Zhejiang Xinyang XY300 Operating Instruction

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300 Utility Vehicle

Operating instruction

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Summary of Contents for Zhejiang Xinyang XY300

Page 1 300 Utility Vehicle Operating instruction...
Page 2 Table of contents (First revision in 2007) If this specification is reviewed, please forgive we will not notice. Notices Technical parameters Placement drawing for whole vehicle Inspection before driving Driving operation Running-in of new vehicle Maintenance and repair VIII Trouble diagnosis and elimination Screwing moment of important bolts Specification and dosage table for fuel, Lubricating oil and brake liquid Circuit diagram...
Page 3 I Notes Please read this operating instruction carefully before using this vehicle, and drive, check and repair it by the requirement in this manual to keep vehicle at good technical status and prolong its using lifetime. Initial running for 1000km of vehicle is period. In this period, it is necessary to accord with the regulation of period(see the chapter—for new vehicle).
Page 4 (I) Common technical data 1 Mass parameters(kg) Mass of whole equipments(not including driver) 540Kg Front shaft 240Kg Rear shaft 300Kg 2 Dimension parameter(mm) Total length total width total height:2630 1230 1890 Minimal clearance apart from ground Wheelbase 1800 Tread front wheel 1058 rear wheel 1070 Approach angle(°) 60...
Page 5 Idling speed (r/min) 1500±10% Ignition type TCI digital Start type electronic start Fuel category RQ-93 lead-free gasoline Lubricating oil category SAE 15W—40 Engraved position of factory number Upper surface on rear part of left crankcase Ignition ahead angle(°/r/min) 10/1500 32/1500 Lubricating type Pressure and splash lubricating type Engine oil pump type...
Page 6 300Kpa 7. Steering organization Adopt gear rack type redirector, transmission rate: 18 1;total circle number of steering plate 3.75 total swing angle of steering wheel 75° 8. Arrester Running arrester adopts front and rear placement dual-pipeline hydraulic pressure brake system, front and rear wheels adopt drum type arrester. And parking arrester adopts mechanical transmission organization to work on rear wheels.
Page 7 III Placement drawing for whole vehicle 1 Engine hood 2 Indicator 3 Front headlight 4 Bump 5 Front tyre 6 Seats 7 Safety Belt 8 Side board 9 Fuel tank cap 10 Rear fender 11 Goods box 12 Reinforce pole 13 Head Rest 14 Top cover 15 Steering Wheel...
Page 8 Side drawing for engine 1 CTV case 2 Oil intake of gear case 3 Flange of transmission shaft 4 Generator 5 Carburetor 6 Starter 7 Idling speed electromagnetic valve 8 Spark plug 9 Oil intake of engine...
Page 9 VIN code position Engine and rear suspension Oil intake of engine Engine oil dipstick Warning Engine oil quantity should be between upper and lower position, over more or less oil would burn out or damage engine. Oil drain plug of engine under the engine Intake of gear case Warning Oil drain plug of engine should be tightened otherwise engine would burned...
Page 10 Warning it is very dangerous to unscrew radiator when engine is hot for steam and water will spurt by the pressure to hurt people at this time. It is necessary to unscrew radiator cover after engine becomes cool. Warning: Please fill up the brake liquid according to the stipulated trademark and type.
Page 11 IV check before drive 1 Check the leakage contain of engine,such as oil cooling fluid fuel lube and so on should have no leakage. 2 Check the height of engine oil, brake liquid and cooling liquid, if necessary, add some. 3 Check the air pressure in tyre.
Page 12 V Driving operation 1. Safety driving notes for farmer vehicle To guarantee your driving safe, please accord with following items —Tie safety belt— Safety belt could avoid you are thrown out of vehicle when happening sudden swerve and accidents, and guarantee running safe effectively. —Inspection before driving —...
Page 13 Meter ‹ Speedometer 4 show running speed for its structure, it will show running speed when stepping down accelerator pedal on neutral position . Odometer 8 show accumulated running total mileages for its structure, it will show accumulated running total mileages when stepping down accelerator pedal on neutral position .
Page 14 When ignition switch is at “ON” position and lamplight main switch is turned to “ ”position, front headlight and rear small light are lightened. When ignition switch is at “ON” position and lamplight main switch is turned to “ ”position, press down lamplight main switch handle, headlight changes to far light from close light;...
Page 15 Press down loudspeaker button on steering wheel (anyone of these two), loudspeaker will hoot. Accelerator pedal and brake pedal At the front of driver’s right foot, the left is brake pedal, farmer vehicle will start or accelerate by stepping it when shift handle is at “D” position or “R” position.
Page 16 Good box overturn roof and self-saving winch When it is necessary to over turn cargo box to discharge good, at first, open the rear door of cargo box, then open towing and turn main switch to position, and press down TRAILER conversion switch on the upside of instrument, at this time, cargo box will over turn backwards;...
Page 17 VI Running-in of new vehicle Cooperation between the surfaces of each part of new vehicle is locating adjusting and running-in phase, for surface friction of each part is big, the result of running-in quality influences greatly using lifetime of farmer vehicle. In running-in period, please implement strictly the regulation about speed limit, load limit and periodic maintenance to reduce 1.
Page 18 transmission organization and fixed equipment. 6. First maintenance of vehicle In running-in period, after running for 1000km, it is necessary to complete first maintenance, maintenance details could refer to “Maintenance and repair”. J 3 $ J 3 < s I . Warning First maintenance is necessary to implement best performance of farmer vehicle, prolong using lifetime and insure safe.
Page 19 Transmission Whether the bolts, flange organization nuts on transmission shaft and the bolts on main driver are tightened. Lamplight Illumination and signal Every kind of lamplights, signal switches buttons, etc Battery Liquid height in storage Liquid surface should be cell(except between upper and lower maintenance-free battery) limit...
Page 20 brake performance Tyre Air pressure, thread, crack Tyre air pressure front and wound wheel 0.25Mpa rear wheel 0.3Mpa Thread depth no less than 1.6mm Lamplight Illumination, signal Every kind loudspeaker lamplights, signal switches and buttons, Battery Liquid height in storage Liquid surface should be cell(except between...
Page 21 Brake liquid Change once every one and half year Brake Check Check — Steering organization Check Check — Accelerator drag wire Check Check — Brake pedal free travel Check Check — Carburetor Check Check — Tyre Check Check — Spark plug —...
Page 22 Front rear axle — Check — suspension Note Period maintenance term takes the first reached value of mileage and time as standard. Inspection in table includes: if necessary, it is necessary to make further wash, lubrication or change. shows no requirement. VIII Malfunction analysis and elimination I Engine malfunction Malfunction...
Page 23 Start 2. Electric There many Eliminate accumulated ‰ difficultly or accumulated carbons on carbons and use gasoline system could not start spark plug to wash Change spark plug Change Insulation body of spark Š plug has been damaged. Change Ignition loop has been ‹...
Page 24 4.Transmission part Surpassing clutch has been Adjust Carburetor ‰ and others damaged Repair or Change Start electric engine has Š Change been locked Repair or Change Other machines locking ‹ malfunction, such Repair linking pole big head or gear Adjust High -pressure wire...
Page 25 Engine works 1. Circuit High -pressure wire Change ‰ abnormally ignition loop leaks electricity Unblock Ignition contacts badly Š Eliminate accumulated There many carbon ‹ accumulated carbons between Change electrodes of spark plug TCI has been burned or hit 2. Air routine valve clearance Adjust...
Page 26 Engine is too 1.Heat radiation Radiating sheet of cooler Remove ‰ condition is bad has oil stain and sand Check, repair and supply Cooler or water pipe leaks cooling liquid Š water Use soft water cooling Corrode, kettle and cooling liquid or Change ‹...
Page 27 5.Lubrication is bad Lubricating oil does not Change ‰ accord with requirement Add engine oil Oil quantity is short Š 6.Others Muffler has been blocked Wash Gasoline 1.Fuel system Fuel is used out Add oil ‰ engine stops happens routine been Eliminate Š...
Page 28 II Malfunction in transmission system Vehicle speed Transmission Shift belt slips Change ‰ does system Speed adjusting plat Change Š increase abrasion is too much engine speed Repair or Change Speeding adjusting plate ‹ Repair or Change slipping is blocked Spring force of adjuster is short Out of gear...
Page 29 leaning parts have been loosened, bent or damaged Tyre Steering Left and right absorber has Adjust or Change ‰ abraded organization, been damaged, spring force abnorma running system, is short suspension Change Tyre is not balance, and Š greatly wheel hub is distorted Check or adjust Front wheel location is ‹...
Page 30 Tyre has tympanic bag Steering Free travel of redirector is Check adjust organization, too big Front wheel running system shakes, swing Fixed bolts on each part of Change tyre or wheel hub or jump steering organization has been loosened Change tyre Change or adjust Fasten Steering...
Page 31 damaged or leaks oil Brake liquid is short Brake pipeline has air Eliminate air Arrester is too hot Repair or Change Brake Brake system Some brake drums and Clean or Change ‰ leaning suspension hoofs have oil stain Gap of brake drum and Š...
Page 32 Brake clip Parking brake drag line Lubricate or Change block could not return Repair or Change Brake branch clip block asion of brake drum Change and brake hoop is too big, and clearance is too great Brake pipeline has been Change concaved V Malfunction in lamplight, circuit and instrument system...
Page 33 Starter does Starter has been damaged Repair or Change ‰ rotate Starting relay has been Change Š when starting damaged Grounding of starter is bad ‹ Repair Ignition switch has been Change damaged electric Circuit system Total fuse has been bur Check and Change ‰...
Page 34 IX Screwing moment of important bolts Sequence Item Quantity Thread diameter Torque Nm number Nuts of cylinder head Spark plug Adjusting nuts valve clearance Fixed bolts camshaft chain wheel Bolts of chain adjuster Fixed nuts crankcase combination Fixed nuts of left cover of crankcase Nuts magnetoelectric...
Page 35 Nuts on lower swing bottom 90 N m head Bolts on lower swing M10 35 55 N m bottom head Bolts on front absorber M12 60 95 N m across bar Nuts on front absorber 25 N m Screws in fix winch M8 16 25 N m Screws in fix brake main...
Page 36 Bolts on hand brake M8 20 28N m Bolts on bumper M10 20 50N m Bolts on fuel tank M8 20 28N m Bolts on transmission M8 25 30N m X Specification and usage quantity for fuel, lubricating oil and brake liquid Category Specification Capacity...