latch : option)
1. To “ON” position located in the key box, Pull forward lock lever located
at the lower right-hand side of the rear of the cab while lifting the hook,
and then the lock will be released.
2. Push cab tile enable switch to “ON” position located in instrument panel
inside the cab in case of the hydraulic cab lock option system applied
in the vehicle
3. Turn the direction change lever installed onto the pump located at the
rear lower right-hand side of the cab to set it to ”U” position.
4. Press the switch as shown, and then the pump works and the cab
starts to ascend.

◆ How to lower the cab (Hydraulic cab latch : option)

1. Position the direction change lever in “D” position.

2. Press the switch as shown, and then the pump works and
the cab starts to descend.
3. Once the cab descended completely, stop pushing the switch.

46 Customer Service Team

How to use AIR SUSPENSION SEAT - Driver

47 Customer Service Team

How to use combi. switch – left lever

48 Customer Service Team

How to use combi. switch – right lever

49 Customer Service Team

How to use combi. switch – right lever

50 Customer Service Team

 Parking brake

Air center parking

51 Customer Service Team

 Meter cluster (Warning lamp Upper side)

E.S.S E.S.S 2
Rear brake Seat belt
Parking brake
Front brake Air pressure Engine oil Battery
warning lamp

Engine check Rear fog Self steering Pre heater

Warning lamp Bogie lift

Air cleaner Light (High beam)

Frt fog lamp
Door open

52 Customer Service Team

 Meter cluster (Warning lamp lower side)

Auto TM Diff lock (F/R)

(Allison)
P.T.O Trailer ABS

Exhaust brake Working lamp TM H/L ASR

TM split
Hook ABS (High)
Auto TM
Oil Temp warning lamp
(Allison TM)
Diff lock (L/R)
Cruise P.T.O
Cab tilt

53 Customer Service Team

circuit diagram – Meter cluster
8 9 9 8
1 2

3 4 9 7 5 6

Customer Service Team

 Binnacle switch

P.T.O switch Side mirror heat & Fog lamp

(Dump/Mixer/Special unit) Pre heater for fuel filter
(15 minute per I time)

55 Customer Service Team

 Binnacle switch

Air con Diff Lock

56 Customer Service Team

Main function & How to operate
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How to operate dump P.T.O

59 Customer Service Team

How to operate dump P.T.O

60 Customer Service Team

 How to operate dump P.T.O

■ Switch and Lever

Push : Working
Push again : Not working

Adjusting Lever
P.T.O S/W

■ Operating circuit

P.T.O S/W Electric

Air flow
Magnetic valve Air tank

Adjusting lever
Hydraulic
Hydraulic
P.T.O flow

TM

Low pressure
Mechanical
Cable

61 Customer Service Team

 How to operate dump P.T.O

■ Switch and Lever

Push : Working
Push again : Not working

P.T.O S/W Adjusting lever

■ Operating circuit
P.T.O S/W Electric
(Oil tank) Hydraulic
Magnetic valve
(Tipping valve)
P.T.O
Air tank Hydraulic pump

TM
Adjust lever

Air flow (Down line)

(Lock off valve)
(Up line)

62 Customer Service Team

 DIFFERENTIAL LOCK

■ Differential lock

Front / Rear Differential lock switch Left / Right Differential lock switch

63 Customer Service Team

 DIFFERENTIAL LOCK

■ Differential lock diagram

Front / Rear Left / Right

Differential Differential
lock switch lock switch

Rear axle

Magnetic valve
reward

Air tank
Magnetic valve

Rear axle
forward

64 Customer Service Team

CLUTCH
1. CONSTRUCTION
2. CONTROL
3. DISASSEMBLY/REASSEMBLY
4. INSPECTION/MAINTENANCE
5. TROUBLESHOOTING
6. LUBRICANT
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 CONSTRUCTION
PUSH TYPE

Engine type : DE12, DE12TI

Spring type : Coil spring
Operating type : Push type
Fixing Weight(kg.m): 1,600~2320
Disc size : 430 x 250 x 11.5

Customer Service Team

 CONSTRUCTION
PULL TYPE

Release bearing

Diapragm spring
Engine type : DV15T/Ti/Tis, DE12TIs
Spring type : Diaphragm spring
Operating type : Pull type
Fixing Weight(kg.m): 2,300~2,600
Disc size : 430 x 242 x 10

Customer Service Team

 CONTROL
CLUTCH CIRCUIT

① Hydraulic fluid arrives from a reservoir tank

② Converting pressure from the Master cylinder into mechanical movement
③ When the hydraulic pressure form master cylinder reaches a piston rod and
a relay valve in the booster
④ Compressed air force a piston and transmits the movement to a clutch release lever

Customer Service Team

 CONTROL
MASTER CYLINDER

Piston
Secondary cup

Make necessary correction or parts replacement

If wear, damaged or other abnormal condition
- Piston and Body wear
- Check valve damaged
- Primary and secondary cup abnormal condition Check valve
※ At mixed oil(engine oil, steering oil etc)

Clearance Between the body and piston Primary cup

Standard(mm) Limit(mm)

0.10 0.15

Customer Service Team

 DISASSEMBLY/REASSEMBLY
CLUTCH PEDAL
DISASSEMBLY/REASSEMBLY

CLUTCH PEDAL

Customer Service Team

 INSPECTION/MAINTENANCE
PEDAL FREE PLAY

40 ~ 50

Type and Specifications

Item Type

Clutch pedal height Clutch booster Manual type Auto type

Free play 40 ~ 50 25 ~ 35

Pedal height About 165 Å

Customer Service Team

 INSPECTION/MAINTENANCE
AIR BLEEDING

- Fill the clutch fluid reservoir during
bleeding operation.
- Remove the bleeder rubber cap
- Connect a vinyl pipe
- Pump the clutch pedal several times
- And hold the pedal depressed
- Loosen the bleeder half a turn
- And tighten it immediately

Customer Service Team

 TROUBLESHOOTING

⊙ ABRASION UP TO DISC FACING RIVET ⊙ ABRASION OF TORSION SPRING

- Only disc has been replaced - Excessive loading
- Clutch cover & flywheel have come - Careless driving(partially-engaged clutch)
to an end. - Poor alignment when installing clutch

Customer Service Team

 TROUBLESHOOTING

⊙ Generation of heat spots ⊙ Vibration Marks on pressure plate

- Disc facing has been stained with - Í
oil or grease. - Excessive vibration of clutch linkage
or engine

Customer Service Team

 TROUBLESHOOTING

⊙ Burnt disc facing ⊙ Excessive abrasion of Disc and Pressure plate

- Disc facing has been stained with - Only the disc has been replaced instead of
oil or grease. clutch cover
- Excessive abrasion of flywheel - Excessive abrasion of flywheel
- Excessive abrasion of clutch cover

Customer Service Team

 TROUBLESHOOTING

⊙ Breakage of clutch cover ⊙ Damage to release bearing

- Frequent use of partially-engaged clutch - Eccentric release bearing
- Overheating of clutch

Customer Service Team

 TROUBLESHOOTING

◇ AVOID DRIVING WITH CLUTCH PARTIALLY ENGAGED

◇ AVOID JACK-RABBIT STARTS AND FREQUENT USE OF ENGINE BRAKE
◇ WHILE DRIVING, CHANGE GEARS STEP BY STEP
CAUTIONS
◇ WHILE DRIVING, IF YOU MEET SLIPPAGE OR TROUBLE WITH CLUTCH,
STOP VEHICLE, PLACE THE GEARSHIFT LEVER 'NEUTRAL', DEPRESS
CLUTCH FOR ABOUT 3 MINUTES, AND RELEASE YOUR FOOT

◇ OUT-OF-BALANCE FLYWHEEL OR CLUTCH COVER

VIBRATIONS ◇ BAD CONTACT SURFACE OF CLUTCH DISC
◇ UNEVEN CONTACT WITH RELEASE BEARING

◇ ANTI-DISTORTION CAPACITY OF DISC DOES NOT SUIT THE VEHICLE

◇ UNBALANCE OF CLUTCH COVER AND DISC
CLUTCH NOISES
◇ RELEASE BEARING IS LACK OF LUBRICANT OR MISALIGNED
◇ DAMAGE OF LINKAGE OR PEDAL, OR DISC SPRING

Customer Service Team

 TROUBLESHOOTING
TROUBLESHOOTING

◇ DAMAGE OF HUB SPLINE OR TRANSMISSION SHAFT

OR PARTICLES STICKING TO THEM
◇ PARTICLES STICKING TO FLYWHEEL OR PRESSURE PLATE
◇ AFTER STOPPING THE VEHICLE, CONTACT SURFACE OF DISC
ENGAGEMENT FACING FORMS A VACUUM STATE
PROBLEM ◇ TOO THICK CLUTCH DISC OR MISALIGNED BEARING
◇ EXCESSIVE FREE PLAY OR ABRASION OF RELEASE SYSTEM
◇ LEAKAGE OR SHORTAGE OF CLUTCH SYSTEM
◇ INFLOW OF AIR TO HYDRAULIC SYSTEM
◇ DAMAGE OF DIAPRAGM SPRING

◇ EXCESSIVE ABRASION OF DISC FACING

◇ OIL STICKING TO DISC FACING FROM TRANSMISSION OR
CRANK SHAFT
◇ GREASE STICKING TO DISC FACING FROM RELEASE BEARING
SLIP
◇ INSUFFICIENT FREE PLAY OF RELEASING BEARING OR
EXCESSIVE FRICTION OF RELEASE LINKAGE
◇ FLYWHEEL WAS REPOLISHED OR MODIFIED INCORRECTLY
◇ DISTORTION OF CLUTCH LEVER OR DIAPRAGM

Customer Service Team

 LUBRICATION

◎ CLUTCH FLUID : HYDRAULIC BRAKE OIL SAE J1703

◎ TOTAL CAPACITY : 0.3 Liter

◎ RESERVOIR CAPACIYT : O.2 Liter

◎ GREASE : MULTIPURPOSE OR CHASSIS TYPE

NLGI NO. 1 OR 2

Customer Service Team

 Steering system
■ Overview Steering system
HCV trucks are used for hydraulic steering system with a mechanical device used to allow the steering and composed
Forward 1axle and forward 2 axles depending on vehicle model.

Gear box

Oil tank

High
pressure

Low
pressure Hydraulic
pump

To engine gear

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 Brake system

■ Exhaust brake system

Exhaust brake

Exhaust brake switch

Air tank
Magnetic valve

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Troubleshooting
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 Troubleshooting (Engine)

▶ Engine not starting intermittently

No Cause
Contact problem of
1 neutral switch
(No hear any sound)
2 Jam flywheel ring gear
Troubleshooting
1. Gear insert and neutral 4 or 5 times and then try engine start again.
2. If not solve after tried 1, neutral switch harness connect directly
and then start again
Only sound relay working but engine not starting.
Open flywheel housing cover located under side and then turning the
flywheel ring gear using by (-) driver. Try engine starting again.

Flywheel check cover

Neutral switch

85 Customer Service Team

 Troubleshooting (Engine)
▶ Starter not working

No Cause Troubleshooting
1 Battery discharge Use jump cable or battery change
2 Neutral switch defect Check neutral switch
check fuse #5 of auxiliary fuse box and Fuse #1 main fuse box.
3 Burnt Fuse
Check the wiring harness for cutting or short of starting
4 Start relay defect Check relay and replace the start relay.

Start relay

86 Customer Service Team

 Troubleshooting (Engine)
▶ Engine overheat
No Cause Troubleshooting

1 Lack of coolant Check coolant leakage point and then driving after added coolant

2 Radiator core blocked Remove dust of radiator core or replace radiator assemble.

3 Coolant pollution Cleaning inside of radiator or change the coolant.

Thermostat and water
4 If thermostat not open, change / if water pimp not working, change
pump failure
5 Broken the fan belt Check fan belt whether damage or not and then replace

87 Customer Service Team

 Troubleshooting (Engine)
▶ Lack of engine power
No Cause Troubleshooting

1 Parking brake locked Release parking brake

2 Contamination of air cleaner element Cleaning air cleaner element or replace

3 Lack of brake lining gap Adjust brake lining gap(0.3mm)

4 Leak of intercooler Check intercooler and change if needed

5 Failure of turbocharger Check turbocharger or change( If oil seal damaged, white smoke
would be come out excessively)

Turbo charger failure

Air cleaner element contamination (Blocked)

88 Customer Service Team

 Troubleshooting (Brake)
▶ Vehicle stop urgently while driving
No Cause Troubleshooting

1. Parts replace when air line burst or leak after blocked air supply line route.
1 Air leak
2. If valve part leaking, parts change after exhaust the air by low pressure

2 Burst of chamber Replace chamber or moving after block air supply line and release spring of chamber

89 Customer Service Team

 Troubleshooting (Brake)

▶ Lack of braking power

No Cause Troubleshooting

1 Lack of air pressure Check whether air leak / charge or not ( air pressure more than 6bar)

Repaired oil leak point and then lining grind or replace after purifying the lining
2 Lining pollution by oil
( Check oil leak for outside)
Excessive lining gap and
3 Adjustment lining gap (Manual : 0.3mm) , Replace when worn out
worn out

4 Over pressure of tire Re- setting for regular air pressure (105~110 psi)

90 Customer Service Team

 Troubleshooting (Clutch)
▶ Clutch problem
No Problem & Cause Troubleshooting

Hard engage clutch pedal

- Check whether air leak / charge or not ( air pressure more than 6bar)
1 1. Lack of air pressure
- Adjust master cylinder rod of clutch pedal (Clearance 0.5mm)
2. No clearance

No servo brake of Clutch pedal

- Check oil leaking point nearby clutch system including hydraulic line
2 1) Damaged hydraulic line
- Check oil lever of oil tank and remove air if air inflow to hydraulic line.
2) Insert air to hydraulic line

Clutch slip
1) Excessive worn our Disc
3
2) Stick oil on Disc
3) Overheat of Disc
- If excessive worn out, move to workshop by low speed & slowly
and then exchange.
- It would be slip if engine & gear oil leak and stick to disc.
( Check appearance)

91 Customer Service Team

 Troubleshooting (Power train)

▶ Abnormal noise Gear box & Differential

No Cause Troubleshooting
1 Lack of gear oil Add gear oil by normal
2 Lack of oil viscosity Exchange gear oil ( SAE 80W 90 ) / Tropical (SAE 85W140)
3 Worn our bearing and gear After dismantle and inspection

Axle & Gear box oil level (Fill in by inlet point)

92 Customer Service Team

 Troubleshooting (Power train)

▶ How to adjust clutch rod

Adjustment master cylinder rod (0.5mm)

(Vehicles is set at the factory before delivery)

93 Customer Service Team

 Troubleshooting (Electric)

▶ Turn on battery charge lamp or excessive discharge

No Cause Troubleshooting

1 Alternator defect Exchange if not belt cut or relaxation

Remove the rust point and fix again tightly

2 Battery terminal rust or relaxation
( If need coating grease)

3 Lack of battery charge Check alternator and Battery charging

4 Battery charging lamp is on continually Check whether alternator defect or not and replace alternator.

Check fan belt

94 Customer Service Team

 Troubleshooting (Electric)
▶ Each lamp and Electric part problem
No Cause Troubleshooting

1 Bulb defect Change bulb

2 Blow out Fuse Change fuse

3 GND problem Check GND and rectification

4 Relay failure Change relay

5 Wiring harness problem Check the wiring harness and repair

Fuse No regarding the electric system

- Engine starting --- Fuse #1

- Head lamp high beam --- Fuse #31

- Head lamp low beam --- Fuse #32

- Turn signal lamp --- Fuse #15

- Wiper of combi. Switch --- Fuse #28

95 Customer Service Team

 Troubleshooting (Electric)

▶ KEY ON RELAY Failure

1. Problem : Electric system problem related with fuse #12 ~ 20 , 23~30

2. Remedy : Change relay
3. Location of KEY ON RELAY : Inside of grove box of passenger seat.

Relay which connected

with white color wire

96 Customer Service Team

Troubleshooting (Tow)

97 Customer Service Team

N
N oo tt ee
Maintenance
N
N oo tt ee
 Efficient driving way for NOVUS
X How to drive for long durability of Engine

1. When engine starting, should be stabilize oil pressure and then increase the rpm gradually until the engine oil reach

to the turbocharger and each bearing. If you are operating high speed before oil reaching,

the engine may be damaged. Especially turbochargers can be fatal.

2. After keeping 3 ~5min at idle rpm condition and then vehicle start driving.

3. When engine oil change, you should be meet same specifications as we recommended grade

and engine oil filter must filling oil inside of filter when changing the filter.

The reason is that oil can not supply to bearing until filter is filling engine oil.

4. Should be keep engine oil change period in any case.

5. Air cleaner is keeping well thoroughly, if debris or dust are insert to intake system, liner and piston ring would be damaged.

As a result engine power and oil consumption would be happen, or you would be meet engine boring case.

6. Keeping engine idle condition approximately five minutes after the engine stop.

Engine stop after cooling the engine.

101 Customer Service Team

 Efficient driving way for NOVUS
X Efficient drive for Electronic Engine
1. Do not engine warming up long time, this is the way of unnecessary fuel waste.

2. Engine rpm keeping at 800rpm when vehicle starting, not to use semi clutch if possible.

3. Proper engine rpm to drive is 1,100~1500rpm.

Gear shifting properly according to the driving condition(1~4speed at 1700rpm. 5~6speed at 1600rpm)

4. Gear shift by low speed at the uphill load, when the speed drops below 1100rpm.

5. Electronic accelerator pedal of the engine is operating by driver’s control, it means that electric signals delivered

to the engine ECU by driver and engine ECU which is receive all vehicle information including the accelerator

pedal and the signal of each sensor in the vehicle's driving conditions determined the optimal condition

to drive the vehicle. Therefore, if you use accelerator pedal frequently, it caused high fuel consumption,

so according to the driving condition, should be reducing the poedal operations time.

If you are constant driving help to reduce the fuel consumption also.

6. At the slip area, keeping engine rpm not to higher than governor speed and use engine brake and gear shifting properly.

102 Customer Service Team

To produce world-class quality

Thank you