OPERATORS MANUAL for Powerstar VX

CONTENTS

1 VIN Plate and Vehicle Data ................................................................................................................................. 1

2 Vehicle Operation ................................................................................................................................................ 1
2.1 Door Operation .......................................................................................................................................................1
2.2 Seat Adjustment .................................................................................................................................................... 2
2.3 Steering Adjustment .............................................................................................................................................. 2
2.4 Instrument Cluster and Dashboard Fittings ........................................................................................................... 3
2.5 Indicator Lights ...................................................................................................................................................... 4
2.6 Digital Read Out Display ....................................................................................................................................... 6
2.7 Engine Tachometer ............................................................................................................................................... 6
2.8 Combination Switch .............................................................................................................................................. 7
2.9 Light Switch ........................................................................................................................................................... 7
2.10 Headlight Adjustment ............................................................................................................................................ 7
2.11 Drive Control Switches .......................................................................................................................................... 8
2.12 Heating and Ventilation ......................................................................................................................................... 9
2.13 Opening Grille ..................................................................................................................................................... 10
2.14 Bunks (Only fitted to sleeper cab) ....................................................................................................................... 11
3 Driving the Vehicle ............................................................................................................................................. 12
3.1 Preparation .......................................................................................................................................................... 12
3.2 Engine Start Up and Shut Down ......................................................................................................................... 13
3.3 Hand Brake Operation ........................................................................................................................................ 14
3.4 Starting Engine and Gear Shifting ....................................................................................................................... 14
3.4.1 Gear Shifting ....................................................................................................................................................... 15
3.4.2 Differential Lock Operation ................................................................................................................................... 16
3.4.3 Transfer Box Operation ....................................................................................................................................... 17
3.4.4 PTO Engagement and Operation ........................................................................................................................ 17
3.5 Run-in Period ...................................................................................................................................................... 18
3.6 Vehicle Performance ........................................................................................................................................... 19
3.6.1 Air Exhaust Brake ............................................................................................................................................... 19
3.6.2 Parking ................................................................................................................................................................ 19

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3.7 Connecting Trailer .............................................................................................................................................. 20

3.8 Speed Limiter ...................................................................................................................................................... 20
3.9 Winter and Coastal Operations ........................................................................................................................... 21
3.9.1 Anticorrosion ....................................................................................................................................................... 21
3.9.2 Air Compressor .................................................................................................................................................... 21
4 List of Lubricants and Quantities .................................................................................................................... 22
5 Standard Tools and Emergency Maintenance Procedures ........................................................................... 23
5.1 Cab Tilting............................................................................................................................................................ 23
5.2 Brake System ..................................................................................................................................................... 26
5.2.1 Tightening Torque Nm ........................................................................................................................................ 26
5.2.2 Brake Pipeline Inspection ................................................................................................................................... 26
5.2.3 Brake Shoes / Linings Inspection ......................................................................................................................... 26
5.3 Spare Wheel Stowing and Removal .................................................................................................................... 26
5.3.1 Tightening Torque Nm ......................................................................................................................................... 26
5.3.2 Spare Wheel Position ......................................................................................................................................... 26
5.3.3 Wheel Replacement ........................................................................................................................................... 27
5.3.4 Air-Inflating Tyre Connection .............................................................................................................................. 29
5.3.5 Tyre Replacement .............................................................................................................................................. 30
5.4 Electrical System ................................................................................................................................................. 30
5.4.1 Technical Data .................................................................................................................................................... 30
5.4.2 Headlamp Adjustment ........................................................................................................................................ 31
5.4.3 Bulb Replacement on Headlamps and Indicators ............................................................................................... 31
5.4.4 Additional Electrical Accessories ......................................................................................................................... 32
5.4.5 Fuse .................................................................................................................................................................... 32
5.4.6 Battery ................................................................................................................................................................ 34
5.5 Chassis Maintenance and Lubrication ................................................................................................................ 35
5.5.1 Chassis Lubrication ............................................................................................................................................ 35
5.5.2 Driving Shaft Lubrication ..................................................................................................................................... 35
5.5.3 5th Wheel Inspection and Maintenance ............................................................................................................... 35
5.5.4 Centralised Lubrication ....................................................................................................................................... 36

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5.6 Vehicle Washing and Maintenance ..................................................................................................................... 36

5.7 Preservation Measures ....................................................................................................................................... 37
5.8 Stored Vehicle Re-commissioning ...................................................................................................................... 38
6 Towing and Recovery ....................................................................................................................................... 38
7 Engine Operation, Maintenance and Repairing .............................................................................................. 40
7.1 Dust Separator Valve Maintenance...................................................................................................................... 40
7.2 Composite Bowl Maintenance ............................................................................................................................. 40
7.3 Air Filter Element Cleaning and Replacement ..................................................................................................... 40
7.4 Fuel System ........................................................................................................................................................ 40
7.4.1 Draining Water from Watertrap and Diesel Filter.................................................................................................. 40
7.4.2 Air Bleeding from Fuel System ............................................................................................................................ 41
7.5 Cooling System ................................................................................................................................................... 41
7.5.1 Cooling System Maintenance .............................................................................................................................. 41
7.5.2 Seed Screen ....................................................................................................................................................... 41
8 Tyre Inflation Pressures ................................................................................................................................... 42
9 Troubleshooting ................................................................................................................................................ 43
Clutch .................................................................................................................................................................. 43
Steering ............................................................................................................................................................... 43
Brake System ...................................................................................................................................................... 43
Electrical System ................................................................................................................................................. 43

Note: Specifications detailed in this operator’s manual may differ according to model. Powerstar reserves the right to change the
specification without prior notification.

DN05/0002/20111209/11

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1. VIN PLATE AND VEHICLE DATA

 Vehicle Identification Number (VIN) Located on the front right of chassis beam

 Data plate inside right hand door on step-well

2. VEHICLE OPERATION
2.1 Door Operation
Exterior door lock:
Neutral Lock: Insert the key and turn anti-clockwise. Return to neutral position and remove
Lock Unlock the key.
Unlock: Insert the key and turn clockwise. Return to neutral position and remove the
key before pulling handle to open the door.

Note: Passenger’s door operation will be opposite to above description.

Ensure proper usage of the door lock is adhered to in order to avoid inconveniences.

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Exterior
Interior door and window:
 Door lock (for driver’s door, push left to lock and right to unlock)
 Door handle (Pull the lever inwards to open)
 Window operating handle

Interior
2.2 Seat Adjustment
 Pull locking mechanism up to adjust angle of backrest
 Pull handle up to adjust rear seat height
 Pull handle up to adjust front seat height
 Pull handle up to move seat forwards or backwards
 Push lever down to deactivate air system on seat.

2.3 Steering Adjustment

 Steering column locks

- Loosen steering column locks anti-clockwise (one on either side of column).

- Adjust rake (forwards and backwards) and reach (up and down) to suit and to
properly see instrument panel.
- Lock column locks securely (clockwise).

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2.4 Instrument Cluster and Dashboard Fittings

1 Digital read out display 9 Interior clock 17 PTO switch

2 Driving lights dial 10 Fuse box cover 18 Diff lock switches
3 Warning indicators 11 Output socket 24V 19 Light adjustment switch
4 Speedometer 12 Combination switch 20 Transfer box switches (1729, 2635)
5 Tachometer (Rev Counter) 13 Grille opening handle 21 Engine powerload switch (1627 Only)
6 Air gauge 14 Radio 22 Engine check switch (1627 Only)
7 Hazard lights switch 15 ABS switch (diagnostics)
8 Heating and ventilation (see page 7) 16 Temperature and fuel gauge

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2.5 Indicator Lights

 Left indicator
 Engine Oil Pressure
 Park brake
 Right indicator
 Air pressure circuit 3 – Park brake
 Battery
 Cold start (pre-heat)
 Hi-Beam lights
 Fog lights front
 Fog lights rear
11 ABS brakes – fault indicator
12 Neutral position (gears)
○
13 Check air flow

 Air pressure gauge circuit 1 – Rear brakes

 Air pressure gauge circuit 2 – Front brakes
 Water temperature – Engine coolant
 Low fuel level warning

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Coolant / Temperature display:

When the engine runs normally, the temperature of coolant of the Weichai Engine should be between 80-102°C. If the
temperature is higher, stop the vehicle and inspect cooling system. If no evident restriction is observed, contact your
service centre.
Cooling System Maintenance
The cooling system relies on good unrestricted airflow through the intercooler and radiator as well as sufficient coolant
level.
The core must be periodically flushed externally to allow correct cooling and optimal engine life. The cleaning frequency
depends on the operating conditions.
Using a hose with tap water pressure, wash through the cores of both the intercooler and radiator from the front and the
back over the whole core area.
Care must be taken to avoid damage to the core during this operation.

Brake pressure:
Caution: If the brake pressure alarm indicator illuminates, stop the vehicle immediately and determine the fault.
Brake pressure alarm will illuminate when the following conditions occur:
- One of the pressures shown on the dual pointer pressure gauge is less than 5.5 bar (0.55 Mpa).
- The air pressure on the emergency line decreases to less than 5.5 bar (0.55 Mpa) which will indicate a leakage.

Air pressure of additional air consumption unit:

- When the pressure of additional air consumption units (pneumatic hi/lo gear shifting and speed limit devices) is less
than 6 bar (0.6 Mpa), the indicator will illuminate.

Battery charge:
- The battery charge indicator will cease to illuminate after the engine has started.
- If the battery charge indicator illuminates while driving then stop the vehicle immediately, shut the engine down and
inspect the V-belt on the alternator.
Note: Do not start the engine if there is no V-belt!

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2.6 Digital Read Out Display

 Oil pressure
 Battery voltage
 Operating hours
 Trip kilometres
 Odometer kilometres

2.7 Engine Tachometer

 Excessive RPM indicator (indicated in red)
Optimum rev range 1200-1900rpm

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2.8 Combination Switch

 Low beam
 High beam (shift downward)
 Head lamp flash (shift upward)
 For left turn
 For right turn
 Hooter (push)
 Wind-screen wiper (rotate):
”O” - off position
“I” - intermittent wiping
“II” - low speed
“III” - high speed
 Wind-screen washer:
Push the switch in and hold. Periodically inspect the wiper blades for dirt and
damage. Adjust the angle of the sprayer nozzles to the optimum position
2.9 Light Switch
 Power off
 Parking lamps
 Head lamps
 Front and rear fog lamps (pull out to first click for front fogs and pull out to second
click for rear fogs)

2.10 Headlight adjustment

Position “0” is selected for an unladen vehicle
Position “1” – “3” are selected depending on load weight. “3” is selected for
heaviest load.

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2.11 Drive Control Switches

Transfer Box Operations
See chapter 3.4.3 for operations

Transfer Box Operations (6x6 only)

See chapter 3.4.3 for operation

Transfer Box Range (4x4 only) Transfer box operations (4x4 only)
= Hi-range (on road driving) See chapter 3.4.3 for operation
0 Neutralise transfer case
Lo-range (off road driving)

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2.12 Heating and Ventilation

 Adjustable ventilation and defrosting  Air and window defrost port  Fan speed dial  Air-con
 Ventilation
port open and close dial  Air, air-con and heat control panel  Temperature dial
 Air port  Air directional flow dial  Recirculator valve

- Ensure that a fan speed has been selected (7) otherwise air conditioner will not function.
- For maximum cooling, activate air recirculation valve (9).
- The indicator lights will illuminate when activated.

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2.13 Opening Grille

 Handle (on passenger side)
 Lock spring

Shift spring loaded handle to activate the release mechanism to open

the front grille.

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2.14 Bunks (Only fitted to sleeper cab)

Lifting Bunk:
To access the storage area under the bunk

- Unclip the safety nets

- Pull the latch in the centre of the bunk out
- Therefore lift the bunk

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3. DRIVING THE VEHICLE

3.1 Preparation

Check emergency accessories (e.g. fire extinguisher, spare tyre, jack, etc.) daily.

Checks before starting the engine:

- Fuel level
- Driver’s cab locking device
- Vehicle illumination, direction indicators and brake lights
- Trailer coupling or 5th wheel (if applicable)
- Engine oil level, steering oil and water level
- Tyre pressure
- Drain water from air tanks

Checks after starting the engine:

- Engine oil pressure
- Steering wheel play
- Brake air pressure

Draining water from air reservoir:

 Water drain valve on air reservoir

Note: Before the drain valve is removed, activate the brake pedal repeatedly
to discharge the brake system.

- Press drain valve to discharge water from reservoir.

- If the valve is blocked, remove and clean or replace the valve.

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3.2 Engine Start Up and Shut Down

Engine start up:
- Ensure park brake is applied and gear lever is in the neutral position
- Insert the ignition key and turn it to the “Ignition” position, the charging indicator, oil pressure and handbrake indicator
lights illuminate. When the engine has started, the oil and charging indicators switch off. The handbrake indicator only
switches off when the handbrake is released. The low air indicator will remain illuminated until operating air pressure
is reached. Do not rev the engine suddenly after starting.
- Do not crank the engine for longer than 10-15 second intervals and wait 1 minute before cranking again.
- Observe oil pressure gauge immediately after starting. If no oil pressure is displayed, shut down the engine
immediately.
Engine shut down:
- Ensure park brake is applied and gear lever is in the neutral position
- Release accelerator pedal.
- Push the exhaust brake switch down, floor mounted in front of the driver’s seat (refer to 3.6.1). This function only
operates when air pressure is 6 bar or more.
- The engine shut down system works by cutting off the fuel feed within the fuel pump and closing the exhaust system.
Do not stop the engine by “stalling from a stationary vehicle position” using the gears.
Note:
- The engine under full load should not be shut down immediately after stopping. Allow the engine to idle for 1 – 2
minutes before shutting down.
- Load and speed on the engine should be increased gradually.
- Avoid unnecessary engine revving.
- Do not rev the engine suddenly after starting the engine. Allow it to idle until oil pressure is stable.
- New vehicles should not be operated at maximum revs. Vehicles should be operated at 80% of engine rated power for
50 hours (or 2 500km) for “running-in” of moving parts and to increase the reliability and operational life of the engine.
 The key should be inserted or withdrawn in this position
Withdrawing the key = Locking of steering wheel
 Running position = Unlocking of steering wheel
 Starting position

The key is retained in “lock” position by a solenoid and only releases when the engine
is switched off.

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3.3 Hand Brake Operation

- The hand brake should always be used while parked. Chocks may be used as a back-up and for safety.
- When the handle is in the brake on position (locked), the hand brake indicator illuminates.
- The handle will return to the released position automatically once released.
Releasing the hand brake:
When the hand brake is released completely, the pressure of the air reservoir should be more than 5.5 bar (0.55Mpa) and
the brake pressure warning light on the instrument panel should be “off”. If the brake pressure indicator comes on whilst
driving, stop and investigate.
- Release the handle from the locking position and push it forwards. The hand brake indicator light goes “off”.
- If the brake boosters are leaking, the brakes can be released by manually adjusting them during emergency conditions
or when towing.
Note: Before the driver leaves the vehicle:
- Activate the hand brake by moving the handle backwards till it locks.
- When inspecting the brakes, keep the handle in the lock position.
 Brake on
 Brake off
 Release clutch

3.4 Starting Engine and Gear Shifting

If the pressure gauge is less than 5.5 bar (0.55Mpa) and the brake pressure alarm indicator on the instrument panel
illuminates, the vehicle cannot be moved until the hand brake is released and the indicator switches off.
- Activate the hand brake to prevent the vehicle from moving.
- Set the transmission to neutral.
- Start the engine and release the hand brake.
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- Commence vehicle driving with a heavy load in 1st gear to preserve clutch life.
Do not attempt to start driving in a high gear range in order to prevent damage to transmission parts.
Caution:
- Whilst the vehicle is still moving slowly, check the foot and hand brake functions.
- No oil and water is allowed on the brake shoes.
- If the brakes lose effectiveness, stop the vehicle and rectify the problem.
3.4.1 Gear Shifting
- Observe the speedometer and rev counter readings while driving. If the speed of the engine exceeds the economic
speed range, change gears.
- Run the vehicle in the optimum gear range by shifting down before climbing a gradient.
- When shifting gears, skip changing is permitted if road conditions allow.
- Press the clutch pedal fully before changing gears.
- Do not use force during gear shifting.
- When reverse or first gear is used during adverse road conditions or during starting, gear shift can only take place after
the vehicle has stopped to prevent damage to the gearbox.
Transmission 8J Fastgear: Transmission 12J Fastgear:

The pressure should be 6.0 bar (0.60 Mpa) in the compressed air system.
The gear layout is type double H, and there are two Flip splitter switch, located on the gear lever knob, to change
neutral positions. When the transmission is in neutral, from low to high gear.
the gear lever should be located between gears 3/4 Down Position = Low range
of the low range or gears 5/6 of the high range. Up position = High range

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Changeover between low and high gear range for 8J:

- Depress clutch pedal.
- Set the gear-shift lever to neutral position.
- Shift gear lever from gear 3/4 (L) to gear 5/6 (H). The engaged gear indicator should illuminate.
- When engaging a gear, shift the gear lever as soon as possible to the required gear (do not use too much force).
- Release clutch pedal gradually.
“L” = Low gear range - gears 1 - 4
“H” = High gear range – gears 5 – 8
Changeover between low and high gear range for 12J:
- In low gear select gears from 1 – 6
- The next change is to engage the splitter air switch to high gear (upper position) and by engaging gear 1 in this range,
gear 1 becomes 7 and changing up will progress through 8 – 12th gears.
Caution:
- Do not hesitate between gear-shifts, otherwise the speed differential will be too large and the gear shifting force will
increase. It is especially important before the transmission has reached working temperature.
- While gear shifting, push the gear lever all the way until the gear shifting has synchronised completely.
- Do not change to a lower gear unless the speed of the vehicle and the engine revolutions are lower than the maximum
speed of the engaged gear. Maximum input and output speed of transmission should be < 2 500r/min and road speed
is 20kph or lower
3.4.2 Differential Lock Operation
 Disengaged
 Engaged
- The corresponding indicator illuminates and a warning buzzer sounds when the
differential lock is engaged.
- The differential lock should be engaged only when the vehicle has stopped or the
vehicle’s speed is extremely slow (walking speed).
- The differential lock cannot be engaged if the wheels are spinning.
- When the vehicle’s differential lock is engaged, accelerate gradually.
- When engaging differential locks, first engage the inter axle lock and then the
differential lock.

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Caution: Do not drive on a tarred surface or at high speed with the differential lock engaged.
3.4.3 Transfer Box Operation
Switch No. 1 2 3
Hi Range Off Off On
Neutral On Off On
Low Range On On Off

Power Divider Switch 6x6 Front Diff Lock Switch 4x4 Rear Diff Lock Switch 6x4
Engages rear power divider Engages front steering Engages two rear axle diff
and front differential differential lock locks
PTO Switch Transfer Case Switch 4x4 Rear Diff Lock Switch 4x4
Engages PTO (Power Take Engages transfer case Engages rear drive axle
Off) differential lock
Power Divider Switch 6x4 PTO Switch
Engages rear power divider Engages PTO (Power Take Off)

3.4.4 PTO Engagement and Operation

8J Fastgear Gearbox:
- Ensure handbrake is activated.
- Ensure air pressure is above 8.2 bar.
- Activate PTO switch situated on floor on left-hand side of driver’s seat or on left side of driver’s seat in front of gear
leaver, depending on body builder (see photos).
- Depress clutch.
- Shift gearbox into a low range.
- Select 3rd gear and gradually release clutch.

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12J Fastgear Gearbox:

- Ensure handbrake is activated.
- Ensure air pressure is full.
- Depress clutch.
- Shift gearbox into a low range.
- Activate PTO switch situated on left side of driver’s seat in front of gear leaver (see photo).
- Flip low-high gear switch from low to high and back to low.
- Select 3rd gear and gradually release clutch.
PTO Switch mounted on floor next to driver’s seat. (Dependant on vehicle configuration)

3.5 Run-in Period

- The engine should not run at maximum RPM during run-in period. It should run with the rated power of less than 80%.
- Driving speed should be varied during this period.
Running in requirements:
Before 2 000Km:
Drive evenly at 3/4 of the rated speed in each gear.
Drive with full trailer load at permissible gear speeds according to the allowable road conditions to develop the optimum
performance of vehicle.

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Fastening wheel nuts:

450N Torque: 450Nm for Aluminium Wheels
m Torque: 550 Nm for Steel Wheels

- Check and tighten the wheel nuts after driving 500km with a new vehicle
- Nuts should be tightened diagonally.

Torque U-Bolts to 450Nm

- Check and tighten the U-Bolts after driving 1000 km with a new vehicle

3.6 Vehicle Performance

3.6.1 Air Exhaust Brake
 Exhaust brake valve actuation button

- Press the button on the floor in front of the driver’s seat to activate the exhaust
brake on the engine.
- The speed of the vehicle can be reduced by activating the exhaust brake when
going downhill if the engine rpm is maintained at 2 000rpm.
- If the engine is equipped with the WEVB (Weichai Exhaust Valve Brake) the use
of the exhaust brake activates the WEVB as well.

3.6.2 Parking
- Pull the hand brake handle into the lock position to park the vehicle.
- In order to prevent a loaded or parked vehicle from rolling, wooden chocks should be placed in front/back of the
wheels. The chocks carried in the vehicle should be of the heavy duty type.

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3.7 Connecting Trailer

- The king pin on the trailer should be 50mm lower than the upper face of the 5th wheel.
- Secure the connection and inspect lock after coupling the tractor to the trailer.
- Connect the air lines and electrical cable.
Connecting compressed air pipeline and trailer electrical cable:
 24V electrical trailer connection plug
 Yellow line to trailer (service line)
 Red line to trailer (emergency line)
 ABS connection plug

- No stretched, broken, worn pipelines or damaged cables are allowed for connections irrespective of the intended
vehicle usage.
Caution: The vehicle and trailer brake pipeline pressure should match.
Connecting brake pipeline:
1. Yellow adapter: supplies brake service line.
2. Red adapter: air supply to emergency / handbrake.
Disconnecting brake pipelines:
1. Disconnect the red adaptor for the dual pipe air supply. The trailer brakes will automatically deploy.
2. Disconnect the yellow adapters for dual pipes control pipeline. The trailer brakes will automatically deploy.
Caution: Be sure to operate in the above-mentioned sequence, otherwise, the trailer is without brakes and may roll away.
If fitted apply trailer park brake.

3.8 Speed Limiter

Speed limiter is a GPS based system, a warning buzzer sounds at 79 km/hr and engine power is reduced to idle at 85
km/h. Full power is restored when the vehicle speed is reduced to 79 km/h.

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3.9 Winter and Coastal Operations

3.9.1 Anticorrosion
- Open the drain valve of the air reservoir daily, to drain oil, water and foreign matter from the reservoir to avoid the inner
wall of the brake pipelines from rusting or perishing (refer to 3.1 for photo).
- Regularly clean the vehicle to remove corrosive matter that may contain salt. Keep the bottom, trailer hook, painted
parts and chrome-plated parts of the vehicle clean.
- During normal vehicle operations, inspect the brake, air and oil pipes for corrosion regularly.

3.9.2 Air Compressor

- The air dryer and pressure regulator provide drying and pressure regulation.
- The first dry barrel on the air dryer is filled with particle desiccant. The compressed air from the air compressor is dried
and filtered when it flows through the desiccant in the dry barrel.
- When the brake pressure rises to 8.2 bar, the pressure regulating valve on the air dryer opens automatically to drop
the pressure in the air reservoir.
- Water drops and foreign matter are removed by the desiccant from the air outlet and dryer.
- The above-mentioned process is repeated constantly to keep the whole brake system clean.
- Replacement of desiccant is done at specific services or annually.

MAIN TECHNICAL DATA

Item Data
Working pressure Maximum 8.5 bar – Minimum 6 bar
Working medium Air
Working temperature range -40ºC ~ +80°C
Current DC
Rated working voltage, power 24V, 100W
Dry Auto opening temperature +7°C ~ + 6°C
temperature Auto closing temperature +29°C ± 3°C
Weight 5.5 Kg

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4. LIST OF LUBRICANTS AND QUANTITIES

Component Filling Qty (L) Lubricant Specification Grade SAE
WP10.290E32,
WP10.290E32+PTO,
WP10.340E32, WP12.420E32,
24 API - CF 4
Engine Diesel oil SAE15W/40
WP10.340E32+PTO CH 4
WP7.270E30 20
8JS118TB+PTO 13
12JS160T 14.5
Transmission Gear oil GL 4 SAE80W/90
12JS200T+PTO 15
12JS200TA+PTO 15.5
Front Axle AR7-01DS 7.2
Gear oil GL-5 SAE 85W/140
(if driven) Hubs x 2 1.5 each
Differential
HL7/015
11.5
Rear axle Gear oil GL-5 SAE 85W/140
Hubs x 4 3 each
Middle axle HD7/016DGS 12 Gear oil GL-5 SAE 85W/140
Middle axle LLF200 8.4
Transfer case Gear oil GL-5 SAE 85W/140
VG1400-3W 7.5
Clutch 0.5 Brake liquid SAEJ1703 DOT 4
Clutch release bearing of sliding sleeve Effective grease NLG12
Front axle hub V14 0.3 each Multi-actionable grease NLG12
Battery terminal Terminal Paint
Washing device of wind screen 5 Water
WP7.270E30, WP10.290E32,
Cooling system WP10.290E32+PTO,
38 Coolant
Density of coolant 35-45% WP10.340E32, WP12.420E32,
WP10.340E32+PTO
3.8
Power steering system Auto transmission oil (ATF) Dexron II
5.8 (4035)
Drivers cab tilting pump 0.4 Auto trans-mission oil (ATF) Dexron II

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5. STANDARD TOOLS AND EMERGENCY MAINTENANCE PROCEDURES

5.1 Cab Tilting
Note: The cab must be tilted to the stop position.

Attention before the cab is tilted:

- Activate the hand brake.
- Set the transmission to neutral.
- Shut off the engine.
- All foreign objects such as tools and other loose items should be removed from the cab.
- Clean the area in front of the cab and gear lever for safety purposes.
- Open radiator grille.

Tilt:
- Day cab - use the pump lever to release the cab locking device at the back of the driver’s and co-driver’s seat (see
photo). Sleeper cab – behind passenger seat.
- Close all doors.
- Set the valve on tilt pump to the “tilt” position.
- Operate the tilt pump until the cab rolls to the stop position.

Returning cab to the normal position:

- Set the valve lever of the tilt pump to the “normal” position.
- Operate the tilt pump until the cab returns to the normal position. Once the cab is in the normal position, a reactive
force will be felt on the pump lever.
- Day cab - lock the locking device at the back of the driver’s and co-driver’s seat with the pump lever. Sleeper cab –
locks automatically.
- Push the gear lever forward until it locks into place.
- Set the lever on the pump in the neutral position.

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Neutral position

Stand clear of front of cab while tilting.

Note:
- The valve handle of the tilt pump should be in the neutral position while driving (as per photo).
- If there is no resistance force during a tilting operation, then:
Inspect the hydraulic oil level in the tilt pump.
- If there is too much resistance force during a tilting operating, then:
Inspect that the locking device of the cab is open.
Inspect that the valve lever of the tilt pump is in the correct position.
- If the hydraulic tilt device is faulty use auxiliary equipment (eg. crane) to tilt the cab.

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Day cab locking device is behind the driver and co-driver seat.

Sleeper cab locking device is behind co-driver seat.

Tilt pump:
 Pump lever (tools on board)
 Oil filler- oil level (use ATF oil)
 Return to driving position
 Tilt forward

5.6.4 Steering Wheel Lock

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5.2 Brake System

5.2.1 Tightening Torque Nm
- Tighten caging bolt to release brakes on boosters and loosen bolt to reapply brakes.
Caging bolt should be set to 40 – 50 Nm.
5.2.2 Brake Pipeline Inspection
- Regularly inspect the brake pipelines for leaks and ensure that the pipelines are in a sound condition.
- Replace any damaged pipeline section with a new part.
- If there is any evidence that the pipeline is bent, flattened or blocked, it should be replaced. This work should be done
under the guidance of the maintenance personnel or at a specified “Powerstar” workshop.
5.2.3 Brake Shoes / Linings Inspection
- The clearance between brake linings and brake drum are automatically adjusted (automatic compensation).
- Inspect lining thickness periodically through inspection hole of the bottom brake plate.
- The minimum thickness should be 5mm. If the lining is worn to the minimum thickness, replace it immediately.
This should be done under the guidance of the maintenance personnel or at a “Powerstar” workshop.
- Powerstar recommends the replacement of worn brake drums to ensure effective braking.
5.3 Spare Wheel Stowing and Removal
5.3.1 Tightening Torque Nm
- Use spherical washers and wheel bolts to centralise the position. Applicable to 1729 & 2635
- Tightening torque of wheel nut is 450Nm (Aluminium) / 550Nm (Steel)
5.3.2 Spare Wheel Position (If Applicable)
Spare wheel under vehicle chassis:

 Lock nuts
 Manual winch

- Turn winch lift until chain is tensioned.

- Slacken lock nut and pull out fixing bolt.
- Lower the tyre and support with the help of lift.
- Remove the spare tyre from the side or rear.
- Remove support.

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Spare tyre on the side of the vehicle chassis:

 Lock nuts
 Winch

- Operate winch lift until chain is tensioned.

- Slacken fixing nut.
- Operate lift to get spare tyre down, loosen the chain entirely.
- Remove the spare tyre from the side of the chassis.
- Remove fixing plate between wheel rims.

Spare tyre on cargo hull front (Tipper Truck):

 Spare wheel winch
 Locking bolt
 Locker

- Remove the locking bolt securing the wheel.

- Operate the winch to raise the wheel.
- Move the cantilever to move the wheel to the outside of the chassis frame.
- Operate winch to get the wheel down to ground.
- Slacken the locker to release the wheel.

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5.3.3 Wheel Replacement

Note: Attention should be given to the following points when a wheel is replaced:
- Tyre loading (PR level).
- Tyre pressure, refer to “Tyre Inflation Pressures”.
- Whether the wheels on vehicle and trailer are on same type of rims. (Attention: Wheels can be located by centre or by
spherical washer).
- A spare wheel located by spherical washer is suitable for both applications; therefore, the vehicle can be driven to a
service station for a wheel replacement.

Note:
1. Use chocks to prevent the vehicle from rolling.
2. Rear wheel sizes are to be matched left to right and front to rear drive axle to avoid damage to the differential. If this is
not adhered too premature differential failure will occur.

Front axle jack position:

- Place the jack beneath the corresponding front axle leaf spring.
- Do not place the jack beneath the differential (driven front axle).
NB: Chock the wheels which are not being
jacked.

Position of jack – Front axle Position of jack - Rear axle

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Rear axle jack position:

- Place the jack directly beneath the rear axle leaf spring. Do not place it beneath the differential housing.
- Do not jack against the S cam.
Pay attention to the following points when a wheel is removed:
- Slacken all the nuts on the wheel.
- Remove all the nuts except three in a triangular position before jacking vehicle.
- Remove these three nuts after you have ensured that the wheel is not supporting any vehicle load.
- Do not damage stud threads while removing/replacing the wheel.
- Coat studs with a thin layer of graphite grease to avoid “dry-grinding” with nut.

5.3.4 Air-inflating Tyre Connection

Four-circuit protective valve:

 Air-inflating connection

The air-inflating connection for the tyre is in front of the four-circuit protective valve.
Remove the protective cover before pressurising the reservoir. It is advised to apply
the foot brake pedal several times to reduce pressure in air system to about 6 bar
(600 KPa). With engine running, the maximum air pressure is 10 bar (1 000 KPa) for
air-inflating.

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5.3.5 Tyre Replacement (if applicable)

Clean rust spots and remove dust from the steel ring and stop ring by wiping the contacting surfaces with paraffin. Coat
the inner surface of the tyre and outer surface of the inner tube with talcum powder.

Note:
- Only wheels and tyres matching the vehicle type must be used.
- If the steering wheel shakes while driving after a tyre change, the cause could be a mismatched wheel combination or
unbalanced wheel. Contact your “Powerstar” service department to confirm wheel information.

5.4 Electrical System

5.4.1 Technical Data

Weichai starter output 24V – 5.4 KW

Battery 24 V – 135Ah
Battery (to be fitted in low temperature of -40°C 165Ah or 180Ah
Head-lamp H4/24V 75/70W
Parking lamp HL24V/4W
Turning signal lamp, brake lamp, reversing lamp, rear fog lamp P25 – 1/24V 21W
Tail light, license plate lamp, side marker, rear marker 24V/10W
Instrument indicator, brake pressure warning light, heating control illumination light 24V / 3W or 24 V /2 W
Instrument illumination light and warning switch indicator, lighting switch 24V . 2W or 24V 1.2 W
Internal illumination lamp, reading lamp LED

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5.4.2 Headlamp Adjustment

- The correct assembly and adjustment of headlamps is very important for night driving. A headlamp focus gauge should
be used to check the headlamp alignment. This inspection is carried out after 6 000Km or after a bulb is changed.
- Park the vehicle on even ground.
- All the tyre pressures should be equal.
- The left and right headlamp must be inspected separately. For this purpose, when one of the headlamps is inspected,
the other lamp should be covered.

Fully loaded vehicle:

- When the headlamp is 10 m away from the correction screen, the brightness cut off line of the lower beam should be
10 cm below the headlamp horizontal centre line.

Unloaded vehicle (with one driver, or with cargo of 75kg):

- Set the adjusting bolts to original position.
- When the headlamp is 10 m away from the correction screen, the brightness cut off line of the lower beam should be
30 cm below the headlamp horizontal centre line.

5.4.3 Bulb Replacement on Headlamps and Indicators

 Indicator lamp socket
 Parking lamp socket
 Headlamp socket
 Adjusting bolts
 Foglamp socket

- Unscrew protective cap.

- Remove wire socket.
- Replace the bulb by taking out the double-filament bulb with clip disc or twist and
release for indicator bulb.
- Replace indicator bulb.

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- Do not handle the bulbs with your bare hands.

- Always use gloves or thin paper.
- After fitting the lamp seat, the guide flange should be engaged with the convex-concave body of the reflecting bowl.
- Firmly connect wire plug of the headlamp.
- Install the headlamp and tighten screws.
- Check beam position of headlamp.

5.4.4 Additional Electrical Accessories

Take note of the following when additional electrical accessories are added:
- Do not add new electrical accessories without a fuse.
- Do not connect any wires parallel to the existing wires.
- Use a voltage adaptor to connect a 12V accessory.

5.4.5 Fuse
 Relays
 Fuses

- All terminals must be connected firmly and have a good contact. Attention should be paid to ground the negative
properly.
- Any damaged cables should be repaired by an approved agent.
- Do not repair or bypass the fuse(s).
- Carry spare fuses for emergencies. Use only equal value fuse. Do not use a higher rated fuse.
- Find the short or cause of overload before the blown fuse is replaced.
- Before carrying out electrical repairs, disconnect the negative terminal of battery.

Fuse functions are described in the cover of the fuse box as below.
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RELAYS
1 FLASHER 9 STARTER CONTROL (IF APPLICABLE) 17 SPARE
2 REAR FOG LAMP 10 STARTER (IF APPLICABLE) 18 HIGH/LOW GEAR (IF APPLICABLE)
3 FRONT FOG LAMP 11 LOW BEAM 19 COMPRESSOR AND CONDENSER
4 WIPER RELAY 12 AUXILIARY BLOCKING 20 HIGH BEAM
5 WIPER INTERMITTENT CONTROL 13 STEERING WHEEL LOCK D+ 21 TRAILER FLASHER
6 HOOTER 14 SPARE 22 PARK LAMP
7 SPARE 15 BRAKE 23 MULTI-POLE SWITCH RESISTANCE
8 STEERING WHEEL LOCK 15 16 SPARE

FUSES AMP AMP AMP

1 L/H HIGH BEAM 10 15 TRAILER ABS (IF APPLICABLE) 5 29 OPEN
2 R/H HIGH BEAM 10 16 SPARE 10 30 SPARE 25
3 DASHBOARD BATTERY POWER 15 17 CAB INTERIOR LIGHTING 7.5 31 STEERING POWER SUPPLY / INDICATORS 10
4 REAR WORKING LIGHT PLUG (IF APPLICABLE) 5 18 SPARE 32 AIRCON COMPRESSOR / CONDENSER 20
5 FRONT FOG LAMP 10 19 SPARE 33 DASHBOARD POWER 10
6 RADIO 5 20 L/H LOW BEAM 7.5 34 WIPER CONTROLLER 15
7 CIGARETTE LIGHTER 7.5 21 R/H LOW BEAM 7.5 35 DIAGNOSIS INTERFACE 5
8 AIR DRIER 5 22 FOG LIGHT SWITCH 5 36 REVERSE LIGHT/NEUTRAL 7.5
9 RADIO KL 15 CONTROL 7.5 23 DASHBOARD ILLUMINATION 10 37 SPARE
10 CLOCK 10 24 L/H AND R/H OUTLINE LAMP / L/H TAIL LAMP 10 38 ELECTRIC HOOTER 7.5
11 ABS POWER 15 25 R/H TAIL LAMP 7.5 39 INTERIOR FAN 20
12 STARTER BATTERY POSITIVE 30 26 TRAILER ABS POWER (IF APPLICABLE) 25 40 PRE-HEATING / ABS IGN 7.5
13 HAZARDS 15 27 REAR FOG LAMP 7.5 41 CHARGING INDICATOR 10
14 SPEED LIMITER BATTERY POSITIVE 5 28 RACOR FILTER (IF APPLICABLE) 42 BRAKE LIGHT 7.5

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5.4.6 Battery
Notice:
- To avoid short circuits do not place conductive objects on the battery.
- Gas evaporating from the battery is flammable. Therefore no smoking, naked flame or sparks are allowed near the
battery.
- When the engine is running, do not disconnect, remove or bridge the terminals of the battery.
Maintenance:
- Keep battery and surroundings dry and clean. When cleaning the battery make sure the filler plugs are sealed firmly.
- Do not clean the battery with gasoline, benzene, paraffin, or similar fluids.
- Keep the vent hole of the filler unblocked and ensure the vent port from one chamber to another is unblocked.
- Coat a thin layer of battery terminal paint on the terminals and surroundings to avoid corrosion.
- Regularly inspect the locking bolts on the negative terminal and tighten where necessary.
- For long term storage turn isolator on battery box off.

Note: See battery for terminal identification.

Electrolyte level inspection:

- Remove the cover to inspect electrolyte level. If a tester is used, the level of the electrolyte should reach the bottom of
tester otherwise the electrolyte should be higher than the upper rim of plates (by 10 - 15mm). Top up with distilled
water to prescribed level and replace the cover.
Electrolyte specific gravity inspection:
- Use an instrument to test the specific gravity. Standard specific gravity is listed.
- Temperature should be 15°C.

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5.5 Chassis Maintenance and Lubrication

5.5.1 Chassis Lubrication
- A grease gun with a lubricating pressure of less than 250 bar (25Mpa) should be used for lubrication.
- Do not use a grease gun without a safety unit, in order to avoid damage to bearings and oil seals during the course of
lubrication.
- Before lubrication, the lubricating connector and grease nipple should be cleaned thoroughly.
- Each universal joint should be lubricated regularly according to the service instruction. For a vehicle equipped with a
front driving axle, the universal joints are to be kept fully lubricated at all times. Inspect the grease seals on the front
axle universal joint and carry out adjustment/repairs.
- Special vehicles and special equipment should be lubricated according to manufacturer’s specifications.

5.5.2 Driving Shaft Lubrication

- Select a lithium based grease to lubricate the driving shaft through attached grease nipple. Do not grease excessively!

5.5.3 5th Wheel Inspection and Maintenance

Inspection:
- 5th Wheel and inspect for excessive wear or cracks on contacting surface.
- The lock and wear ring are not worn outside the permitted tolerance, lock for damages and cross bolt of the wear ring
is secure.
- The supporting seat bolts to connecting plate are tight and for cracks or damages.
- Rubber shock sleeve for damages. The method is to try and separate the portion between the 5th Wheel and
supporting seat with a crowbar. A large clearance indicates a worn rubber mounting.
- Specified lubricating points are greased sufficiently.
- The safety lock and lever mechanism operates normally without jamming.

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Maintenance:
 Lock hook
 Wear ring
 Interface
 Release Lever

NB: Use 5th wheel specific grease.

- The specified lubricating points of the 5th Wheel have been lubricated before a delivery. These points need sufficient
lubricating during a service. A thin layer of lubricant is coated on the contact surface.
- The vehicle should be separated from the trailer regularly (weekly) to perform the necessary maintenance on the lock
hook, wear ring and release lever. Clean dirt from the lock hook, wear ring, cross bolt and king pin. These parts will
deteriorate rapidly if not cleaned, apply new lubricant.
- Regularly clean contacting surfaces and trailer sliding plate. After cleaning, apply a thin layer of lubricant to contacting
plates.

5.5.4 Centralised Lubrication

- Vehicles equipped with centralised lubrication require regular inspections on the lubricating pipe lines.

5.6 Vehicle Washing and Maintenance

- Wash the vehicle with clean water.
- Before any maintenance, clean and inspect the chassis.
- After the vehicle has been washed with a degreasing detergent, grease the chassis, where applicable.
- Keep brake pipe lines free of paint, gasoline, benzene, kerosene, mineral oil, etc. and remove dirt with water. Avoid
contact between brake pipelines and grease or detergent when lubricating the vehicle. Note: Chemical reactions
caused by salt spray and grime deflected from the road during driving affect the life expectancy of the components at
the bottom of the cab and chassis.
- Damaged paint surfaces should be touched up with protective paint and rust-resisting paint to restrict further damage.

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5.7 Preservation Measures

Perform the following for a preservation period of 12 months:
- Wash the entire interior and exterior of the vehicle including the chassis, engine, engine compartment and vehicle body.
Lubricate all points. Store the vehicle in a well ventilated and dry place.
- Tyre pressure should be 2 bar (0.20Mpa) higher than the specified pressure. Do not expose the tyres to direct sun light.
- Check antifreeze.
- Change oil and oil filter.
- Check engine oil level.
- Drain condensed water from air reservoir.
- Seal air intake, exhaust pipe and ventilation holes.
- Inspect paint film is good condition. Repair damaged paint film where necessary.
- Spray rust-resisting material on chassis, engine and engine compartment. Where necessary, spray wax on painted and
chrome-plated parts.
Note: Only wax and rust-resisting material, which is approved by “Powerstar” technical service department, can be used.
- Place wheel chocks to prevent the vehicle from rolling and release the hand brake.
For a vehicle with mechanical transmission:
- Disengage clutch.
- Disconnect battery or remove.

Periodical maintenance for a battery not in service:

- Apply acid-resisting grease to battery terminals. The battery should be charged once a month, or trickle charged in the
long-term with a current of 0.06 A.

Discharge and re-charge battery every three months:

- Inspect electrolyte level is between minimum and maximum.
- Even if maintenance has been carried out perfectly, the life of battery remains limited.

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5.8 Stored Vehicle Re-commissioning

Precautions before using:
- Inspect tyre pressure according to “Tyre Inflation Pressure”.
- Check tension on v-belts. Multi-groove/rib belt is auto tensioned.
- Release clutch locker.
- Remove all covers from air intake, exhaust pipe and ventilation holes.
- Inspect oil levels on steering gear, transmission and drive axle/s.
- Drain engine oil and replenish with oil approved by “Powerstar” technical service department.
- Use only specified removal detergents to remove the wax from the painted surfaces.
- Inspect antifreeze.
- Connect battery terminals.
- Start engine and inspect oil pressure and pipelines for leaks.
- Inspect all electrical functions, air conditioner and auxiliary heater.
- Inspect brake system function.

6. TOWING AND RECOVERY

The front towing hook is used to move or tow the vehicle. Where possible, the towed vehicle’s engine should run to
activate the power steering and air pressure of the brake system.

Note: Should the air pressure in the brake system be insufficient, the spring brake cylinder can be released by mechanical
or pneumatic means. Care should be taken when a vehicle is recovered from soft or muddy territory especially when it is
heavily loaded. The vehicle should be gradually recovered. Avoid towing or recovering the vehicle in a diagonal direction
to prevent damage to the chassis. Detach the trailer from the horse before towing. Recover the vehicle by hooking the rear
of the vehicle.

Engine not running:

- Set transmission to neutral.
- Set transfer case to highway driving position for all wheel driven vehicles.

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Vehicles equipped with 8JS 118TB:

- Place the gear lever between gears 5 and 6. If the gear (H) indicator on the instrument panel remains off, the drive
shaft between the drive axles should be removed.
- Towing speed should not exceed 60km/h.
Towing distance exceeding 100Km:
- Before towing the vehicle, remove the drive shaft between the drive axles.
Rear axle fault:
- Remove both drive shafts.
Note:
- For vehicles fitted with a differential lock, engage the differential lock (horizontal) before removing driving shaft.
- Double driven rear axles: Both rear axle drive shafts should be removed.
- All wheel drive vehicle: Remove the drive shaft between rear axle and transfer case.
Rear axle HL7.HD7:
- Remove the oil drain plug from the reduction gear hub and collect runoff.
- Remove outer cover from the reduction gear hub.
- Remove the spring clip ring with Circlip pliers.
- Remove the half shaft by using a special tool or a M8 bolt 120mm in length.
- Refit the outer cover.
If the towing distance is more than 100Km, fill the reduction gear hub with clean oil.

Rear axle HL7,1 spring clip ring Rear axle HL7.HD7 with driving shaft removed

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7. ENGINE OPERATION, MAINTENANCE AND REPAIRING

7.1 Dust Separator Valve Maintenance

- Remove dust from dust separator valve regularly (1). It should be maintained
once a week if it is used in a dusty environment. In severe conditions, it should be
cleaned daily.
- Squeeze the rubber-bellow to expel the dust (2).

Air cleaner
7.2 Composite Bowl Maintenance (fitted behind air cleaner housing cover)
- The composite bowl air filter should be maintained regularly.
- Slacken butterfly nut.
- Remove and clean composite bowl and cover.
- Install composite bowl and cover.

7.3 Air Filter Element Cleaning and Replacement

- Remove and clean housing cover.
- Slacken lock nuts and remove filter element.
- Clean the air cleaner housing, gasket and seal.
- The filter element cannot be cleaned but should be replaced as prescribed in the “Powerstar” service schedule. The
service life of the filter is shorter in a dusty environment.
- Replace housing cover.

7.4 Fuel System

7.4.1 Draining Water from Watertrap and Diesel Filter
Water draining:
- Place a fuel collecting pan under the coarse filter.
- Slacken the fuel drain bolt and observe the draining liquid. When only diesel flows out, tighten fuel drain plug.
- Inspect engine while idling.

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7.4.2 Air Bleeding from Fuel System

- Air in the fuel system is caused once all the fuel in the tank is consumed, or when the vehicle is not used for extensive
periods. Use the manual fuel pump to perform air bleeding after filling the tank and prior to starting the vehicle.
Air bleeding of diesel coarse filter:
- Ensure Raycor filter is primed.
- Place a fuel collecting pan under the diesel coarse filter.
- Slacken bleeding bolt.
- Operate hand fuel pump to bleed air until air bubbles disappear and diesel flows out.
- Tighten air bleeding bolt (with tightening torque of 15Nm).
- Inspect engine while idling.
7.5 Cooling System
7.5.1 Cooling System Maintenance
A defective cooling system can affect the power and oil consumption, reliability and service life of the engine. In order to
ensure a good cooling system, regular maintenance should be carried out.
Only coolants recommended by “Powerstar” should be used. In emergency situations, clean soft water, like rain water or
spring water and river water. The vehicle must be taken to a service agent to have the cooling system flushed.
- During the service process, pay attention to the cooling water temperature and top up if required.
- Check the tension of the drive belt to avoid slipping.
Regularly grease the water pump and the bearing of the tensioner with a hand pump.
- When the ambient temperature drops below 5°C, antifreeze should be added to the coolant. When antifreeze is not
available, completely drain the engine and radiator after the vehicle has stopped.
- Back flush the radiator core with a hose pipe, with water pressure not exceeding 2.5 bar.
7.5.2 Seed Screen
1. Remove screen by lifting.
2. Clean screen by blowing with compressed air.

Note: Do not wet. Clean between once a day and once a week depending
on severity of operating conditions.
7.5.3 Service Precautions
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1. Auto tension adjusted.

2. The bearing of the water pump and tensioner pulley should be lubricated after 250 hours operation with a calcium
based grease. Do not over grease.
3. The reliability of the water pump depends on the water seal. Inspect the water pump for signs of leakage. If leakage
occurs (usually no leakage occurs during running but while stationary), the water seal may be damaged and needs to
be repaired or replaced. Contact “Powerstar” technical service department for repairs.

8. TYRE INFLATION PRESSURES

Pressure of tyre (Unit: Bar)
Size of Tyre
Single wheel Double wheel
315/80R22.5 8 7

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9. TROUBLESHOOTING
Category Problem Solutions
Clutch Clutch slipping There is oil on the clutch disc, or the clutch is worn. Ask your service station to repair / replace it.
Clutch fails to disengage completely There is air in the hydraulic system. Inspect the seal status of the system, top up the hydraulic
fluid in reservoir and bleed air (see section 3.1).
Steering Noise in power steering There is air in the hydraulic system. Inspect seals, and top up steering fluid (see section 3.1 and
4).
Turning is not smooth or jerks Steering fluid is insufficient. Inspect seals, and top up fluid (see section 4).
Wandering - Steering gear has excessive clearance. Send to service station for repair.
- Air pressure of tyres are insufficient. Inflate the tyres as prescribed (see section 8).
Brake While driving, the warning indicator comes - Warning: Stop immediately!
System on - No or poor braking: Observe reading on circuit pressure meter. Inspect brake system for
leakages.
No / poor braking No air pressure. Observe circuit pressure meter and increase air pressure by raising the engine
revolutions. Inspect the brake system for leaks. Inspect the pressure regulator and air
compressor. Ask a service station to repair.
Brake effect is uneven Tyre(s) is worn or damaged. Replace tyre(s) (see section 5.3.5).
Air supplied by the compressor is Inspect the air compressor unit function.
insufficient
Pressure regulator discharges frequently Replace pressure regulator or send to service station for repair.
Air compression system leakage Inspect system and seals for leakage. Ask service station to repair if detected.
Fails to release hand brake - There is no or insufficient air pressure in the hand brake pipelines. Inspect system for leakage.
- It is recommended to release the spring energy storage diaphragm cylinder by means of the
mechanism or pneumatic method in case the vehicle needs to be towed.
Electrical Starter fails to work Battery is discharged or faulty, charge / replace the battery (see section 5.4.6.) or check the
System starter motor.
Terminal clip of battery is slack or Clean the terminal and coat it with acid-resisting grease and tighten the terminal clamp (see
corroded section 5.4.6).
Charging indicator lamp remains off (when Bulb is faulty, replace the bulb.
ignition is switched on)
Wire is broken Repair connector or replace the wire.
V belt is slack or broken Check tension or replace.

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