Operation and Maintenance Manual: JST Series

JST
Series
OPERATION AND
MAINTENANCE MANUAL
Page 1/100
JST OPERATION AND MAINTENANCE MANUAL 20100610.doc
Updated 6/12/2010
JST
Series
CHAPTER 0:
INTRODUCTION
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Updated 6/12/2010
JST
Series
This manual covers operation and maintenance information for the JST. It is to be used
as a guide to operators and maintenance personnel for use and care of this equipment. This
manual should be read before attempting to operate or repair this equipment.
This manual follows the guidelines set forth in Air Transport Association Specification No.
101. Arrangement of information corresponds to this accepted format. Page numbers run
consecutively within each chapter. Pages are identified in the lower corner of each page with
chapter number, section number, page number within that section, and the date of publication or
revision.
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SECTION 1 TABLE OF CONTENT
JST
Series
CHAPTER 0: ________________________________________________ 2
INTRODUCTION ____________________________________________ 2
SECTION 1 TABLE OF CONTENT________________________________________4
SECTION 2 RECORD OF REVISIONS_____________________________________6
SECTION 3: TLD SALES INFORMATIONS ________________________________7
SECTION 4: GENERAL WARRANTY CONDITIONS _________________________8
SECTION 5 GENERAL WARNING _______________________________________10
SECTION 6: INFORMATION AND OPERATION___________________________13
CHAPTER 1. _______________________________________________ 17
GENERAL INFORMATION & OPERATING INSTRUCTIONS _____ 17
SECTION 1: MAIN COMPONENTS ______________________________________18
SECTION 2: OPERATING PROCEDURE _________________________________24
SECTION 3: SPECIFICATIONS AND CAPABILITIES _____________________36
SECTION 4: SHIPPING PROCEDURE __________________________________40
SECTION 5: STORAGE PROCEDURE __________________________________41
CHAPTER 2. _______________________________________________ 42
MAINTENANCE SECTION ___________________________________ 42
SECTION 1: SERVICING ______________________________________________45
SECTION 2: TROUBLE SHOOTING ____________________________________56
SECTION 3: REMOVAL / INSTALLATION / REPAIR _______________________66
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JST
Series 79
CHAPTER 3. _______________________________________________
OVERHAUL/MAJOR REPAIR. ________________________________ 79
SECTION 1: STEERING________________________________________________80
SECTION 2: ENGINE & TRANSMISSION ________________________________83
SECTION 3: ENGINE & TRANSMISSION RUBBER BLOCK BRACKETS.______84
SECTION 4. DRIVE SHAFT ____________________________________________85
SECTION 5: REAR AXLE REDUCTION GEAR BOX. _______________________86
CHAPTER 4. _______________________________________________ 96
ILLUSTRATED PARTS LIST__________________________________ 96
CHAPTER 5. _______________________________________________ 97
MANUFACTURERS LITERATURE ___________________________ 97
ANNEX 1: DAILY EQUIPMENT INSPECTION _____________________98
ANNEX 2: MAINTENANCE CHECKLIST____________________________99
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SECTION 2 RECORD OF REVISIONS
JST
Series
Continuing improvement and advancement of product design may cause changes to the model
group which may not be included in this publication.
Each publication is reviewed and revised, as required, to update and include the changes in later
additions.
We reserves the right to modify or make changes within a specific model group without notice
and without incurring any liability to retrofit tractors previously shipped from the factory.
Contact your TLD dealer for maintenance that is not covered in this publication.
ISSUE DATE
UPDATE NUMBER
DELETED
INSERTED
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DESCRIPTION OF CHANGE
Updated 6/12/2010
SECTION 3: TLD SALES INFORMATIONS

SALES DEPARTMENT AND AFTER SALES DEPARTMENT
LOCATION IN THE WORLD
JST
Series
AN INFORMATION, A QUESTION...
DON' T HESITATE TO CONTACT US.
EUROPE
SALES DEPARTMENT AND AFTER SALES
DEPARTMENT
Parc d'Affaires SILIC
21, rue du Jura ,BP 10525
94 633 RUNGIS
FRANCE
Tel : +33 1 45 60 71 40
Fax : +33 1 45 60 57 00
SPARE PARTS DEPARTMENT

3, rue Gustave EIFFEL
37 270 MONTLOUIS SUR LOIRE
FRANCE
Tel : +33 2 47 45 77 42
Fax : +33 2 47 45 16 11
ASIA
DEPARTMENT
TLD-ASIA
CHINA
Unit 1412, Fotan Industrial Centre, 26-28 Au
Pui Wan Street, Fotan, Shatin
New Territories, Hong Kong
Tel: +852 2692 2181, Fax: +852 26912604,
E-Mail: Enquiries@TLD-Asia.com

TLD-ASIA
SINGAPORE
07-02 Lipo Factory Building
621 Aljunied Road
SINGAPORE 389834
Tel: ( 65 ) 744 - 15 - 39
Fax : ( 65 ) 746 - 56 97
U.S.
North and South America, Australia
DEPARTMENT
TLD-AMERICA
Corporate Headquarters
TLD America
812 Bloomfield Avenue, Windsor, CT 06095
Tel: +1 (860) 602 3400, Fax: +1 (860) 688 7895
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JST
SECTION 4: GENERAL WARRANTY CONDITIONS
Series
This document presents the warranty conditions offered to any customer for all the pieces of
equipments manufactured in the TLD facilities and sold to him through the authorized TLD Sales
and Service network. The general warranty conditions hereunder described do govern the
relationship between final customer of a TLD product, hereunder called the buyer and TLD
factory, called the manufacturer , following the sales of new product manufactured by TLD,
through an authorized TLD Sales and Service organization of TLD Group, called the seller , i.e.
TLD Europe (Headquarters in France), TLD America (Headquarters in Connecticut, USA) or TLD
Asia (Headquarters in Hong Kong), or any other subsidiary or any other authorized distributor.
The fact that the buyer places an order of a TLD product means that he has read the present
policy and does accept its provision. Any other general or particular provision, that differs from or
contradicts one of the general or particular conditions described hereafter which may appear in
any document from the buyer and especially in its general purchasing conditions, cannot be used
against the manufacturer unless accepted by TLD in a written agreement.
ARTICLE 1:
TLD warrants that each new item of equipment is of good workmanship and is free from
mechanical defects provided that:
1) The product is installed and operated in accordance with printed TLD Equipments instructions.
2) The product is used under normal operating conditions, for which it is designed,
3) The product is not subject to misuse, negligence or accident,
4) The product receives proper care, lubrication, protection and maintenance under the
supervision of trained personnel,
5) The product is normally protected from exterior aggressions whatever their origin.
ARTICLE 2:
This warranty expires, unless otherwise agreed by TLD in a special provision, 27 months after
shipment by the manufacturer, or 24 months after being placed in service, or after 2000 operating
hours if the main engine of the unit is under 50KW or 3000 operating hours if main engine of the
unit is above 50KW, whichever first occurs.
ARTICLE 3:
The TLD Warranty is strictly limited to the replacement of defective parts and if the repair does
justify it, to the assistance of a technician. Parts shipping expenses, travelling and housing
expenses of personnel are to be paid by customer.
ARTICLE 4:
The TLD Warranty does not apply to fluids, oils, fuses, bulbs, accumulators, paint, seals, tires,
bumpers, pads and other consumables or normally wearing type items unless found to be
defective prior to use.
ARTICLE 5:
All warranty claims from the Buyer must be sent by written to Seller who will be in charge of
dealing with the Manufacturer to address the problem in a timely manner.
ARTICLE 6:
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All the expenses related to a warranty claim will be invoiced to the buyer until TLD employees
JSTor delay the
have evaluated the claim. Whatever the circumstances, the buyer should not refuse
payment. If the evaluation concludes to TLD s full responsibility, a credit memo will be issued in
Series
favour of the buyer. Under no circumstance other than those accepted by TLD,
the buyer of the
defective parts at the manufacturer address can accept without a formal letter from the buyer and
without the effective return no warranty claim.
ARTICLE 7:
This warranty is extended by TLD only to the buyer of new products from TLD or of its authorized
distributors. The products purchased under this warranty are intended for use exclusively by the
buyer and his employees and by no other person. Therefore, there shall be no third party
beneficiary of this warranty.
ARTICLE 8:
This warranty does only apply to the primeval reason. In other words, the consequences on the
product linked to its use after first problem are not covered by this warranty.
ARTICLE 9:
Under no circumstances whatever shall TLD and the seller be liable for any special or
consequential damages, whether based on lost goodwill, lost resale profits, work stoppage,
impairment of other goods or otherwise, and whether arising out of breach of any express or
implied warranty, breach of contract, negligence or otherwise, except only in the case of personal
injury as may be required by applicable law
ARTICLE 10:
The warranty is automatically void by TLD in the following cases:
1) The product has received some modification, not advised by TLD or not done following TLD
requirements
2) Some original parts have been replaced by parts not provided by TLD.
ARTICLE 11:
This warranty and all undertaking of TLD shall be governed by the laws of manufacturers country
and discussed in front of nearest court from the manufacturers facility even in case of multiple of
defenders.
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SECTION 5 GENERAL WARNING
JST
Series
FOREWORD
This instruction manual is intended for all users of the machine: the company manager, the Department Head,
the driver, as well as the whole personnel who works with or near to the equipment
GENERAL WARNING:
1 - Before using the machine, go through this manual and comply with all its instructions
2 - Also carefully read the instructions that appear on the plates fixed onto the machine and keep them
readable
3 - Keep this instruction manual at the disposal of all operators
4 - Make sure that any person to whom you entrust the machine is qualified to fulfil the safety requirements
linked to its use
5 - Avoid unsupervised interventions on your equipment when not being used
6 - Never use a machine which does not looks to be in good condition
7 - Never apply a load or a stress exceeding the maximum operating load of the machine
8 - Never use the machine for an operation it is not designed to perform
9 - Become thoroughly familiar with the safety regulations applicable to the machine and enforce them
scrupulously
10 - The manufacturer declines his responsibility for the consequences of a disassembly of the machine or
any modification made without his supervision
OBLIGATION TO GO THROUGH THE USERS MANUAL
The company manager is compelled to make the operators fully acquainted with the
regulations of the instruction manual.
Read this entire chapter BEFORE attempting to operate this tractor
The company manager is responsible for the enforcement of the applicable users regulation
The user must imperatively read and assimilate this instruction manual in order to be able to
comply with it during start- up and use
The instruction manual must be kept during the life- span the machine, including in the event
of a resale, of a change of user or manager
The instruction manual is not a training manual but it specifies, when required, if a training is
necessary.
GENERAL INSTRUCTION
The company manager must make sure that the machine is delivered with the instruction
manual and the certificate of conformity for the member states of the European Community
* The location of the instruction manual is specified on the dispatch note when leaving
the factory
* The certificate of conformity is placed with the dispatch note
Only trained and qualified operators with appropriate driving license and accredited by the
company manager may operate the vehicle within the scope of the use for which it has been
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designed
JST by the
The vehicle may only be used in accordance with the conditions established
manufacturer in this instruction manual and declines the manufacturer his responsibly
Series
Any use that does not comply with the regulations of this instruction manual
might cause risks
of injury to people, property and the environment
The manufacturers responsibility is limited to the assembly configuration of the equipment as
described in the certificate of conformity
Before each use, the driver should check that the machine is in good condition
Operators should not use the equipment if all lighting devices are not working properly.
MACHINE NORMAL USING DOMAIN
THE JST IS MADE TO TOW BAGAGE TRAILERS THE ALLOWED MAXIMAL LOAD AND THE
GENERAL USING CONDITIONS ARE INCLUED IN THIS DOCUMENTATION
ONLY USE THE JST TRACTOR FOR TOWING GSE TRAILERS AND BAGGAGE CARTS. OTHER
TOWING APPLICATIONS ARE NOT RECOMMENDED.
NOT RESPECT THIS REGULATION IS RESPONSIBILITY OF THE USER: ALL DAMAGES OR INJURIES
MAKE IN THESE CIRCONSTANCES CANT BE HELD TO RESPONSIBLILITY OF TLD
MODIFICATION OF THE TRACTOR
The manufacturer is not responsible in case of any modification, addition or combination with equipment from
another origin.
The manufacturer declines any responsibility for consequences resulting from changes in the characteristics or
modifications made without his written consent, and concerning either the mechanical, electrical, hydraulic part
or the mechanically welded structure.
If the client wants a modification to be made, he must imperatively consult the manufacturer.
For your safety and in order to benefit from the total guarantee of the manufacturer, you must only use
guaranteed genuine spare parts.
NOTE
Safety is more than quality design and construction. It also requires proper operation and maintenance
practices.
Every component is specifically designed and carefully built by TLD to produce the safest equipment available
today.
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Good understanding of the instructions mentioned below will enable operators to use the tractor in safe
JST
conditions..
Series
SAFETY INFORMATION
This manual provides important information to familiarize you with safe operating and maintenance
procedures for the tractor TLD.
Even though you may be familiar with similar equipment, you must read and understand this manual before
operating this tractor.
Safety is everyone's business and must be one of your primary concerns.
Knowing the guidelines covered in this manual will help provide for your safety, for the safety of those around
you, and for the machine's proper operation
Safety is a very important aspect which affects the life of your tractor
Before you operate, maintain or in any other way, use this tractor, READ and STUDY this manual
KNOW how to safely use the tractor's controls and what you must do for safe maintenance
If you have ANY QUESTION about the safe use or maintenance of this tractor ASK YOU SUPERVISOR NEVER GUESS - ALWAYS CHECK!
REMEMBER that a careful driver not only protects himself, but also other people with whom he works; at the
same time, he avoids dangers which could damage the tractor and the loads being towed.
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SECTION 6: INFORMATION AND OPERATION JST

Series
A.SAFETY FEATURES
The following features are standard equipment on the JST series:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Diesel engine
Automatic transmission
Power boosted disc brakes systems
Power steering
Four-wheel disc brakes
Split braking systems
Four functions LED rear lights
Mechanically operated parking brake
Adjustable over center parking brake hand lever
Lighted transmission shift control
Rear hitch visibility from the seat
Low center of gravity
Ease of maneuverability
Center of steering wheel horn button
Labeled controls
Low operator seating with adjustable seat for proper leg room
Seat belts
Anti-skid floor
Anti-skid brake pedal
Recessed headlights
Handrail
Back-up alarm
Turn signals with hazard warning
Amber flashing light
Work lights
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B.OPERATOR RESPONSIBILITIES
JST
Series
This chapter must be read and thoroughly understood prior to operating or performing any
maintenance on this equipment.
WARNING: FAILURE TO COMPLY WITH THE FOLLOWING SAFETY
PRECAUTIONS CAN RESULT IN SERIOUS INJURY OR DEATH AS WELL AS
EQUIPMENT DAMAGE.
1. Always follow the global safety rules applicable in your field.

2. Before using this tractor, always check for proper operation and condition of the lights,
brakes, steering, transmission shifter, park brake and tires.
3. Do not operate a tractor with defective features; refer to the maintenance section of the
Operation and Service Manual.
4. Always wear suitable footwear when operating this equipment and avoid loose fitting
clothing that might get caught in moving parts.
5. Always bring the unit to a complete stop, place the transmission in neutral, and set the
park brake before quit the unit.
6. Always bring the unit to a complete stop before shifting from forward to reverse or from
reverse to forward.
7. Always check the path clear prior to backing.
8. Check local station rules and, if permitted, sound the horn prior to backing.
If sounding the horn is not permitted, follow the applicable station rules for alerting other
personnel prior to backing.
9. Always be sure the load is secure prior to moving.
10. Always use safety chains between wagons to protect the wagons from accidental release.
11. Always use particular caution when in congested areas and near blind corners and rows
of carts. Be alert for other equipment and personnel.
12. Never operate at speeds which are not consistent with operating conditions. Always limit
speed to ensure adequate time for braking in an emergency.
13. Do not use the tractor to push other equipment. Use the proper towing equipment.
14. Do not allow the tractor to be pushed by other equipment. Use the proper towing
equipment.
15. Do not tow objects from any point on the tractor other than the hitch provided.
16. Do not remove radiator cap when the engine is hot as serious burns may result. Allow the
radiator to cool before removing the cap.
17. Never refuel the unit while the engine is running.
18. Do not fill the fuel cell above the bottom of the filler screen. Do not overfill. Clean off any
spilled oil or fuel. Do not smoke while refueling. Do not store, spill or use fuel near an
open flame.
19. Do not check the engine oil while the engine is running.
20. Do not use the battery in this unit to start other vehicles.
ALWAYS EXERCISE GOOD COMMON SENSE, STAY ALERT AND BE AWARE

OF WHAT IS HAPPENING AROUND THE TRACTOR AT ALL TIMES.
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C.MECHANICAL RESPONSIBILITIES
JST
Series
This chapter must be read and thoroughly understood prior to performing any maintenance on
this equipment.
WARNING: FAILURE TO COMPLY WITH THE FOLLOWING SAFETY
PRECAUTIONS CAN RESULT IN SERIOUS INJURY OR DEATH AS WELL AS
EQUIPMENT DAMAGE.
1. Always follow the Station Safety Rules. If a written list of safety rules is not posted at the
station, obtain one prior to operating this tractor.
2. Always review the Operator Responsibilities Section prior to operating this equipment.
3. Always keep hands and feet away from rotating parts and tires. Wear secured clothing.
4. Always wear suitable footwear when operating or servicing this equipment. Avoid wearing
loose-fitting clothing that might get caught in moving parts.
5. Do not use the tractor to push other equipment. Use the proper towing equipment.
6. Do not allow the tractor to be pushed by other equipment. Use the proper towing
equipment.
7. Always stop the engine when adjusting fan and alternator belts.
8. Always keep hands clear of the cooling fan.
9. Do not remove radiator cap when the engine is hot, as serious burns may result. Allow
the radiator to cool before removing the cap.
10. Do not check the engine oil while the engine is running.
11. Always disconnect the battery positive cable when working on the engine or under the
hood.
12. If electrolyte is spilled, always wash hands or clothing immediately.
13. Do not touch the engine, exhaust or hydraulic components when they are hot as serious
burns may result.
14. Do not smoke near the battery. Fumes from charging electrolyte are explosive. Always
keep the battery away from sparks, flame and smoking materials.
15. Always remove metal bracelets, watch bands, etc. prior to installing, removing or
servicing the battery.
16. Do not short circuit the battery terminals.
17. When connecting the battery, the positive terminal must always be connected first
prevent sparks from accidental grounding.
18. Do not substitute the throttle return springs with lighter or other springs.
19. Check the brakes and fill the master cylinder with DOT 3 brake fluid
20. Check all lights.
21. Check the horn operation.
22. Check the neutral start only switch for proper adjustment and operation.
23. Check tire and wheel condition along with proper inflation pressures. Unless beads are
seated when mounting tires, over-inflation can result in explosion.
24. Torque all lug nuts to 130 ft-lbs (front wheel), 362 ft-lbs (rear wheel). Check again the
torque after 5 hours of operation.
25. Always use proper lifting equipment safely when removing or replacing heavy
components.
26. When working underneath the tractor, be sure it is supported properly on secure jack
stands. Do not rely on hydraulic jacks to support the tractor.
27. If the tractor is on a hydraulic or air operated lift, always be sure the safety support or lock
is in position prior to working under the tractor.
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28. Always use a proper transmission jack, and secure the transmission when removing or
JST
replacing it.
29. Always jack the drive wheels off the floor when troubleshooting the drive system.
Series
30. Never refuel the unit when the engine is running.
31. Do not fill the fuel cell above the bottom of the filter screen. Do not overfill. Clean off any
spilled oil or fuel.
32. Do not smoke while refueling.
33. Do not store, spill or use fuel near an open flame.
34. Do not use the battery in this unit to start other vehicles.
35. Do not attempt to install or adjust control cables with the engine running.
36. Always replace a control cable which exhibits any gradual or sudden increase in no-load
friction or resistance or decrease in usable stroke, or which have moisture inside or have
been frozen.
37. Do not use heat to attempt to dry or thaw a control cable.
38. Do not remove the seals from a control cable or attempt to lubricate it. Any control cable
which exhibits possible lubrication problems should be replaced.
39. Do not attempt to repair or modify a control cable. Any damaged control cable should be
replaced immediately.
40. Always avoid exposing control cables to fuels, oils, chemicals, paint, water or dirt as
damage may result.
41. Always adjust each control cable so that the utilized stroke of the cable is centered within
the cables available stroke.
42. Always deflate a tire and wheel assembly prior to removing it for servicing or dismounting.
43. Follow safety recommendations for replacement or servicing of tires installed on a multi
pieces rim. Refer to: Chapter 2/ Servicing section 1/ Preventive maintenance/ Tire
replacement section
44. Do not use wheels or wheel components that are cracked, bent pitted or corroded. Insure
that all wheel components are of the same type and size, and that wheel size and tire
size match. Inspect all components carefully prior to use.
45. Do not attempt to seat a tire bead or side or lock ring by using inflation pressure or any
flammable or explosive substance such as starting fluid or ether. Never inflate a tire
beyond 40 psi to seat tire beads.
46. Do not hammer, pry or weld on or near an inflated or partially inflated wheel and tire
assembly.
47. Do not rework, weld, heat or braze any wheel parts for any reason.
48. Always use a safety cage or other restraining device and a clip-on air chuck with a
remote valve and pressure gauge when inflating a tire. Insure the tire and wheel
assembly is properly assembled prior to inflating it. Visually inspect it for proper seating of
beads or sides or lock rings prior to removing it from the cage.
49. Do not add air to a tire that has been in service with less than 80% pressure without first
fully deflating, removing, disassembling and inspecting the tire assembly for damage.
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JST
Series
CHAPTER 1.
GENERAL INFORMATION &
OPERATING INSTRUCTIONS
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SECTION 1: MAIN COMPONENTS
JST
Series
The JST is a two rear-wheels drive heavy duty towing vehicle. It incorporates:
o 4-cylinder engine diesel or dual LPG/gasoline,
o Automatic transmission,
o Heavy duty front and rear hydraulically assisted power disc brake system,
o 12 Volt electrical system.
A.ENGINES AND TRANSMISSION

The tractor is powered with industrial engines, with four stroke cycle and direct injection. The
engines are certified by the manufacturer to meet the more advanced emissions standards, which
are applicable at the date of manufacture.
The JST is equipped with an automatic transmission with oil cooler and torque converter.
B.DRIVE SHAFT
The tractor drive shaft is an automotive type with double universal joints and a sliding spline
coupling.
C.DRIVE AXLE
The drive axle assembly consists of the differential assembly, the reduction gears and the axle
shafts. It is mounted to the chassis by a pivoting cradle assembly supported by two leaf-springs.
D.SUSPENSION
Both front and rear axles incorporate two heavy-duty leaf-springs. Gas shocks absorbers could
be provided as option.
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The steering axle is of welded steel tube construction mounted to the chassis by two semi-elliptic,
multi-leaf spring assemblies. This is to insure constant ground contact of JST
both wheels over
uneven ground. Turning movement from the steering wheel is transmitted to the axle via a power
steering. This arrangement provides a high angle of lock with minimum amountSeries
of steering effort.
Hydraulic pressure is supplied by a hydraulic pump mounted on the transmission PTO.
DESPITE THIS SUSPENSION SYSTEM, IT IS RECOMMENDED THAT YOU DRIVE

OVER SMOOTH AND EVEN SURFACE.
E.BRAKING SYSTEM
The service brake is disk brake type, powered hydraulic braking system. The hydraulic braking
system uses a dual line master cylinder to supply hydraulic pressure for both the front (simple
caliper) and rear brakes (double calipers).
The parking brake is operated by a rod attached to the hand brake lever and a drum on the rear
of the transmission.
F.WHEELS AND TIRES

The front axle utilizes 1 piece wheels that have 5 bolts.
The drive axle employs 2 pieces heavy duty wheels that have 6 bolts.
The JST tires are pneumatic type which gives a smooth ride combined with maximum drawbar
pull. Remember to check the pressure of your pneumatic tires regularly. Uneven tire pressure will
not only increase tire wear, but will also decrease tractive performance.
Front pressure: 58 PSI cold
Rear pressure: 104 PSI cold
G.FUEL CELL
The fuel cell is integrated inside the tractor frame, below the floor on the right side of the tractor.
The fuel cell is equipped with a filler cap and a fuel gauge.
H.ELECTRICAL SYSTEM
The tractor uses a 12 Volt, automotive type, negative ground, electrical system. The system
includes a 90 A.h battery, ignition switch, two headlights, amber flashing light, turn signals,
taillight, horn, various gauges and all other circuits.
If tractor is equipped with a cab, the following is added to the above list: wiper motor, heater
blower motor and interior cab light.
I.FRAME AND BUMPERS

The frame is a heavy-duty welded assembly 1 inch heavy steel plate. The frame consists
essentially of inner and outer frame rails and front bumper. The outside frame rails are formed
and welded to the inside frame rails. The front bumper is welded to the frame rails.
For corrosion resistance the entire frame is protected from rust by primer and paint.
J.SEAT
The tractor utilizes two seats adjustable forward/backward. As an option the tractor can be fitted
with a comfortable suspended seat.
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K.HITCHES
JST
The tractor is equipped as standard with an E-type rear hitch. Alternative towing brackets could
Series
be provided as option, for both rear and front of the tow tractor.
L.CAB
The cab, which fully encloses the driving compartment, was designed for and fitted to the JST.
The cabs have a front, back and top windshields for maximum visibility. All windows consist of
safety glass. A wiper is fitted at front & rear windshield. The wipers are operated by a switch
located in the central console. The wipers can be operated only if parking brake is at released
position. A safety sensor switch under the parking brake lever control the wipers operation.
Doors are available as option: they include sliding window, ergonomic locks inside and outside.
M.GEAR SHIFTER
The gear shift unit is located on the seat plate between the seats, immediately to the right of the
driver position. As standard, the unit has four positions: Forward fast gear, Forward low gear,
Neutral and Reverse.
The JST is equipped with a forward-reverse gear inter-lock to prevent wrong engagement of drive
gear.
N.PARKING BRAKE LEVER

The parking brake lever is connected by a rod to the park brake drum mounted on the drive axle.
The park brake is used for parking or holding the tractor on grades and should always be set for
parking and released before driving. The brakes are engaged as the lever is pulled toward the
operator. Push the lever away from the operator (down) to release the brake.
O.PEDALS
The accelerator pedal is connected to the engine via a cable.
The foot brake pedal operates the hydraulic brakes on the front and rear wheels.
P.INSTRUMENTATION
The control layout is designed to combine maximum driving comfort with maximum efficiency.
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IT IS ESSENTIAL THAT THE OPERATOR BECOMES ACCUSTOMED TO BOTH

JST
THE LOCATION AND OPERATION OF THE CONTROLS, BEFORE
ATTEMPTING
TO DRIVE THE TOW TRACTOR FOR SAFE OPERATION.
Series
Switches
Ignition switch
Horn control switch
Headlamp dipped/main beam switch
Direction-indicator switch
Roof beacon switch
Rear working light switch
Alert light switch
Wiper control switch
Windscreen washer switch
Heating system / Air-conditioning switch
Ventilator speed selector
Defroster system
Cab dome light switch
Wiper sensor switch
An automotive type switch that incorporates an

anti-restart function.
The headlight toggle-switch controls the
headlights
Turn signal light lever mounted on the steering
column
Controls the windshield wiper motor
The heater switch controls the heater blower

motor
Operates the interior cab light (if equipped with

cab)
Operate the wiper only with parking brake at
released position.
Lights
Pre-heat indicator light
Indicates when the engine is pre-heating
Park brake light / Low-brake fluid warning
Indicates if the parking brake is engaged or

when the brake fluid level is low
Low-level battery light
Indicate when the battery level is low
Turn signal / alert signal light
Indicates when the turn signals or the alert

signal light are on.
Low-oil pressure light
Indicates when the engine pressure is low
High water temperature light
Indicates when the cooling temperature is high
Low-level Fuel/LPG light
Indicates when the fuel / LPG level is low
Reads the state of remaining fuel.
Indicators
Fuel/LPG level indicator
Page 21/100
Updated 6/12/2010
Reads elapsed time the unit has been in

JST
operation.
Measures the temperature of the engine
Series
cooling system
Engine hour-meter
Engine coolant temperature indicator
Transmission oil pressure
Reads the transmission oil pressure
Battery charging, voltmeter
Reads the state of charge of the battery (Volt)
Battery charging, amper-meter
Reads the state of charge of the battery

(Ampere)
Speed indicator
Reads the speed of the tractor
Engine oil pressure indicator
Reads the engine oil pressure
Gearbox temperature
Reads the gear box temperature
Engine speedometer
Reads the speed of the engine
: Standard feature
Page 22/100
: Optional
Updated 6/12/2010
JST
Pre-heat
Series
indicator light
Low-level
battery light
Low-brake
fluid warning
Low-oil
pressure light
Park brake light
Turning
lights
Low-level Fuel/LPG
light
High water
temperature light
Engine coolant
temperature indicator
Temperature gauge
different for DEUTZ
engine.
Engine hourmeter
Fuel/LPG level
indicator
For DEUTZ engine

indicated temperature
is up to 130 Degrees.
Page 23/100
Updated 6/12/2010
O.OPTIONS
JST
Series
The JST can be equipped with the options below:

-
Cabin with doors. Includes front wiper (with water cleaner), heater, rear mirror, cabin inside
top light. In addition, air condition, cabin fan, and rear wiper as option (Air condition only can
be available on DEUTZ D2011 L04W at present.)
Cabin without door. Includes front wiper (with water cleaner), rear mirror, cabin inside top
light. In addition, cabin fan, and rear wiper as option
Front metallic bumper. More protection for the chassis and engine.
Page 24/100
Updated 6/12/2010
Front and Rear shock absorber. To keep the unit in better balance.
2kg fire extinguisher .Safety equipment.
Front and rear rubber bumper.
Engine high temperature cut off. Engine protection equipment.

Engine low oil pressure cut off. Engine protection equipment.
Dog bone type engine hood lock.
Page 25/100
JST
Series
Updated 6/12/2010
Battery Voltmeter.
Speedometer. Indicate the instantaneous speed (KM/H) and running distance (KM).
Rear view mirror. The option without cabin.
Reflective tape.
Page 26/100
JST
Series
Updated 6/12/2010
Handrail basket for luggage. The option without cabin.
Suspended seat.
Lockable fuel cap.
Protectoseal fuel cap.
Page 27/100
JST
Series
Updated 6/12/2010
Extension rear hitch equipment.
Single lever front hitch.
Side hitch.
Three lever shifter .One forward, one reverse and neuter.
Page 28/100
JST
Series
Updated 6/12/2010
Simple metallic dashboard. With low fuel lever, high engine temperature and low oil engine
JST
indication light.
Series
Keyless ignition key.
Other color than White RAL9016, according to the customer requirement.

Front spare wheel, tubeless type.
Rear spare wheel,tube type.
Full printed manual.
Page 29/100
Updated 6/12/2010
SECTION 2: OPERATING PROCEDURE
JST
Series
Read this entire chapter BEFORE attempting to operate this tractor

- No unauthorised person may drive this tractor
- Be familiar with the controls and their functions before you start the tractor
- Observe the limits on weight of the loads to be towed and unladen weight of the tractor
- Inspect your machine by doing a pre-operational inspection
- Have any broken or missing parts, correct or replace before use
- Verify that all maintenance has been performed
- Verify that all the instruction and safety labels are in a place and readable
These are as important as any other equipment on the tractor
Before putting the tractor into service, the following items must be checked and executed
BEFORE DRIVING
At each team work beginning, check condition of the battery, pneumatic and bandages of trails and
be sure that tyre pressures are correct
Be sure that all driving parts are in good working condition and fill all the fluid levels if necessary
Advise immediately all defects and use a defective trail before it is not repaired
Verify the brakes of trails
Immobilise the load and verify the limit capacity of the trail and tractor
Set parking brake
Walk around and inspect tractor for damage or missing equipment
Check for :
- Pressure and the good state of the pneumatic tires.
- Look for cuts, cracks in side walls, foreign objects in treads
- Look for loose wheel nuts
- Damage to lights
- Fire extinguishers fully loaded and in place
Look underneath tractor for leaks of coolant, hydraulic fluid, transmission fluid, or lubricating oil. If
leaks are detected, repair as soon as possible
Check engine oil level
Check engine coolant level. Add coolant as necessary, but do not overfill. Make a visual check for
leaks
Check hydraulic system reservoir by removing filler cap to ensure there is enough fluid for
operation
A very low fluid level indicates a serious leak in the system. Repair as soon as possible
Inspect engine compartment for loose hardware, loose wires, and leaking lines or fittings
When all mechanical checks are completed, move to the driver's seat in the cab
Check the operation of the stop and tail lights, head lights, and dash panel lights
Check fuel level gauge to make sure tank is full
Check that the driving seat is adjusted to your requirements
Check that all controls are in working order
WARNING: DO NOT LOOSEN OR REMOVE RADIATOR CAP WHILE COOLANT IS HOT
HOT COOLANT UNDER PRESSURE CAN CAUSE SEVERE BURNS
Page 30/100
Updated 6/12/2010
Fuel contamination due to moisture condensing on the inner surfaces of fuel tank can be minimised
JSTalways be filled up at
or eliminated by keeping the fuel tank as full as possible. The fuel tank should
the end of the day's operation (as part of the post- operation maintenance routine)
Series
DRIVING INSTRUCTION
Place shift lever in park.
Buckle seat belt.
Make sure parking brake is set.
Verify that nobody and nothing is ahead of you BEFORE starting any motion of the tractor
Turn ignition switch and engage starter.
Apply foot brake.

Release the parking brake.
Move the transmission shift lever into the required position, Forward or Reverse.
Gently press the accelerator pedal, further press the accelerator until the required speed is
obtained.
To slow the tractor, slowly release the accelerator pedal and apply the service foot brake. For an
emergency stop, release the accelerator pedal and press hard on the service brake pedal.
Each time you park, apply the hand brake; turn the starter switch to the .OFF. position and return
the transmission shift lever to park.
WARNING: THE MAXIMUM DURATION OF CONTROL FOR AN OPERATOR
SHOULD NOT EXCEED 6H PER DAY
WARNING: MATCH DRIVING SPEEDS TO LOADS BEING TOWED AND WEATHER
CONDITIONS. SLOW DOWN WHEN TOWING HEAVY LOADS AND WHEN ROAD SURFACE IS
WET OR ICY, ESPECIALLY ON GRADES.
TOWING INSTRUCTION
Ensure the trailer load is secure and is within the rated drawbar pull of the tow tractor.
Ensure the towing coupling is secure.
Start as slowly as possible to allow any slack in towing arrangements to be taken up.
Ensure the trailers load is not wider than the aisles en route.
Upon stopping vehicle place transmission shift lever in neutral, put parking brake
ON, and turn ignition switch to OFF position.
SAFE AND EFFICIENT TOWING DEPENDS ENTIRELY ON YOU, THE OPERATOR. IF YOU
ARE AN EXPERIENCED DRIVER, THE FOLLOWING RULES WILL SERVE TO REFRESH
YOUR MEMORY. IF YOU ARE A TRAINEE, THEY WILL ASSIST YOU TO BECOME AN
EXPERT DRIVER.
Page 31/100
Updated 6/12/2010
JST
Series
WARNING: ONLY QUALIFIED AND AUTHORIZED DRIVERS SHOULD BE PERMITTED TO

DRIVE.
GENERAL PRECAUTIONS
- Do not operate any levers or pedals if anyone is in any position to be hurt by the machine's
movement
- Pay extra attention when working in narrow congested areas or in case of blind- travel
- Always look around in all directions BEFORE changing your direction of travel
- Always follow all safety rules or each particular site during operation
- Maintain a towing speed which is compatible with the load and the ground conditions
- Avoid driving over loose or uneven surfaces
- Slow down when approaching corners
- Observe pedestrians carefully and do not follow the vehicle in front too closely
- Do not brake sharply and only select neutral once the tractor has effectively stopped
- Maintain a safe distance from the edge of loading wharf
- When cornering, pay close attention to the trajectory of the trailer (Aircraft)
- Make sure that bridges and ramps are able to withstand the weight of the tractor and the load
being towed
- Verify that access bridge are enough resistant to wear the combined weight of tractor and his load
- Verify before climb or descent from vehicles (trucks, trails etc) that the adequate precautions are
been take to avoid all movement included the dump
- Stop, look at and listen when arriving to a rail way then to cross it in diagonal, slowly and only to
the authorized points
- Always park at more 2,5m of the rails
- Hold the wheel steering in hand during the operation
- During towing wide load, foresee a lot of space for the overtake of parked vehicles, objects and/or
pedestrians
- Never overtake another vehicle on crossroad or on bifurcations or when something masks the
visibility for you
- Never drive in elevators, truck or other until you have received the order and before you be sure
that they can wear the combined weight of tractor and the load
- Doesn't brake roughly
- Manoeuvre to a prudent speed and be careful to the pedestrians and other vehicles and to the
passage heights
- Slow down on wet or irregular grounds and in the turning
- Remove all object being located on your way
- To the crossroad, in the passages and the corridors, slow down and horn and drive on the right
side of the road
- Be careful to the pedestrians which can appear suddenly to the masked entries
- If your trip involves crossing road bridge plates, ensure they are secure and are strong enough to
withstand the combined weight of the tractor and trailer.
- When approaching the destination, reduce speed sufficiently far away to ensure a slow, rolling
stop. A sudden halt could cause load displacement.
- Ensure the trailers parking brake is applied before disconnecting the trailer coupling.
- Do not block fire fighting equipment from use by parking or depositing a trailer in front of the
equipment.
- Report any mechanical or electrical irregularities immediately.
- Ensure road bridge plates are secure and strong enough to withstand the weight of the tractor or
the combined weight of the trailer and its load.
- Do not carry unauthorized passengers.
- Always be alert; Watch out for pedestrians and never drive too close behind other vehicles.
- Travel at a speed consistent with road and load conditions.
Page 32/100
Updated 6/12/2010
- Slow down when approaching corners and junctions. Avoid sudden stops. When cornering, watch
JST
for the trailers rear end swing
- Never climb onto, or get out of the machine while it is in motion
Series
- Never operate the tractor with any part of your body outside of the operator's
compartment
- DO NOT leave the driver's cab with the tractor running
- ALWAYS properly shut down the tractor before leaving the tractor
- ALWAYS park the tractor on solid, level ground
On severe slopes
- ALWAYS park the tractor perpendicular to the steepest slope to prevent accidental movement
- Use proper flags, warnings or barriers when parking in areas of traffic
- Do not park your vehicle in such a way as to obstruct fire brigade access points
- Never park your tractor or leave towed equipment (aircraft, trail,...) in front of a fire equipment, an
emergency issue or all other place where it could constitute an obstacle or a danger
- During parking, use the parking brake and put the contact to key on the STOP position
- If the tractor must be leaves with nobody for watch on it, remove the ignition key
- Never release towed equipment (aircraft, trail...) with the equipment parking brake unapplied
- Never park your vehicle on a slope
- If it is necessary to park tractor on a (breakdown etc), chock the tractor wheels
WARNING: IF PROBLEMS OR EQUIPMENT MALFUNCTIONS ARE OCCURRED WHILE
OPERATING THE TRACTOR, IT MUST BE PROPERLY SHUT DOWN AND THE PROBLEM
CORRECTED.
CONTINUING TO USE MALFUNCTIONING EQUIPMENT CAN NOT ONLY BE UNSAFE FOR
THE OPERATOR AN OTHER PERSONNEL, BUT CAN LEAD TO FURTHER DAMAGE TO THE
TRACTOR AS WELL
WARNING: IN CASE OF ACCIDENT, IMMEDIATELY ADVISE ALL INCIDENT TO YOUR
SUPERIOR
NEVER NEGLECT AN INJURY EVEN IF IT APPEARS INSIGNIFICANT, GO IMMEDIATELY TO
THE INFIRMARY FOR MEDICAL TREATMENT, WHAT COULD AVOID COMPLICATIONS.
AREA
CAUSES OF FAILURE
ENTIRE MACHINE
DRIVING STATION
UNDERNEATH
RISK
SAFETY STEPS
WHAT CAN HAPPEN IF

HOW TO PREVENT THE FAILURE
PRECAUTIONS AND SAFEGUARDS
ARE NOT OBEYED
A moving tractor can run over or crush Keep away all people from around
body parts between tractor and other tractor and always switch off the engine
object and cause irreparable injury or before leaving the driver's cab
death
Keep head, arms, hands, legs and feet
Personnel injuries may happen if parts
inside the operator's compartment at all
of the body or members (hands, legs,
time
ect) are outside of the driver's cab
Unit lifted for service could fall and If tractor must be lifted for service, it
injure / kill personnel around
must be securely blocked so that all 4
Page 33/100
Updated 6/12/2010
DURING SERVICE
(four) wheels may safely turn

JST:
DURING SERVICE
The motor must be turned off when
Series
possible
If procedures require the motor to be
running during service, care must be
taken to avoid moving objects
The
battery
cable
should
be
disconnected when possible to avoid
Hot surfaces (engine) could cause having the motor accidentally started
Care should be taken to avoid hot
serious burns
surfaces
Batteries produce flammable gasses
Batteries should be well ventilated
that could be ignited causing burns an
before servicing particularly if welding is
explosions
required near the batteries
Batteries contain strong acid that may
Protective clothing, gloves and eyewear
cause severe burns if spilled or
must be worn when working on batteries
splashed on body parts or in the eyes
Moving parts steering axles, and
wheels could cause serious injury if
persons are struck by moving parts or
caught in belts
ENGINE
BATTERIES
TYRE
A contact with batteries plug, or all

electric part without protection (or
when the protection have been
removed) can cause an electric chock
Welding near the wheels may damage
the tyre, which may explode
May cause serious injury or death
Page 34/100
Avoid to remove the plastic protection,

and avoid to touch electric parts where
current can be.
If welding has to be done near the wheel
or on the rim, remove the tyre
Updated 6/12/2010
JST
AVOID, whenever possible, servicing, cleaning or examining the machine in congested
areas and avoid,
whenever possible, servicing or providing maintenance to the tractor unless the wheels are adequately
Series
choked to prevent accidental movement of the tractor
- To carry out work behind the wheels, switch off the motor
- Never attempt to repairs yourself if you are not authorised and if you are qualified
- Never doing maintenance work without refer you first to the maintenance manual and the driving notice
- Never assemble other pieces that the ones provided by TLD and never modify equipment existing: the
mounting of other pieces than TLD one or equipment existing modification without authorisation of the
manufacturer could make a dangerous vehicle and cancel the guarantee covering this one
- Does not modify the construction to change vehicle capacity or stability without refer to TLD
ELECTRICITY
DO NOT alter the electrical or hydraulic settings from that indicated in the manual or as set at the factory
DISCONNECT the batteries when possible while working with electrical systems to prevent short circuits
Also, disconnect the batteries when working around the engine can help prevent accidental engine starting
BE SURE the battery area is well ventilated (clear of fumes) if it is connected to a battery charger or when
working on or around the batteries with sparks or flames Fumes from the batteries could be ignited by a spark
and explode
- Does not verify state of batteries at proximity of a nude flame, particularly during the battery charging
- Not smoke in the battery charging zones
WELDING
- Before carrying out any arc welding operations on the tractor, proceed as follows:
Disconnect the batteries
Disconnect the electronic control box and appliances
Place the ground clamp on the part to be welded
Weld as close to the ground clamp as possible
Page 35/100
Updated 6/12/2010
JST
SECTION 3: SPECIFICATIONS AND CAPABILITIES
Series
DRIVELINE CAPABILITY VERSION WITHOUT CAB COULD SLIGHTLY CHANGE DEPENDING
ON THE MOTORIZATION
JST-20
JST-25
JST-30
Drawbar pull, daN [lbs]
2,000daN (4,400lbs)
2,500daN (5,500lbs)
3,000daN (6,600lbs)
Gross weight, kg [lbs]
3,420 KG ( 7,540lbs)
3,640 KG (8,025lbs)
4,220 KG (9,300lbs)
Recommended towed load*

JST-20
JST-25
JST-30
Maximum recommended
towed load
Towing operation
25,000Kg
(55,000lbs)
33,000Kg
(72,700lbs)
40,000Kg
(88,000lbs)
Maximum recommended
towed load
Push back operation
14,000Kg
(30,800lbs)
14,000Kg
(30,800lbs)
14,000Kg
(30,800lbs)
* Surface, Dry even concrete
DIMENSIONS
Length, excluding coupler
Width, overall
Height, overall, w/o cab
Height, overall, with cab
Wheelbase
Turning Radius
Ground Clearance
ENGINES
DEUTZ D2011L04W
Type
Number of Cylinders
Cylinder Arrangement
Max power
Max torque
Total Displacement
Compression Ratio
Combustion System
Weight w/o Cooling system
Lubrication
SAE Oil
Oil Temp in Sump Oil
Oil capacity with filter
Alternator
2830mm (111)
1440mm (57)
1496mm (59)
2050mm (81)
1600mm (63")
3450mm (57")
125mm (5)
Diesel
4
Upright in now
48 kW @ 2600 RPM
184 N.m
naturally aspirated engine with direct injection
Water
Pressure Lubrication
130
10.5 liters
12V
Page 36/100
Updated 6/12/2010
PERKINS 404D22
Type
Number of Cylinders
Max power
Max torque
Total Displacement
Compression Ratio
Combustion System
Lubrication
SAE Oil
Alternator
ZENITH ZPP428
Type
Number of Cylinders
Max power
Max torque
Total Displacement
Compression Ratio
Combustion System
Lubrication
SAE Oil
Alternator
CUMMINS B3.3
Type
Number of Cylinders
Max power
Max torque
Total Displacement
Compression Ratio
Combustion System
Lubrication
SAE Oil
Alternator
FOTON 4JB1
Type
Number of Cylinders
Max power
JST
Series
Diesel
4
Vertical In-line
35.5 kW @ 2800 RPM
140 N.m @ 1800 RPM
2.2 liters
LPG/Gasoline
4
Vertical In-line
46 kW @ 3000 RPM
157 Nm @ 1800 RPM
2.8 liters
9.4:1
Diesel
4
Vertical In-line
48 kW@ 2600 RPM
214 N.m @ 1600 RPM
3.3 liters
18
Naturally aspirated
245
15w40
7.5L
12V
Diesel
4
Vertical In-line
46 kW @ 2800 RPM
Page 37/100
Updated 6/12/2010
Max torque
Total Displacement
Compression Ratio
Combustion System
Lubrication
SAE Oil
Alternator
TRANSMISSION
Type
ELECTRICAL SYSTEM
Type
FRAME
Structure
SUSPENSION
Front axle
Rear axle
BRAKING SYSTEM
Service brake
Parking Brake
DRIVE AXLE
Type of drive
Ratio of Drop Box
STEERING SYSTEM
Type
Front axle construction
175 N.m @ 1800 RPM

2.8 liters
18.2:1
Naturally aspirated
241
JST
Series
15w40
12V
Automatic, heavy duty, 3 speed forward with torque
converter
12 Volt, Negative ground
Welded construction, from 12mm to 25mm (1/2 to 1)
Leaf springs type
Leaf springs type
Hydraulic power braking system
Front and rear brake with dry discs and calipers
Dual circuit
Drum brake on driving shaft at axle input, mechanically
actuated by a cable
Rear, heavy duty driving axle
1 : 8.8
Power steering (double-acting cylinder) with adjustable
steering wheel column position
Steer cylinder
Inclined King Pins, Bushings and Sealed bearings
HYDRAULIC SYSTEM
Hydraulic pump flanged on transmission PTO
TIRES
Front
Rear
DRIVE SHAFT
Type
COOLING SYSTEM
INSTRUMENTS
Type
Group
185/70 R14 tubeless (standard)

225/75 R15 tube type (standard)
Automotive with double universal
Heavy-duty rubber mounted radiator with dual electric fans
Dual circuits: water for engine and oil for transmission
Electrical
Oil Temperature, Oil Pressure,
Hour Meter
SENSORS
Group
Interlock sensor (0 speed). Located beside the drive shaft. It

reads the drive shaft move and gives information to the
transmission. The prevent downshift from forward to reverse
Page 38/100
Updated 6/12/2010
gear (and reverse to forward)

Wiper sensor switch located under JST
the parking brake lever.
This sensor controls the wiper. Wipers can be activated only
Series
if parking brake is released.
Page 39/100
Updated 6/12/2010
SECTION 4: SHIPPING PROCEDURE
JST
Series
WARNING: EXTREME HAZARD EXISTS WHEN REFUELING AND DE-FUELING

THE TRACTOR - NO SMOKING, NO OPEN FLAMES, NO ELECTRICAL DEVICES.
BATTERY
Disconnect battery terminals from battery plugs.
Leave battery in battery box.
RADIATOR
Drain engine coolant from radiator and engine block.
FUEL CELL
Drain fuel from fuel tank into appropriate container.
Disconnect fuel line at lowest readily accessible connection and drain fuel from fuel line.
Reconnect fuel lines.
Leave fuel cap on tank, but loosened.
CHECKS
Make certain fuel line is connected.
Make certain shut-off valve on radiator is closed.
Make certain fuel cell drain valve is closed.
Page 40/100
Updated 6/12/2010
SECTION 5: STORAGE PROCEDURE
JST
Series
Transmission
FOR ONE MONTH

No special attention needed.
FOR INDEFINITE PERIOD

Drain transmission fluid.
Refill transmission.
Drive axle
No special attention needed.
Drain drive axle by removing drain

plug located on the underside of the
differential carrier housing. Reinstall
plug after draining.
Tires
The tractor should be raised and axles

chocked to prevent tire contact with
ground.
Tire pressure should be reduced to
15PSI.
Lubrication
Ensure that all points are lubricated

with specified grease oil.
The tractor should be raised and axles

chocked to prevent tire contact with
the ground.
Tire pressure should be reduced to
15PSI, and sprayed with a rubber
preservative.
Ensure that all points are lubricated
with specified grease oil.
Fluid levels
All fluid levels should be checked and

topped up as necessary.
All fluid levels should be checked and

topped up as necessary.
Wheel
bearings
Wheel bearings should be repacked.
Wheel bearings should be repacked.
Battery
Disconnect battery terminals
The battery should be removed and

stored separately. The battery must be
stored in a cool dry place and must not
be exposed to direct sunlight.
If the battery is stored in the open, it
must be covered for protection against
dirt and moisture. A slow charge
should be given to the battery every
one and two months.
NOTE: Prolonged storage may be detrimental to the seals in the transmission.
Page 41/100
Updated 6/12/2010
JST
Series
CHAPTER 2.
MAINTENANCE SECTION
Page 42/100
Updated 6/12/2010
GENERAL DESCRITION
JST
Series
By definition, preventive maintenance includes regular maintenance and checking
operations
which should prevent failures occurring.
Preventive maintenance operations should enable the operator to discover premature wear or
deterioration of the equipment.
GENERAL CLEANING INSTRUCTIONS

For a complete cleaning of the vehicle, clean normally (High pressure cleaning should be
avoided).
Make sure electrical components, safeties, name plates and stickers, are well protected.
For electrical components, dry air of 29 psi maximum is recommended.
For mechanical parts cleaning, use degreasing products and then blow air.
Batteries must be cleaned in order to prevent serious damages due to chemical reactions and
current branching off.
WARNING:
SOLVENT MAY AFFECT SKIN, EYES, AND RESPIRATORY TRACT.
USE ONLY IN WELL VENTILATED AREA.
AVOID PROLONGED BREATHING OF VAPORS.
KEEP AWAY FROM SPARKS AND FLAME.
TO AVOID POSSIBLE PERSONAL INJURY, NEVER EXCEED 30 PSI AIR PRESSURE FOR
CLEANING AND DRYING PURPOSES. USE EYES PROTECTION WITH SIDE GUARDS AND
APPROVED NOZZLES ON AIR HOSES.
CAUTION:
NEVER IMMERSE ELECTRICAL COMPONENTS, PACKING, OR RUBBER, PLASTIC OR
TEFLON PARTS IN DRY-CLEANING SOLVENT.
WIPE PARTS WITH A CLEAN, LINT-FREE CLOTH.
DRY CLEANING SOLVENT CAN REACT WITH MATERIALS AND RESULT IN SEVERE
DAMAGE OR DESTRUCTION OF PARTS.
Clean parts in a tank or spray using dry-cleaning solvent
Wash cleaned parts by flushing or spraying. When necessary, use a soft bristle,
non metallic moistened in dry-cleaning solvent.
Except for bearings, dry parts using compressed air after cleaning.
Page 43/100
Updated 6/12/2010
Unless specifically called for in maintenance procedures, do not use metal

JST
scrapers, wire brushes, abrasive wheels, or abrasive compounds
when cleaning
parts.
Series
Clean electrical parts such as relays or switches with a lint-free cloth moistened
with dry-cleaning solvent.
Clean the heat exchanger coil by reverse flushing with a steam cleaner or with a
pressure washer and soap solution. Do not use a cleaner that will attack
aluminum or copper.
Clean the exterior surface of the batteries with a weak solution of baking soda
and water.
Apply the solution with a soft-bristle, non metallic brush to remove corrosive
build-up on the battery cable terminals.
Wash painted surfaces of the unit with a solution of pound of soap chips to one
Gallon of water. Rinse with clean water and dry with a lint-free cloth or allow to
air dry.
FIRST MAINTENANCE PROCEDURE
The first maintenance has to be done between 10 and 125 hours of operations.
Check oil leaks and correct if necessary.
Check hoses and connections. Check electric wiring.
Check wheels nut torque after 10 operations hours, also after 50 operation hours, and
after each wheel replacement.
Check batteries fluid level.
Page 44/100
Updated 6/12/2010
SECTION 1: SERVICING
JST
Series
A.PREPARATION FOR USE

Fuel System
Check all fuel line connections to make sure they are properly connected, from
fuel tank to fuel pump to carburetor. (Gasoline only)
Make certain fuel cell drain valve is closed.
Fill fuel cell with correct fuel.
Battery
Check the battery fluid level. Top up with distilled or approved drinking water, as
necessary
Connect the battery cables, if disconnected, positive first.
Brake System
Check brake oil tank oil level.
If low, check for leaks in brake lines.
Engine and Transmission
Check engine oil level, add oil if needed.
Check transmission fluid level.
NOTE: This check is just to determine if there is fluid in the transmission. If any fluid shows
on the dipstick, do not add transmission fluid until it is checked with the engine running,
after the engine has reached normal operating temperature.
Check transmission cooling lines for proper connections.
Rear Axle and Reduction Gear Box
Check oil level in the rear axle and gear reduction box and add oil, if needed. The rear
axle and reduction gear box are internally connected.
Tire Inflation
Check air pressure in tires and add air if needed.
After a removal wheel, its imperious to tighten at the recommended nuts tightening:
After 2 hours, then 50 hours, and every 200 hours periodically:
recommended for front wheel nuts tightening: 110 ft.lbs (148 N.m)
recommended pressure for Front wheels: 58 PSI (4.0BAR)
recommended for Rear wheel nuts tightening: 362 ft.lbs (504 N.m)
recommended pressure for Rear wheels: 104 PSI (7.2BAR)
Page 45/100
Updated 6/12/2010
JST
Series
Hydraulic Fluid
Check level at reservoir. A dipstick indicates the minimum required level.

Grease instructions
Add grease in every grease valve.
1. Front axle spindle. 2 grease cap on each side (bottom and top).
2. Drive shaft.2 for the universal swivels,1 for the sliding shaft
3. At leaf spring attachment with the frame.
B.PREVENTIVE MAINTENANCE SCHEDULE

The tractor should be maintained in accordance with the following schedules.
Daily
check
Fuel level.
Engine oil level.
Pressure of the pneumatic tires:

- Drive Wheels 104PSI
- Steer Wheels 58PSI
Tire treads for damage.
Remove any stone, etc.
Operation of the headlights and if aimed
correctly.
Operation of backup, tail, stop and turn
signal lights
Operation of the cab marker lights, the
heater, the wiper and cab light, if
equipped.
Weekl
y or
50
hour
check
Monthl
y or
200
hours
Two
month
s or
400
Hours
Six
month
s or
1200
hours
Yearly
or
2400
hours
Horn.
Hydraulic oil level.
The wheel lug nuts are tightened to 130

& 362 ft. - lbs. (*)
The level of the brake fluid in the master
cylinder. If low, top up as necessary.
Battery charge and fluid level.
Drive axle U-bolts and tighten if required.
Page 46/100
Updated 6/12/2010
Daily
check
Transmission fluid level (with engine

running and at normal operating
temperature).
Cylinder head bolt torque and all nuts
and bolts for tightness. If required, torque
to specified torque with oiled threads.
Drive axle and reduction gear box oil
level.
Weekl
y or
50
hour
check
hours
hours
Exhaust system for leaks and holes.
Change drive axle oil. (First change only;

then yearly thereafter)
Check Engine oil level
Hydraulic oil.
Remove water from fuel separator

Inspect engine oil cooler hoses.
Inspect brake pads; replace if pads are

less than one-eighth (1/8) of an inch.
Change: Intake air filter.
The adjusting
operators seat.
Six
Yearly
JST
month
or
s or
2400
Series
1200
Hydraulic oil.
Two
month
s or
400
Hours
King pins and steer pin for looseness.
Parking Brake
With the parking brake handle in lock
position, the tractor should not move on
an 8 or less percent grade. If the tractor
does not move, no adjustment is
necessary, but if the tractor rolls, then
adjustment is advised.
Alternator belts: to be tightened if
necessary.
Monthl
y or
200
hours
slides
beneath
the
The service brake pedal pivot.
Check the drive shaft points, attachment

bolts. Tighten these and use "Loctite"
glue if necessary
The parking brake linkage.
The throttle linkage.
The steering axle, king pins, bearing nut

adjustment.
Page 47/100
Updated 6/12/2010
Daily
check
Weekl
y or
50
hour
check
Monthl
y or
200
hours
The sliding pins on the rear brake

calipers.
All grease fittings.
Hood latches and hinges.
Rear & front hitch support

inspection and retightened.
bolts
Cab door handles (if equipped).

Change fuel filter
Replace Engine oil and filter
Idle RPM and mixture, adjust if
necessary.
Inspect front wheel bearings; clean and
repack.
Hub slotted nut retightened procedure:
1. use 150n.m to tighten the nut
2. return back 1/4 circle
3. use cotter pin to fix the nut
Change the engine belts
Change parking brake shoes
Two
month
s or
400
Hours
Six
Yearly
JST
month
or
s or
2400
Series
1200
hours
hours
The differential bolts and tightened to

492 in. - lbs.
Drain, flush and refill the hydraulic brake

system, and bleed the brake system.
(*): Lug nuts must be retightened to 130 & 362 ft. - lbs. after any change of a
wheel and anytime the lug nuts have been loosened for any reason, and at the
intervals specified in this Preventive Maintenance Section.
A proper and regular maintenance will allow operator to avoid any mechanical failures. Pay
attention to lubrication schedule.
Page 48/100
Updated 6/12/2010
Check engine oil level
JST
Series
Air cleaner cleaning

The cover can be taken out after de-tighten the screw location at the side.
Element cleaning
Tap the element filter paper lightly without causing any damage or blow dust off with
compressed air
Note
1. Always replace the element if the filter is damage
2. wash the element if heavily contaminated
How to wash the element
1. Soak the element in water containing neutral detergent during approximately 30 minutes
and then wash. Use care not to scratch the filter paper
2. After washing, rinse the element with clean water
3. Allow to dry naturally or use a dryer (cold air). Never use compressed or hot air
Note
The element should be replaced after washing six times of after it is used for one year.
Battery electrolyte check
1. The battery electrolyte should be between the upper an lower levels
2. if the electrolyte level is bellow the lower mark, remove the cap and add distilled water to
the upper level through the water inlet port.
CAUTION:
BE SURE TO USE DISTILLED WATER.
WEAR PROTECTIVE GLASSES WHEN WORKING ON THE BATTERY
Page 49/100
Updated 6/12/2010
Tire replacement
1. Never enter the tractor after jacking it up.
2. Refer to the service data for tightening torque of the hub nuts
3. Adjust the air pressure after tire replacement
4. Pay attention of rim deformation, cracks and loose matching bolt nuts
5. Do not increase the air pressure exceeding the specified range
JST
Series
Front wheel
1. Locate the tractor at a horizontal place
2. Apply the parking brake and insert the jack under the body
3. Jack the body up until tires are almost raised from the ground and loosen hub nuts
4. Jack the body up until tires are lifted from the ground and remove hub nuts, the the
wheels
5. Reinstall the wheels in the reverse procedure after repairing and replacing the tires.
Tighten the hub nuts uniformly in diagonal directions and in the sequence shown
6. Check and adjust the air pressure of the tires after the wheels are reinstalled
CAUTION:
FOLLOW SAFETY PRECAUTIONS FOR MOUNTING AND DEMOUNTING TUBE TYPE TRUCK
TIRES INSTALLED ON MULTI PIECES RIM WHEELS.
Improper installation or servicing of tires on Multi pieces rims could lead to severe injuries. Please
find below instructions and recommendation to avoid these risks.
Deflation and Disassembly
Always check tire/rim assembly for proper component seating prior to removal from
vehicle.
Always deflate tire by removing valve core prior to dismounting from vehicle or
disassembly of components.
Never position body in front of rim during deflation.
Always follow assembly and disassembly procedures outlined in the manufacturer's
instruction manual or other recognized industry instruction manuals.
Use proper tire rubber lubricant.
Never use a steel hammer to assemble or disassemble rim components -- use a lead,
brass, or plastic type mallet.
Rim Inspections
Always select the proper tire size and construction to match the manufacturer's rim or
wheel rating and size.
Never use damaged, worn, or corroded rims/wheels or mounting hardware.
Always clean and repaint lightly rusted rims.
Never use rim/wheel components you cannot identify. Check rim parts against multipiece rim/wheel matching chart.
Page 50/100
Updated 6/12/2010
Assembly and Inflation
JST
before
Series
Always check to see that removable rings are properly seated

inflating.
Always inflate tire in safety cage or use a portable lock using guard. Use a
clip-on type air chuck with remote valve so that operator can stand clear
during tire inflation.
Never attempt to seat rings while tire is totally or partially inflated.

Never re-inflate or add inflation pressure to a tire that is flat or seriously
under inflated without removing and checking for ring seating and rim
damage.
Never use an assembly with excessive side ring play, wide gaps between
ring ends or butting ring ends.
Killer Wheel in the
Never hammer components of an inflated or partially inflated assembly.
Inflation Cage
WARNING
TRAJECTORY WARNING: STAY OUT OF THE TRAJECTORY AS INDICATED BY SHADED
AREA
Hydraulic oil replacement.

1. Open the hydraulic oil tank cover and dismantled the oil return pipe and draw out the oil to a
container.
2. Start the engine under idle speed, turn over the steering from dead side to dead side several
times till all the hydraulic oil out of the system.
3. Shut down the engine.
4. Connect the oil return pipe, and add new hydraulic oil into tank.
5. Start the engine, turn over the steering from dead side to dead side .Add hydraulic oil to the
tank at the same time till theres no bubble .
6. Shut down the engine and check the oil lever. Screw down tank cover.
Page 51/100
Updated 6/12/2010
JST
Series
Check the transmission frequently to make sure that there are no oil leaks.
Check transmission oil level every 200 hours
Check the level with one of the dipstick (long dipstick can be accessed from the engine
hood, short dipstick is located at the top of the transmission
Procedure
1. Start the engine and shift the transmission through all drive ranges, for at least 2
minutes each to fill the clutch cavity and oil passage, then shift to neutral
2. Run the engine for at least 2 minutes at 10001200 RPM to clear the system from air
3. Check the oil level while the tractor is on level ground and the parking brake applied
4. With the engine at low idle and transmission in neutral check the oil level as follows
Page 52/100
Updated 6/12/2010
Change the transmission oil filter every 500 hours

Change the filtering cartridge
JST
Series
Note: every two replacements of the filter, it is necessary to replace transmission oil
Change the transmission oil every year or 1000 hours, whichever occurs first
For the oil filter replacement procedure please refer to the Manufacturer Appendices
enclosed below.
Change the rear axle oil
Change the rear axle oil after 50 working hours, only for first change. Then change the oil
every 1000 hours or yearly.
Page 53/100
Updated 6/12/2010
JST
Series
C.LIQUID & LUBRICANTS

ENGINE
CAPACITY
UNIT
PERKINS 404D22
CUMMINS B3.3
DEUTZ D2011L04
FOTON4JB1
HYUNDAI 420
SPECIFICATION
7.5
10.5
5L
15W40
20W20
15W40
10W30
CAPACITY
GEAR BOX: GRAZIANO PST2

ATF oils corresponding to specifications DEXTRON II D or type A suffix
A of General Motors or C3 pd Detroit Diesel Allison (e.g. MOBIL ATF 220
and FIAT TUTELA JI/A and GI/M) or corresponding to specification MILL2104B and API CC (e.g. MOBIL DELVAC 1110) or to specifications
MIL-L2104C and API CD (e.g. MOBIL DELVAC 1310) viscosity 10W20
12.5 liters
TYPE
CAPACITY
COOLING CIRCUIT
Anti frozen fluid
11 L
TYPE
CAPACITY
DOT3
1.5 L
TYPE
CAPACITY
L-HM 46
TYPE
CAPACITY
GL-5
6L
TYPE
BRAKING
HYDRAULIC SYSTEM
20 L
DRIVE AXLE
FUEL TANK
UNIT
Diesel
CAPACITY
60 L
1- WHEN REPLACING HYDRAULIC PARTS OR COMPONENTS, IT IS INDISPENSABLE

TO FILTER AND CHECK THE HYDRAULIC OIL BEFORE REUSING IT, IN ORDER TO
AVOID DETERIORATION OF THE COMPONENTS
2- IT'S FORBIDDEN TO MIX TWO OILS
Page 54/100
Updated 6/12/2010
TYPE
DRIVE SHAFT
NLGI Grade No.2 Lithium grease
JST
Series
CAUTION : THE DRIVE SHAFT NEEDS TO BE GREASED EVERY 250 HOURS OR 3MONTH AT
LEAST. THE DRIVE SHAFT COULD BE SERIOUSLY WORN EVEN DAMAGED IF IT WAS LACK OF
LUBRICATION.
TYPE
FRONT AXLE BEARING ROD END

Lithium grease Every 500 hours.
Page 55/100
Updated 6/12/2010
JST
Series
SECTION 2: TROUBLE SHOOTING

A-LOSS OF POWER
CHECK ENGINE BY APPENDIX

Restriction in the induction system.
Air in fuel system. Defective fuel pump.
Exhaust system restriction. Check oil level and
suitable type according to engine manufacturer.
OK
CHECK TRANSMISSION
Check oil level
Check no whistler
OK
CHECK REAR AXLE

Check the drive shaft. No loose
Page 56/100
Not OK
REPAIR OR ADJUST ENGINE
Not OK
ADJUST OR REPAIR
Updated 6/12/2010
B-REAR AXLE
JST
Series
REAR AXLE NOISE
CHECK LUBRIFICATION
OK
CHECK BEARINGS
OK
TEAR DOWN AND INSPECT

AXLE AND DROP BOX
Page 57/100
Not OK
OVERHAUL AXLE
Not OK
REPLACE BEARING
Updated 6/12/2010
C-STEERING
JST
Series
VEHICULE PULLS TO ONE SIDE
CHECK BRAKES
OK
CHECK WHEELS BEARING
OK
CHECK THE TIRE MATCH AND

INFLATION.
Check for abnormal wear inside the tire.
Inflation: refer to chapter 2 section 1 TYRE
OK
CHECK STEERING ARM LINKAGE

Cylinder, axial swivel, and tie rods.
Page 58/100
Not OK
REPAIR BRAKES
Check brake pads and rotor
Not OK
ADJUST OR REPAIR BEARINGS

See chapter 2 section 3 rotor
Not OK
CHANGE TIRES OR ADJSUT
Updated 6/12/2010
D-BRAKE SYSTEM
JST
Series
EXCESSIVE STOPING DISTANCE
CHECK BRAKE PADS FOR GLAZING OR

EXCESSIVE WEAR
OK
CHECK FLUID LEVEL

Check for any fluid leak
Check hydraulic pump pressure
OK
BLEED BRAKES
Chapter 2 section 3 brakes
Page 59/100
Not OK
REPLACE BRAKE PADS
Not OK
TOP UP AS NECESSARY
Updated 6/12/2010
BRAKE SYSTEM
JST
Series
BRAKES DRAGG OR UNEVEN PULL
CHECK BRAKE PAD AND ROTOR
OK
CHECK FOR SIZED PISTONS
Not OK
REPLACE PADS OR ROTOR AS NEEDED
Not OK
INSTALL A NEW CALIPER ASSEMBLY
Page 60/100
Updated 6/12/2010
BRAKE SYSTEM
JST
Series
BRAKE SPONGY OR EXCESSIVE TRAVEL
CHECK FLUID LINES, FITTINGS AND MASTER

CYLINDER FOR LEAKS
OK
CHECK FOR LEAKS & REFILL SYSTEM
Not OK
TIGHTEN FITTINGS, REPAIR LINES OR

OVERHAUL MASTER CYLINDER, BLEED
SYSTEM
Not OK
REPAIR OR REPLACE CALIPERS
Page 61/100
Updated 6/12/2010
BRAKE SYSTEM
JST
Series
HARD PEDAL
CHECK PRESSURE TO BRAKE BOOSTER
OK
INSPECT BRAKE PADS & ROTOR
OK
CHECK LINES
Page 62/100
Not OK
REPLACE PADS OR ROTOR
Not OK
REPLACE PADS OR ROTOR
Updated 6/12/2010
E-ALTERNATOR
JST
Series
ALTERNATOR NOISY
CHECK MOUNTING AND PULLEYS
OK
REPLACE ALTERNATOR
Not OK
ADJUST
Not OK
ADJUST
Page 63/100
Updated 6/12/2010
ALTERNATOR
JST
Series
ALTERNATOR OUTPUT CONSISTENLY HIGH
CHECK BATTERY FORSHORTS OR INADEQUATE FLUID

LEVEL
OK
CHECK WIRING BETWEEN

BATTERY, ALTERNATOR AND
VOLTAGE
OK
CHECK VOLTAGE REGULATOR
Not OK
REPLAE OR REFILL THE BATTERY
Not OK
REPAIR WIRING
Not OK
REPAIR REGULATOR
Page 64/100
Updated 6/12/2010
F-BATTERY
JST
Series
BATTERY WILL NOT STAY CHARGED
CHECK FOR SHORTED CELL
OK
CHECK ALTERNATOR
OUTPUT AND BELTS
OK
CHECK VOLTAGE REGULATOR
OK
CHECK FOR BREAKS IN WIRING
Page 65/100
Not OK
CHANGE BATTERY
Not OK
REPLACE ALTERNATOR OR
ADJUST BELTS
Not OK
REPLACE REGULATOR
Updated 6/12/2010
JST
SECTION 3: REMOVAL / INSTALLATION / REPAIR
Series
DESIGNATION:
Here are recorded the initial thickness and limit thickness of brake pads and
disks on JST baggage tractor.
Please refer to following instructions and replace the components when limit
thickness is reached.
Designation
Front brake disc initial thickness
Front brake disc limit thickness
Front brake pad initial thickness
Front brake pad limit thickness
Rear brake disc initial thickness
Rear brake disc limit thickness
Rear brake pad initial thickness
Rear brake pad limit thickness
Drum brake shoe initial thickness
Drum brake shoe limit thickness
Page 66/100
Thickness
(Pad and pad support)
10mm
8mm
18mm
9mm
26mm
20mm
13mm
6mm
5mm
2.5mm
Updated 6/12/2010
A.BRAKES
JST
Series
1.Brake pads
a-Disassembly
Remove the caliper from the mounting plate by releasing the two nuts.
Then take out the caliper, and be careful of the oil pipe on it.
Remove the retainer clip and the retainer pad by sliding it out. See as below.
Page 67/100
Updated 6/12/2010
Retainer clip
JST
Series
Retainer pad
Remove the two springs on the brake pads, and remove the pads.
If you have to remove the entire caliper, do not forget the clamp the oil pipe with an
appropriate tool to avoid oil leaks.
b-Installation
Clean the piston extremity before installing the new pads.

Install the new pads, and put the retainer springs back.
Slide the retainer pad and add the retainer clip.
Use a piston compressor tool to keep space for the rotor.
Adjust the caliper ears with the mounting plate holes.
Install the two nuts on the mounting plate.
If you removed the entire caliper from his oil pipes, do not forget to bleed the brake
system.
WARNING: BE SURE THE TOLERANCE BETWEEN BOOSTER AND BRAKE
PEDAL IS PROPERLY RESPECTED.
REFER TO CHAPTER 2, SECTION 3, BRAKE PEDAL.
Page 68/100
Updated 6/12/2010
2.Rotor.
JST
Series
a-Disassembly
Block the rear tires. Jack the front wheels off the ground.
Remove wheel to access to the drive axle hub.
Remove caliper assemblies. Follow the procedure as above.
Remove the cotter pin from the hub nut and remove the nut and washer.
Remove the bearing

Remove the hub and the rotor together
Turn it back and release the four nuts to remove the rotor
Press the rotor off from the hub cap.
b-Installation
Check the thickness and out of plane limits of the rotor. The minimum limit should be .885
inches.
If the rotor thickness is not sufficient change it by a new one.
Adjust the rotor with the hub on the spindle and tighten nuts.
CAUTION:
DO NOT FORGET TO CHANGE THE JOINT INSIDE THE ROTOR THAT AVOID GREASE TO
ENTER, EVERY TIME YOU CHANGE THE ROTOR.
Page 69/100
Updated 6/12/2010
JST
Series
Install the rotor on the drive axle.

Install the bearing, washer and nut.
Tighten the nut and replace the cotter pin.
Check out if there is no play between rotor and drive axle.
c-Bleeding brake system procedure.
If you removed caliper for any reason, you must bleed the system to remove air from it.
Bleeding operation can be done either manually or using a pressure bleeding equipment.
Check the master cylinder reservoir fluid level.
Be careful: never reuse the brake fluid that you get after the bleeding operation.
Manual bleeding requires two people:

One to pump the brake pedal, the second to keep open the bleeding valves.
Make sure the master cylinder is full.
Open the bleeder valve and press hardly the brake pedal.
Then close the valve and let the pedal return slowly to initial position. (Do not forget to
close the valve after every pedal stroke)
Make this operation several times until the caliper would completely be bled, then refill
the master cylinder.
Make the same operation for every caliper.
Check the fluid level in the reservoir frequently during the bleeding procedure.
Page 70/100
Updated 6/12/2010
Pressure equipment Bleeding

Install the special bleeding adapter to the master cylinder.
Bleed all rear calipers, then front calipers.
JST
Series
Check-Out
Check brake pedal for sponginess or hard pedal.
Drive tractor slowly and make several slow speed stops.
Check all brake fluid line fittings and caliper areas for fluid leakage.
3-Parking brake
a-Brake lever
(1)-Removal
Remove the cover of the hand brake handle.

Remove the two nuts
Disconnect the electrical wires.
Remove the cable from the lever by removing the stop screws
(2)-Installation
Follow the inverse procedure to install the brake lever.

The parking brake lever should not be limited by the sensor; otherwise the sensor will be
broken soon.
Page 71/100
Updated 6/12/2010
b-Parking disk
(1)-Removal
JST
Series
Release the four nuts form the brake disk cap.

Remove the cap to access to the shoes brakes
Remove the lower spring that links the two brake shoes. (see part 9 below)
Then remove the two springs that link the shoes with the mounting plate. (See parts 5,6).
Remove the central plate with the link spring (parts 10, 11)
Press the two cylinder springs by turning it to 90 (parts 14,15)
Disconnect the brake cable from the right drum.

Then, extract the two shoes and change by new ones.
(2)-Installation
Place the central plate with the link spring (parts 10, 11) on the left shoe.
Install the two new shoes, connect the brake cable, and put the two cylinder springs in
the adapted place, then turn it to lock the shoes.
Place correctly the two springs at the top of the shoes.
Then connect the two shoes with the lower spring (part 9).
Page 72/100
Updated 6/12/2010
4.Brake pedal
JST
Series
a-Removal
Remove screw and washer from brake pedal rod (secures brake booster push rod to
brake pedal). N6,7,8
Separate booster push rod off from pedal arm by releasing screws.
Remove the sensor.
Remove brake pedal pivot bolt and pedal.
b-Installation
Place brake pedal in installed position and insert brake pedal pivot bolt from left.
Secure with locknut.
Slide booster push rod onto rod on left-side of pedal arm and secure with new cotter pin.
Install the sensor.
Adjust the pedal move by tightening the screw at the top.
Brake Pedal Adjustment:

The rod end between the brake pedal and booster gate should be properly
adjusted to avoid pressure on the master cylinder when the pedal is released.
Page 73/100
Updated 6/12/2010
JST
Series
Please make sure that there is no effort applied on the rod end when the pedal is
released (Not depressed).
The contact between the rod end and booster should be done with a minimum clearance
of 1mm.
After adjustment, please check if unit is braking properly.
(Max speed without load. Braking distance < 6m)
Page 74/100
Updated 6/12/2010
B.WHEELS AND TIRES
JST
1.Rear Tire and Wheel Removal/InstallationSeries
CAUTION: DO NOT REMOVE THE HUB NUT FOR WHEEL REMOVAL.
Jack the rear wheels off the ground

Remove the 6 lug nuts which secure the wheel to the drive axle hub and remove the
wheel.
Remove the tire for repair or replacement as required, using proper tire tools.
Install the new or repaired tire onto the wheel.
Install the wheel to the hub with eight 6 lug nuts and torque to 362 ft. - lbs. (504 N.m)
2.Front Tire and Wheel Removal/Installation
Jack the front wheels off the ground.

Remove the five lug nuts which secure the wheel to the steer axle hub and remove the
wheel.
Remove the tire for repair or replacement, as required.
Install the new or repaired tire on the wheel.
Install the wheel to the hub with five lug nuts and torque to 110 ft. - lbs. (148 N.m)
C- MASTER CYLINDER / BOOSTER

Page 75/100
Updated 6/12/2010
JST
Series
1. Removal
Disconnect brake lines from the master cylinder outlet ports.

Remove the master cylinder from the booster by removing the 4 attachment nuts.
Unplug the brake fluid level connector.
Release the two collars that maintain pipes on the tank cover.
Remove the cylinder tank cover and gasket, and pour out the brake fluid.
2. Installation
Prior to installing the master cylinder in the tractor, bleed the master cylinder as follows:
Support the master cylinder in a vise and loosely install a plug in the outlet port.
Fill the reservoir with brake fluid and depress the cylinder piston several times until all
bubbles cease to appear in the fluid.
Tighten the plug and attempt to depress the piston. The piston travel should be greatly
restricted after all air is expelled
Install the flexible pipes between master cylinder and brake fluid tank.
Replace the reservoir cover and gasket assembly.
Prior to installing the master cylinder, adjust the length between the inner face of the
master cylinder piston to the end of the push rod of the booster as required to be within
tolerance, by turning the adjustment nut.
Install the master cylinder.
Remove the output port plug and install the brake line.
Bleed the braking system.
D- HYDRAULIC PUMP & COMPONENT.

Page 76/100
Updated 6/12/2010
1- Hydraulic tank.
The JST hydraulic tank is part of the frame.
JST
Series
Remove the collars and disconnect the flexible pipes.

Remove the bolts from the top plate to access to the tank for maintenance.
After any maintenance operation, replace the rubber seal by a new one.
2- Hydraulic pump.
JST is equipped with a 10cc hydraulic pump flanged on transmission PTO.
Max output pressure is 20Mpa.
Max speed is 2500 RPM.
Disconnect flexible pipes from the pump output and input ports.
Bleed the hydraulic oil remained in the pipes.
Remove the bolts that link the pump to the transmission PTO.
Remove the pump.
E-BATTERY.
JST series tractor is using a 12V 90A.h battery.
To prevent any damage of the battery:
Store the unit in an appropriate dry location.
Avoid any contact with water.
Do not forget to remove electrical plugs before any major repair.
Check regularly the battery voltage.
Refill the battery when it is necessary.
1.Removal:
Remove the 4 bots that maintains the battery into the table.
Remove the connecting cables and remove the battery from the vehicle.
F-LIGHTS AND BULBS.

Page 77/100
Updated 6/12/2010
Before any use of the unit, check out the lights of the vehicle.
JST
Replace bulbs if any deficiency:
Work light (12V, 55W)
Series
Rear light LED (Stop, Turn and Back up lights)
The rear lights are not replaceable separately. The entire rear LED assembly must be
replaced.
Front lights 3 bulbs.
o Headlamp. Bulbs are not replaceable separately.
o Turning signal lights (12V, 21W)
Flashing beacon light is not replaceable separately.
G-RADIATOR AND COOLING SYSTEM.

DEUTZ F4M2011 is using a heavy duty radiator with dual circuits: oil for engine, oil for
transmission. This radiator is equipped with a dual electric fans system.
Other engines are using a heavy duty radiator with dual circuits: coolant water for engine, oil for
transmission. Theres an expansion tank in engine cooling circuit, with a 0.9BAR pressure cap.
Page 78/100
Updated 6/12/2010
JST
Series
CHAPTER 3.
OVERHAUL/MAJOR REPAIR.
Page 79/100
Updated 6/12/2010
SECTION 1: STEERING
JST
Series
If the tractor has been properly lubricated and maintained and has not experienced damage to
the steering system, the steering components should provide lengthy service without an overhaul.
Should an overhaul be required, follow the procedure below:
JST is using a hydraulic double acting cylinder between the axle body and the right wheel arm.
Additional spacers between leaf spring and front axle are installed to avoid engine
housing stroke. (30mm)
A-DISASSEMBLY
Jack up the front end of the tractor using normal jacking procedures (Apply hand brake,
and place blocks under front chassis).
Grasp the top and bottom of each tire and shake it to determine any looseness while
observing the hub and spindle area.
If there is any move in the hub, try to tighten the hub retainer nut. If move still occurred, the
bearings and seals should be replaced. Following the procedures as below (Chapter ROTOR)
Inspect the steer cylinder for damage. Also check for wear of the rod ends by grasping
the cylinder and shaking it. If the rod ends are loose, replace the rod ends.
Replace Bearing rod end

2 bearing rod ends between linkage bar and the wheel arms.
Remove the rod ends by removing the pin that goes through rod end and wheel arm.
Remove the bolts and washers above and below this pin.
Page 80/100
Updated 6/12/2010
JST
Series
Bearing rod ends are threaded and screwed in the linkage bar.
When installing the linkage bar and rod ends, use lock nut to adjust the bar length.
CAUTION: rod ends have different threads: right and left one.
2 bearing rod ends at the cylinder extremities
Remove the flexible pipes on the cylinder and bleed the hydraulic oil.
After the removal of rod ends on the linkage bar, remove as well the bolts and washers at
the cylinder extremities.
Remove the cylinder for inspection if needed.

The bearing rod ends of this unit are lubricated with grease cap.
Page 81/100
Updated 6/12/2010
Grease the bearing rod ends every 500 hours. (If swivels are equipped with grease
JST
cap)
Series
B-ADJUSTMENT
With the wheels pointing forward adjust the toe in by loosening the tie rod and turning
the threaded rod end in or out.
After the toe-in adjustment is complete grease the tie rod ends as in regular maintenance.
See assembly scheme below:
Page 82/100
Updated 6/12/2010
SECTION 2: ENGINE & TRANSMISSION
JST
Series
This is a generic removal explanation, for further technical details; please find engine
specifications on the illustrated parts section.
A-REMOVAL
Disconnect the battery cables from the battery.

Remove the hood & radiator first
Drain the oil from the engine and oil filter
Remove the exhaust pipe.
Remove all electrical cables and hoses linked to the engine, as well as throttle cable and
other temperature sensors.
Close the fuel line shut-off valve.
Disconnect the air intake line.
Disconnect the drive shaft from the transmission (see chapter above)
Remove the floorboards to access to the transmission.
Make sure the shifter is in neutral and remove the gear shift connecting cable from the
transmission.
Remove the hoses linking pump to hydraulic tank.
Make sure that there are no hose, cable and wire still linked to the engine & transmission
system.
Remove the bottom bolts from both left and right motor & transmission mounts.
Attach a chain hoist to the engine & transmission and remove it smoothly.
B. INSTALLATION
Lower the engine & transmission into the tractor with a chain hoist and adjust it to be
properly mounted on the rubber blocks.
Fix properly the mounting bolts of engine/transmission system.
Remove the chains; connect the gearshift cables to the transmission.
Install the drive shaft.
Connect hydraulic wires to the pump, and master cylinder.
Connect fuel line, sensors and electric wires to the engine.
Install the oil filter, reinstall radiator and throttle cable
Install the exhaust pipe
Attach air filter hose.
Connect the battery ground cable.
Connect battery cables to the battery.
Refill engine and transmission with correct oil according to lubricate chart.
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JST
Series
SECTION 3: ENGINE & TRANSMISSION RUBBER
BLOCK BRACKETS.
The rubber blocks used for the transmission and the DEUTZ engine are semi spherical types.
For removal of these rubber blocks, proceed as follow:
Disconnect the engine and transmission as described on section 2.
After the engine and transmission block is out of the tractor, separate the two rubber parts.
In normal use condition, rubber blocks need not to be replaced.
However, as mentioned in the maintenance check list, please check the rubber blocks regularly to
notice any abnormal stretch or wear.
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SECTION 4. DRIVE SHAFT
JST
Series
A-DISASSEMBLY
Chock the wheel securely

CAUTION:
DO NOT ENGAGE THE PARKING BRAKE.
Remove the four yoke bolts securing the rear of the park brake disk.
Disconnect the rear part of the drive shaft.
Remove the four yoke bolts securing the front of the transmission.
Remove the drive shaft by handling it to not damage the linked parts.
B-INSTALLATION
Connect the front part of the shaft by installing four bolts to attach the drive shaft coupling
plate to the transmission.
Assembly front and rear parts of the sliding shaft.
Install the four yoke bolts securing the rear section drive shaft to the park brake disk.
Be careful to let the drive shaft universal joints free of bind.
Do not forget to add lithium based grease in the universal joints and sliding shaft
Page 85/100
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JST
SECTION 5: REAR AXLE REDUCTION GEAR BOX.
Series
If the tractor has been properly lubricated, maintained, the drive axle will provide many hours of
service without an overhaul. If, however, an overhaul is required, follow the procedure below:
A.BRAKES PADS AND CALIPERS REMOVAL
Remove drive axle from tractor

Disconnect the parking brake linkage and remove brake lines linked to the rear axle.
Drain the gear case by removing the gear case oil drain plug located at the bottom of the
reduction gear case.
Brakes lines and

connectors
Remove the rear four nuts on the caliper brackets
Page 86/100
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JST
Disassemble calipers from the brackets and rotor.
Check the brake pads thickness and change it if necessary by removing the maintaining
Series
springs.
Check the rotor thickness. The initial thickness of the rotor is 26.5mm.
B. AXLE SHAFT
Remove the wheels from the drive axle.

Support axle, on suitable supports on both sides of axle assembly
Drain the gear case by removing the gear case oil drain plug located at the bottom of the
reduction gear case.
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JST
Series
Insert threaded rod

to remove hub case
Remove the attachments screws from the axle shaft and insert the threaded rod in the
suitable tapped holes (see photo above).
By tightening the threaded rods, the axle shaft will be released.
Because of the tight fit axle shaft, it may be necessary to use a flat chisel with small
hammer and lightly tap the back edge of the axle shaft at several points.
Then remove the entire shaft with seals together.
Page 88/100
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C. AXLE HOUSING
JST
Series
1. Remove Drive Axle and bevel gear.
Remove the drive axle from the tractor and fix it in an appropriate vise or heavy support.
Remove bolts, nuts and washers from case and cover
Use a chain to lift the upper part of the gear box.
Because of the tight fit housing, it may be necessary to use a hammer and tap the axle
shaft housing to separate the two parts.
Remove upper part of the reduction box with differential and gear assembly.
Page 89/100
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2. Differential and Gear Assembly. JST

(a) Removal.
Series
Rotate the gears to see if there is any roughness which could indicate worn or damaged
bearings.
Remove bolts and separate gear and case if required.
Check the bearings and seals.
Look carefully at the surface of the gear teeth for any scoring, surfacing or abnormal wear.
Page 90/100
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Inspect the differential assembly
Check for any surfacing or machining pinions.

Check the bearing and replace if necessary.
Clean before assembly. Gears, bearings, pinions should be cleaned in a suitable solvent
such as kerosene or diesel fuel oil.
Page 91/100
JST
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(b).Installation.
JST
Series
(a) Gear assembly.

Replace bearing if necessary,
Install differential and gear assembly in housing.
Install flanges that maintain the gear and tighten nuts.
Install splined bushing and tighten it until there is no play between gears.
Grasp and rotate the gear to check the tightness.
Put the reduction gear box in the drive shaft housing

Install all bolts around the cover
Page 92/100
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(b) Axle Shaft and brakes
JST
Clean and lubricate hub cavity and carefully fit axle shaft into housing.
Series
Install the nuts and washers
Install caliper on the rotor.
Connect brake lines to calipers.
Install drain plug in axle housing.
Install tires and wheels.
Install axle in vehicle.
Check lubrication.
Page 93/100
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D.REDUCTION GEAR BOX.
JST
Series
Cotter pin and

castellated nut.
1.Removal
Remove the parking brake assembly from the drive axle input shaft flange.
Remove the cover nuts and washers and the parking brake shoes (refer to chapter above
repair section.)
Remove the cotter pin and castellated nut
Remove the input shaft rear cap and gasket by removing the attachment
Remove the input shaft flange from the front side of the reduction gear case.
Grasp the input shaft from inside the reduction gear case and extract the shaft, together
with its bearings, from the case housing.
Remove the reduction gear from the case housing by removing the bevel pinion bearing
nut.
2.Inspection
Inspect all parts as follows:

Inspect the reduction gear and drive gear for wear or damage.
Replace the gears if they are surfaced or broken.
Remove the bearings with a puller.
Replace oil seals and gaskets with new parts.
Page 94/100
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3.Installation.
Assemble the reduction gear as follows:
Install new bearings and seals and lubricate the bearing.
Install the reduction gear and secure the gear with the bevel pinion bearing nut
Place the input shaft into the gear case housing.
Tap the case cover into the installed position.
Install the gear case cover attachment bolts.
Install the drain plug into the gear case.
Install the parking brake shoes
Install the cap and tighten the attachments bolts.
Page 95/100
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JST
Series
CHAPTER 4.
ILLUSTRATED PARTS LIST

SEE ENCLOSED FILES
Page 96/100
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JST
Series
CHAPTER 5.
MANUFACTURERS
LITERATURE
REFER TO ENCLOSED FILES
Page 97/100
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ANNEX 1: DAILY EQUIPMENT INSPECTION

JST
Series
WHILE OPERATORS SHOULD NOT ATTEMPT TO PERFORM REPAIRS, THEY
DO HAVE THE RESPONSIBILITY TO REPORT IMMEDIATELY ANY PROBLEMS
TO THEIR SUPERVISOR, SO THAT REPAIRS CAN BE MADE IN A TIMELY
FASHION BY QUALIFIED MAINTENANCE PERSONNEL.
DAILY EQUIPMENT INSPECTION - JST TOW TRACTOR

Vehicle S/N: __________________
Operator: _____________________
[9] Good
[
Date: ____/____/____
[A] Adjustments Completed
Check the engine oil and ensure

that the level is within operating
range.
On water-cooled systems, inspect
the coolant/water level at the
coolant surge tank. (Do not
remove the radiator cap to
perform a routine coolant level
check.)
Inspect the tire treads for damage
or wear. Remove stones lodged in
the treads and report any damage,
cracked sidewalls, limited tire
tread, or unusual wear.
Check that other lights are in
working order, including the
backup, tail stop and turn signal
lights, if the vehicle is equipped
with such.
Operate the horn. It should be
crisp in sound and loud enough to
be heard under most operating
conditions.
Check the fuel level. (Green caps
indicate a diesel-powered vehicle,
while red caps indicate gasoline.)
[N] Needs Repairs
Check the power steering fluid level by opening the

cap to inspect the level. Ensure that the level is
within operating range and then replace the cap.
Check the inflation pressure of each pneumatic tire.
Drive wheels or rear wheels require 7.2bar (104psi)
while steering or front wheels require 4.0bar (58psi).
Adjust tire pressure as required.
Make sure the headlights are working and aimed

correctly.
Ensure the operation of the cab marker lights, the

heater, the window wiper, and cab light, if so
equipped.
Ensure that all controls are in good working order.

Report any faulty controls and do not use the
equipment until repairs have been completed.
While correctly positioned in the drivers seat, adjust

it to suit your requirements. If your vehicle is
equipped with a Rider Safe seat, the vehicle will
remain inoperable until you activate the seat by
sitting on it.
Page 98/100
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ANNEX 2: MAINTENANCE CHECKLIST
JST
Series
PREVENTIVE MAINTENANCE CHECKLIST - JST TOW TRACTOR

Vehicle S/N: __________________
Operator: _____________________
[9] Good
Date: ____/____/____
[A] Adjustments Completed
[N] Needs Repairs
Visual Inspection
[ ]
Check for accident damage, paint
condition, and overall appearance
[ ]
Examine vehicle underside for
leaks
[ ]
Check seat condition
[ ]
Inspect fuel cap and gasket for
security and color
Overhead Inspection
Drain engine oil and replace oil filter
[ ]
[
[
]
]
Examine tractors hitch and pin
Ensure legibility of all warning

placards
Check transmission fluid level
Add engine oil
Start engine and inspect oil filter and drain plug for
leaks
Inspect master cylinder fluid level and clarity
[
[
]
]
[
[
]
]
Inspect power steering pump and hoses

Examine accelerator linkage and cable to injector
pump. Inspect return spring
Inspect air intake system. Replace air filter
Drain any water accumulated in fuel filter. Replace
filter if water reached element
Operational Inspection
[
[
]
]
Test neutral safety circuit

Start engine and check oil
pressure
Check anti-restart switch
[
[
[
[
]
]
]
]
[
[
]
]
Check condition of all gauges

Operate horn
Check brake pedal for firmness
Check steering for smoothness and
excessive free play
Check transmission shifting and
performance
While driving check for unusual
noises from differential,
transmission, and brakes. Watch
for exhaust leaks and listen for
exhaust rattles
Evaluate engine performance.
Check for excessive smoke
Check parking brake adjustment
Check service lights
B PM Inspection
[ ]
Inspect brake linings, clean and
pack wheel bearings
Check transmission for leaks, security of mounts, and

linkage condition
Inspect exhaust system
Check differential gear oil level and input shaft for
leaks. Check brake rotor for rear-end leaks from axle
tube. Examine u-joints and drive shaft
Check back of rotors for leaking calipers and inspect
rigid and flexible brake lines
Inspect all fuel Lines
Examine park brake linings. Check park brake lever

adjustability
Check front suspension for binding or abnormal
[ ]
looseness (for this step front tires and suspension
must be free to move, raise front-end if on lift.)
Grease all fittings on suspension and drive line
[ ]
Check inflation pressure of pneumatic tires, rear
[ ]
wheels require 7.2bar (104psi) and front wheels
require 4.0bar (58psi) Check tire wear, and condition
[ ]
Inspect wheels for damage. Check lug bolt holes for
cracks and distortion.
(Mfg. recommended torque setting for lug nuts
148N.m at front and 504N.m at rear)
Inspect the front wheel hub slotted nut.
[ ]
Hub slotted nut retightened procedure:
1. use 150n.m to tighten the nut
2. return back 1/4 circle
3. use cotter pin to fix the nut
Check the rear and front hitch support bolts for loose
[ ]
and retightened them.
Open Hood Inspection
Check battery condition
[ ]
Inspect hood hinge and latches
[ ]
Check oil cooler and hoses for leaks
[ ]
Page 99/100
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Change fuel filter and bleed the

fuel system
Inspect belts
[
[
]
]
[
[
]
]
Check tow eyes for security

Start engine and check max. rpm of 2800. Adjust as
required
Check alternator output range (13.9 - 14.2 volts DC.)
Test oil temperature and pressure safety circuits
Page 100/100
JST
Series
Updated 6/12/2010

Operation and Maintenance Manual: JST Series

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JST

SECTION 1 TABLE OF CONTENT

SECTION 2 RECORD OF REVISIONS

SECTION 3: TLD SALES INFORMATIONS

SPARE PARTS DEPARTMENT

SPARE PARTS DEPARTMENT

SECTION 5 GENERAL WARNING

OBLIGATION TO GO THROUGH THE USERS MANUAL

MACHINE NORMAL USING DOMAIN

MODIFICATION OF THE TRACTOR

SECTION 6: INFORMATION AND OPERATION JST

1. Always follow the global safety rules applicable in your field.

ALWAYS EXERCISE GOOD COMMON SENSE, STAY ALERT AND BE AWARE

SECTION 1: MAIN COMPONENTS

A.ENGINES AND TRANSMISSION

DESPITE THIS SUSPENSION SYSTEM, IT IS RECOMMENDED THAT YOU DRIVE

F.WHEELS AND TIRES

I.FRAME AND BUMPERS

N.PARKING BRAKE LEVER

IT IS ESSENTIAL THAT THE OPERATOR BECOMES ACCUSTOMED TO BOTH

Horn control switch

Headlamp dipped/main beam switch

Roof beacon switch

Rear working light switch

Alert light switch

Wiper control switch

Windscreen washer switch

Heating system / Air-conditioning switch

Ventilator speed selector

Cab dome light switch

Wiper sensor switch

An automotive type switch that incorporates an

Controls the windshield wiper motor

The heater switch controls the heater blower

Operates the interior cab light (if equipped with

Indicates when the engine is pre-heating

Park brake light / Low-brake fluid warning

Indicates if the parking brake is engaged or

Low-level battery light

Indicate when the battery level is low

Turn signal / alert signal light

Indicates when the turn signals or the alert

Low-oil pressure light

Indicates when the engine pressure is low

High water temperature light

Indicates when the cooling temperature is high

Low-level Fuel/LPG light

Indicates when the fuel / LPG level is low

Reads the state of remaining fuel.

Reads elapsed time the unit has been in

Engine coolant temperature indicator

Transmission oil pressure

Reads the transmission oil pressure

Battery charging, voltmeter

Reads the state of charge of the battery (Volt)

Battery charging, amper-meter

Reads the state of charge of the battery

Reads the speed of the tractor

Engine oil pressure indicator

Reads the engine oil pressure

Reads the gear box temperature

Reads the speed of the engine