Technical training of New Model –N800

Chassis
 Content

1 N800 Overview

2 Chassis Technology

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 Overview
N800 series medium-body

Long Base 3360（Large-

Wheelbase Short Base2750 Long Base 3360
tonnage）

Single KingC Double

Cab Pattern Single Cabin King Cabin Double Cabin Single Cabin King Cabin Double Cabin
Cabin abin Cabin

Length（with the container） 5350 5980 5980

width（with the container ） 2020 2020 2130 2020 2130 2020 2130 —

Height（with the container

2987 2988 2986 2986 2981 2981 2980 3060 2979 3059 2973 3053 — — —
no-load）
SIZE
Approach Angle(°) ≥19 ≥19 ≥19

Departure Angle(°) ≥17 ≥17 ≥15.5

Min Turning Diameter（m） 10（independant）/10.8Non-independant 13 13.5

Min Ground Clearance Independent 175；Rigid axle suspension183 183 —

CAPAC
Seat capacity 3 6 3 6 3 6
ITY
kerb weight(kg) 2610 2620 2635 2645 2745 2755 2735 2760 2875 2810 — 2910

payload(kg) 2195 2685 2170 2660 1865 2355 3070 3045 2735 3700 — 3400
MASS
Total load(kg) 2390 2880 2365 2855 2255 2745 3265 3240 3125 3895 — 3790

Gross vehicle weight (kg) 5000(Independent)/5500(Rigid axle suspension) 6000 6705 — 6700

TANK Volume(L) 65 100 100

Front
Non-independant
suspe Form Inde Non Inde Non Inde Non Non-independant
nsion

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 Overview
Inverting & Locking Device
Front cab FRT Inverted support ASM

torsion bar spring

self-locking handle

inverted
supports
Rear cab

rod; locking
hook

bracket;
turning bar lock limit handle
handle

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Chassis Technology

1 Driving System

2 Steering System

3 Transmission System

4 Braking System

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 Driving System
1、Front suspension

Spring;FRT

FRT; shock
absorber

Overhang
limit

front axle

stabilizer
bar

Non-independent suspension
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 Driving System
Front suspension is of the independent suspension structure, which contains the
integral front axle, leaf spring, stabilizer bar
(improve steering performace) and limit block(prevent the clash of the frame from
the leaf spring), double cylinder gas shock absorber

1.1 Front Spring

Front spring: variable stiffness characteristics

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 Driving System
1.2 FRT stabilizer bar

Function: Prevent excessive lateral tilt when the body is turning and avoid overturning,
also improve driving comfort.

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 Driving System
2、Rear Suspension

rear shock
absorber

Rear limit
block

rear leaf
spring

Form of rear suspension: non-

independent suspension
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 Driving System
The rear suspension is of non-independent suspension structure, which contains
the integrated rear axle, leaf spring, stabilizer bar(improve steering performace)
and double cylinder gas shock absorber.

2.1 Rear Leaf Spring

Rear leaf spring

Main & sub springs: 2 stiffness stages characteristics

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 Driving System
3、Front wheel alignment angle

γ：kingpin caster angle α：camber angle β：kingpin inclination

angle

A—R： toe-in

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 Driving System
3.1 Front wheel alignment parameter

2750 wheelbase non- 3360 wheelbase non-

Alignment parameter
independent suspension independent suspension

camber angle 0º15´±30´ 0º15´±30´

toe-in(mm) -2～2 -2～2

kingpin caster angle 3º±1º 3º±1º

kingpin inclination angle 12º±30´ 12º±30´

When the vehicles deviate or abnormal wear trace appears in tire, driving performance is b
ad, and the kingpin caster Angle, wheel camber Angle or toe-
in tested are too much different with the standard after the four-wheel alignment, only toe-
in can be adjusted, it is required to replace relevant parts to change other parameter.

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 Driving System
3.2 Toe-in adjustment

Adjust the of toe-in through turning the tie rod

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 Driving System
3.3 Tyre

Torque

Wheelbase 2750 3360 3360(large-tonnage)

wheel hub 6JJ×16 6JJ×16

Tyre model 7.00R16LT-10PR 7.00R16LT-12PR 7.50R16LT-14PR

 Steering System
1、Steering System
steering
wheel

Steering
Column

steering
gear

rocker
arm

drag link

power steering oil pipe Power Steering Pump oil tank

Steering system is re-circulating ball type with hydraulic power steering.

Power steering fluid, type : PSF1982 (or ATF) ; Volume:1.5L ;
Free gap: 20°
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 Steering System
1.1 Steering gear & linkage
input shaft
inlet tube

outlet tube

steering gear

pitman arm

output shaft

drag link

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 Steering System
1.2 Steering linkage

knuckle

steering
curved
arm

FRT axle tie rod steering arm

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 Steering System
1.3 Steering column

Adjustment
Equipment

Steering
Column

Height of steering wheel is adjustable, and the anti-theft device is included in

steering gear.

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 Transmission System
1. Clutch system
1.1 Clutch
pressure
flywheel clutch disc
plate

Diaphragm Type spring system

Diameter of clutch： 278 mm
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 Transmission System
1.2 Operated clutch arrangement
inlet tube

Master Cylinder

pedal & bracket ASM

gearbox Wheel Cylinder

release Release fork

bearing

dust cover
clutch tube

Cable-operated control structure，clutch gap is auto-ajustable Clutch master

cylinder free path is 10-15mm
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 Transmission System
2. Transmission parameter
Item Parameter

Model of gearbox 6MTI420

Rated torque 420N*m

Distance between shafts 99 mm

1st gear 5.979

2nd gear 3.434

3rd gear 1.862

Speed ratio
4th gear 1.297

5th gear 1

6th gear 0.759

Reversed gear 5.701

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 Transmission System
Maintenance schedule: maintenance-free during use
Transmission fluid : type GL5 80W-90 Volume : 3.7L

2.1 Transmission gear arrangement

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Transmission System

5th 4th 3rd 2nd 1st reverse

gear gear gear gear gear gear 6th gear

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 Transmission System
2.2 Gearbox
1）Left Side View
pin housing bolt housing control cover locating ball Reverse light odometer joint parking
switch brake bolt

side cover of rear

side cover idler gear hole cover

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 Transmission System
2）Right Side View
Cable; Cable; Shift
cable clamp bolt Selection

Refill plug
drain plug drain plug

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 Transmission System
3）Internal Structure

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 Transmission System
Item Description Item Description Item Description

1 input shaft 13 1st gear 25 plate

2 bearing 14 R/1 synchronizer 26 6th synchronizer

3 bushing 15 R/1 fork 27 6th gear

4 1/2/3/R gear shifter shaft 16 reverse gear 28 conical bearing

5 4/5 fork 17 step ring 29 Reverse idle gear

6 4th gear 18 bearing 30 idler shaft

7 1/R block 19 6th gear 31 Countershaft

8 Interlock plate 20 odometer driving gear 32 2/3 dual gear

9 3th gear 21 needle bearing 33 4/5 synchronizer

10 2/3 fork 22 bushing 34 4/5 dual gear

11 2/3 synchronizer 23 oil seal 35 magnet

12 2nd gear 24 2nd shaft flange 36 conical bearing

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 Transmission System
4）Input shaft

Joint bearing Bearing bearing Snap ring

Input shaft Snap ring
ring bushing

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 Transmission System
5）Output shaft

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 Transmission System
Item Description Item Description Item Description

1 bolt 12 BRG; Needle 23 BRG; Needle

2 Flange nut 13 reverse gear 24 4th gear

3 O-RING 14 reverse gear ;joint ring 25 3rd gear

4 FLANGE; 2ND SHAFT 15 R/1 Synchronizer 26 BRG; Needle

5 bushing 16 1st gear joint ring 27 3rd gear joint ring

6 Drive Pinion; Odometer 17 1st gear 28 2/3 Synchronizer

7 6th gear 18 BRG; Needle 29 2nd shaft

8 bearing; 2nd shaft 19 snap ring 30 bushing

9 Thrust washer 20 4/5 Synchronizer 31 BRG; Needle

10 thrust; ring 21 joint ring 32 2nd gear joint ring

11 bushing 22 retainer 33 2nd gear

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 Transmission System
6）Countershaft

Thrust
washer Joint
4/5 dual 2/3 dual cone
bearing Adjustment bearing ring
gear gear Countershaft bearing bushing
sheet 6th gear

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 Transmission System
7）Reverse idle gear
Idle shaft Bracket; Needle Idle gear

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 Transmission System
8）Synchronizer ASM

Steel ball

spring

Guide block

1/2/3/R
gear hub

1/2/3/R
gear sleeve

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 Transmission System
9）Triple-cone synchronizer
Synchronizer Inner ring MD ring Outer ring Joint ring Gear

1/2/3 gear is with triple-cone synchronizer in order to reduce the shift force
between gears( while 4/5/6/r gear is with one-cone synchronizer)

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 Transmission System
10）Self-locking & interlocking
Interlocking locking ball
plate

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 Transmission System
11）Gear selecting & shifting mechanism

Gear selecting
cable

Gear shifting cable

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 Transmission System
Gear selecting mechanism rotating
Gear selecting
arm
shaft

Gear selecting & shifting pin

6 gear shift fork
4-5 gear shift fork (neutral position)
2-3 gear shift fork
R-1 gear shift fork

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 Transmission System
Gear shifting mechanism
rotating
Gear selecting arm
shaft

R-2-4-6 gear 1-3-5 gear

Gear selecting & shifting pin

circle around the rotation
shaft and make gear shift as
the direction of arrow

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 Transmission System
3、Transmission shaft
3.1 2750 wheelbase

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 Transmission System
3.2 3360 wheelbase

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 Transmission System
4、Front & Rear Axle
4.1 Front Axle
Wheel hub bearing Oil seal knuckle kingpin

Front axle

bolt
Adjustment
gasket

bushing bearing

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 Transmission System
4.2 Rear Axle
Rear axle
Oil refilling Vent Plug
plug & gasket

Oil drain plug &

gasket

Rear
Gear ring brake

Inner oil seal Wheel speed

Inner bearing sensor
Brake drum
Half shaft
Wheel hub
Outer oil seal Outer bearing Main
washer Nut BRG reducer

Full-floating rear axle, gear oil: API GL-5 80W-90, volume: 3.4L, first change at 3000 km, and then change
every 24000 km.
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 Transmission System
4.3 Main reducer & Differential
Planet gear Main reducer
Bearing housing
gasket
cover
bearing Adjustment nut

Gear shaft
gasket Half shaft gear

Snap Ring Guide

bearing clip
Guide bearing Clip bolt
sleeve
Adjustment gasket
Drive & driven pinion
Outer bearing
Inner bearing
Dust Proof
O-ring flange
Differential housing Bearing nut
seat Oil seal

Main reduction ratio: 4.875

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 Transmission System
Main reducer adjusting requirement

1）The backlash of drive &driven gear after adjustment is 0.18～0.23mm。

2）The correct position of contact spot after adjusting drive &driven gear
is as follow:
Front side: it is close to the middle of the gear flank, and 2-5mm distance
to the small side of the drive gear, contact length is no less than 50%
Reverse side: it is close to the middle of the gear flank, contact length is
no less than 40%, and contact width is a half of the gear width.
3）When the oil seal is installed, coat a little grease on the bearing
before the drive gear and driven gear get engaged. The pre-tightening
torque of the bearing is 0.98～ 1.96N.m after the differential installed.

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 Transmission System
1、Braking System
Vacuum Master
Booster pedal ABS
cylinder Parking Brake

Vacuum Release
container Front brake handle Rear brake

Hydraulic brake, vacuum booster, ABS, double circuit diagonal arrangement and drum brake.

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 Braking System
2、ABS
2.1 ABS Arrangement

4 speed wheel sensors, 4-channels arrangement. ABS locates in front of the

frame.
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 Braking System
2.2 Wheel speed sensor arrangement

Front wheel speed sensor Wheel speed sensor Front gear ring

Gear ring

Rear axle wheel speed sensor

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 Braking System
3、Braking booster / master cylinder

Master cylinder &

vacuum booster

Vacuum
Vacuum tube
reservoir Connecting with vacuum booster

Braking master cylinder: series-longitudinal design to guarantee mutual

independence for both braking circuit.

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 Braking System
4、Front & rear brake
4.1 Front & rear brake structure
front brake rear brake

Brake disc Brake

Brake Wheel Gap adjustment Front wheel disc
Rear axle Gap Brake Wheel speed
cylinder speed equipment gear ring gear ring adjusting cylinder sensor
sensor
equipment
Dual two leading shoe brake
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 Braking System
4.2 Brake gap adjustment
Manual adjustment of brake gap for the 1st time:
1）Hold up the wheel, and make it completely
off the ground
2）Take down the rubber plug from the rear
regulation hole of the braking plate
3）Insert the screwdriver into the regulation
hole, and twist the little gear in the direction
shown by the arrow till the wheel stopped
4）Press on the rubber pushrod near the
regulation hole (important), and turn the
regulator back by 5-9 notches (general brake gap
to 0.25～0.40mm ).
5）Repack the rubber plug.
Rubber pushrod
Self-adjusting while the brake shoe
gap is too large

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 Braking System
4.3 Brake gap adjusting equipment

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 Braking System
5、Parking brake
5.1 Operated mechanism
Parking brake
handle

Adjusting nut

cable pre-stressed centre

brake
Signal
joint
cable & pipe
ASM

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 Braking System
5.2 Actuating mechanism
Brake drum
Return
Brake spring
shoe
Brake
Supporting arm
plate
Extension
spring
Compressed
spring & cover
Adjusting
bolt

Braking plate

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 Braking System
6、Exhausting brake

Switch; exhausting
brake

Signal; exhausting
brake

Operating conditions:
（1）Engine speed reaches to 1100rpm
（2）No stepping on clutch pedal or accelerator
pedal
（3）Ensure the gear position is in low gear (1-3th
gear) JMIE
 Braking System
Exhausting brake

Exhausting brake; Exhausting brake; Vacuum

throttle valve Electromagnetic valve

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