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Linhai LANDBOSS LH800U-2D Service Manual

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SERVICE MANUAL
LH800U-2D
2014.0

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Summary of Contents for Linhai LANDBOSS LH800U-2D

  • Page 1 SERVICE MANUAL LH800U-2D 2014.0...
  • Page 2 Foreword This manual is designed primarily for use by the UTV factory certified service technicians in a properly equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly.

  • Page 3: Table Of Contents

    CONTENTS CHAPTER1 ………………………………………………General Information ↖ CHAPTER2 ………………………………………….……………Maintenance ↖ CHAPTER3…………………………………….………. ………………Chassis ↖ CHAPTER4…………………………………………..………………Final Drive ↖ CHAPTER5………………………………………………….……………Brakes ↖ CHAPTER6……………………………………………….………Transmission ↖ CHAPTER7…………………………………………Rear and Front Gearcase ↖ CHAPTER8………………………………………………….….………Electrical ↖ WARNING Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors. Gasoline is extremely flammable and explosive under certain conditions.

  • Page 4: General Information

    CHAPTER 1 GENERALINFORMATION LH800U-2D SERVICE MANUAL 2014.0 CHAPTER 1 GENERAL INFORMATION The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each UTV model for spare parts information and service. 1.1 IMPORTANT INFORMATION 1.2 V.I.N AND ENGINE SERIAL NUMBER 1.3 VEHICLE DIMENSIONS...

  • Page 5: Important Information

    CHAPTER 1 GENERALINFORMATION LH800U-2D SERVICE MANUAL 2014.0 1.1 IMPORTANT INFORMATION PREPARATION FOR REMOVAL PROCEDURES 1. Remove all dirt, mud, dust and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. 3. When disassembling the machine, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been ”mated ”through normal wear.
  • Page 6 CHAPTER 1 GENERALINFORMATION LH800U-2D SERVICE MANUAL 2014.0 Replace distorted circlips. When installing a circlip ① , make sure that the sharp-edged corner ② is positioned opposite the thrust ③ it receives. See sectional view. ④Shaft CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc. on the connector.
  • Page 7 CHAPTER 1 GENERALINFORMATION LH800U-2D SERVICE MANUAL 2014.0 CONVERSION TABLE How to use the CONVERSION TABLE Use this table to convert METRIC unit data to IMPERIAL unit data. METRIC MULIPLIER **mm 0. 3937 **in **cm 0.03937 **in CONVERSION TABLE METRIC TO IMP Known Multiplier Result...
  • Page 8 CHAPTER 1 GENERALINFORMATION LH800U-2D SERVICE MANUAL 2014.0 V.I.N AND ENGINE SERIAL NUMBER Record the frame VIN and the engine serial number from your UTV in the spaces provided. Frame VIN (found on the front right side of the frame tube) The vehicle frame is important for model identification when registering your vehicle, obtaining insurance or whenever replacement parts are required.
  • Page 9 CHAPTER 1 GENERALINFORMATION LH800U-2D SERVICE MANUAL 2014.0 PAGE. 1- 6 CHAPTER 1 GENERAL...

  • Page 10: Vehicle Dimensions

    CHAPTER 1 GENERALINFORMATION LH800U-2D SERVICE MANUAL 2014.0 VEHICLE DIMENSIONS PAGE. 1- 7 CHAPTER 1 GENERAL...
  • Page 11 CHAPTER 1 GENERALINFORMATION LH800U-2D SERVICE MANUAL 2014.0 NOTES PAGE. 1- 8 CHAPTER 1 GENERAL...

  • Page 12: Maintenance

    CHAPTER 2 MAINTENANCE LH800U-2D SERVICE MANUA2014.0 CHAPTER 2 MAINTENANCE The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each UTV model for spare parts information and service. 2.1 PERIODIC MAINTENANCE 2.2 THROTTLE PEDAL INSPECTION 2.3FUEL SYSTEM...

  • Page 13: Periodic Maintenance

    CHAPTER 2 MAINTENANCE LH800U-2D SERVICE MANUA2014.0 2.1 PERIODIC MAINTENANCE GENARAL CAUTION Mark on the following chart D：Due to the nature of the adjustments marked with a D on the following chart, it is recommended that service be performed by an authorized dealer. ▲：...
  • Page 14 CHAPTER 2 MAINTENANCE LH800U-2D SERVICE MANUA2014.0 Item Hours When Remarks l Air Filter-Main Element Weekly Inspect ; Replace if necessary Brake Pad Wear / Parking Inspect periodically 10 hrs Monthly Brake Pads 10 hrs Monthly Check Axle boots, looseness, Front and rear axle boots damage, replace if necessary Battery 20 hrs...
  • Page 15 CHAPTER 2 MAINTENANCE LH800U-2D SERVICE MANUA2014.0 Item Hours When Remarks Transmission Oil Level 100hrs Monthly Check monthly and change annually Spark Plug 100 hrs 12 months Inspect-replace if necessary Shock 100 hrs Inspect seals Brake Fluid 200 hrs 24 months Change every tow years Spark arrestor 300 hrs...
  • Page 16 CHAPTER 2 MAINTENANCE LH800U-2D SERVICE MANUA2014.0 2.2 THROTTLEPEDAL INSPECTION THROTTLE FREEPLAY If the throttle pedal has excessive play due to cable stretch or cable mis-adjustment, it will cause a delay in throttle speed. Also, the throttle may not open fully. If the throttle pedal has no play, the throttle may be hard to control, and the idle speed may be erratic.
  • Page 17 CHAPTER 2 MAINTENANCE LH800U-2D SERVICE MANUA2014.0 FUEL LINES 1. Check fuel lines for signs of wear, deterioration, damage or leakage. Replace if necessary. 2. Be sure fuel lines are routed properly and secured with cable ties. CAUTION: Make sure lines are not kinked or pinched.
  • Page 18 CHAPTER 2 MAINTENANCE LH800U-2D SERVICE MANUA2014.0 2.5BRAKING SYSTEM INSPECTION The following checks are recommended to keep the braking system in good operating condition. Service life of braking system components depends on operating conditions. Inspect brakes in accordance with the maintenance schedule and before each ride !Keep fluid level in the master cylinder reservoir to the indicated level on reservoir.
  • Page 19 CHAPTER 2 MAINTENANCE LH800U-2D SERVICE MANUA2014.0 To adjust (set up) the mechanical parking brake, use the following procedure Note: The adjusting on the caliper is for the wear out of the pads. 1. With the engine off, loosen the adjustor on the lever. 2.
  • Page 20 CHAPTER 2 MAINTENANCE LH800U-2D SERVICE MANUA2014.0 2.7 WHEELS Inspect all wheels for runout of damage. Check wheel nuts and ensure they are tight. Do not over tighten the wheel nuts. WHEEL REMOVAL 1. Stop the engine, place the transmission in gear and lock the parking brake.

  • Page 21: Tire Pressure

    CHAPTER 2 MAINTENANCE LH800U-2D SERVICE MANUA2014.0 2.8TIRE PRESSURE TIRE INSPECTION CAUTION: l Maintain proper tire pressure. Refer to the warning tire pressure decal applied to the vehicle. l Improper tire inflation affect Tire Pressure Inspection maneuverability. l When replacing a tire always use original equipment Front Rear size and type and replace in pairs.
  • Page 22 CHAPTER 2 MAINTENANCE LH800U-2D SERVICE MANUA2014.0 3.0STEERING COLUMN INSPECTION When assemble the steering column, check the direction of the column. CHAPTER 2 MAINTENANCE PAGE. 2- 11...
  • Page 23 CHAPTER 2 MAINTENANCE LH800U-2D SERVICE MANUA2014.0 NOTES CHAPTER 2 MAINTENANCE PAGE. 2- 12...

  • Page 24: Chassis

    CHAPTER 3 CHASSIS LH800U-2D SERVICE MANUAL 2014.0 CHAPTER 3 CHASSIS WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each UTV model for spare parts information and service. 3.1 FRONT A-ARM REPLACEMENT 3.2 REAR A-ARM REPLACEMENT 3.3 REAR STABILIZER BAR REMOVAL/INSTALLATION...
  • Page 25 CHAPTER 3 CHASSIS LH800U-2D SERVICE MANUAL 2014.0 3.1 FRONT A-ARM REPLACEMENT 1. Elevate and safely support the front of the vehicle and remove the front wheel. 2. Remove cotter pin from ball joint stud at wheel end of A- arm and loosen nut until it is flush with end of stud. 3.
  • Page 26 CHAPTER 3 CHASSIS LH800U-2D SERVICE MANUAL 2014.0 5. Examine A-arm bushing. Replace if worn or tore. Discard hardware. 6. Install new A-arm assembly onto vehicle frame. Apply Loctite™ 263 to screw threads of the A arm bolts and torque new bolts to 37~44 ft. lbs (50~60 Nm ). DO NOT reuse old bolts.
  • Page 27 CHAPTER 3 CHASSIS LH800U-2D SERVICE MANUAL 2014.0 4. Loosen bolts that secure the A-arm to frame. 5. Remove the nut from the upper portion of the stabilizer. 6. Examine the A-arm bushing and A-arm shaft. Replace if worn. Discard hardware. 7.
  • Page 28 CHAPTER 3 CHASSIS LH800U-2D SERVICE MANUAL 2014.0 Upon A-arm installation completion, test vehicle at low speeds before putting into regular service. 3.3 REAR STABILIZER BAR REMOVAL/INSTALLATION 1. Elevate and safely support vehicle with weight removed from the rear wheel(s). 2. Remove the rear wheel to gain access to the stabilizer bar, each side.
  • Page 29 CHAPTER 3 CHASSIS LH800U-2D SERVICE MANUAL 2014.0 hinge pin removed 6. With the hinge pins removed, remove the box from the frame. Two people maybe needed to remove the bed from the frame. CAUTION: Use caution when removing the box. It is recommended to have two people to carefully remove the box from the frame.
  • Page 30 CHAPTER 3 CHASSIS LH800U-2D SERVICE MANUAL 2014.0 3. Remove the steering column bolts. 4. Remove the upper of the steering column. 5. Remove the cotter pins and the tie rod end bolts (both sides). 6. With the cover bolts removed, remove the steering assy and the lower of the steering column.
  • Page 31 CHAPTER 3 CHASSIS LH800U-2D SERVICE MANUAL 2014.0 NOTES CHAPTER 3 CHASSIS PAGE. 3-...

  • Page 32: Final Drive

    CHAPTER 4 FINAL DRIVE LH800U-2D SERVICE MANUAL 2014.0 CHAPTER 4 FINAL DRIVE WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each UTV model for spare parts information and service.
  • Page 33 CHAPTER 4 FINAL DRIVE LH800U-2D SERVICE MANUAL 2014.0 4.1 WH E E L , H U B , AND SPINDLE TORQUE TABLE Item Specification heel Nuts 69 Ft.Lbs 95 Nm Front W heel Nuts 69 Ft.Lbs 95 Nm Rear W Front Hub Nut on Spindle/ outer CV joint 101 Ft.Lbs 137 Nm Rear Hub Retaining Nut...

  • Page 34: Brakes

    CHAPTER 4 FINAL DRIVE LH800U-2D SERVICE MANUAL 2014.0 4.3 FRONT HUB AND KNUCKLE REMOVAL/INSPECTION 1. Elevate front end and safely support machine under footrest/frame area. CAUTION: Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.
  • Page 35 CHAPTER 4 FINAL DRIVE LH800U-2D SERVICE MANUAL 2014.0 4.4 FRONT HUB INSTALLATION 1. Inspect the hubstrut bearing surface for wear or 18ft.lbs(24NM) damage. 2. Apply grease to drive axle spindle. 3. Install spindle through the backside of the hubstrut. Install the hub onto the spindle. 4.
  • Page 36 CHAPTER 4 FINAL DRIVE LH800U-2D SERVICE MANUAL 2014.0 NOTE: The outer CV joint cannot be disassembled or repaired, if damage or faulty the drive axle assembly must be replace. 1. Drive Axle/Outer CV Joint Assembly. 2. Boot Band “A”. 3. Outer Board Boot. 4.
  • Page 37 CHAPTER 4 FINAL DRIVE LH800U-2D SERVICE MANUAL 2014.0 chapter. 2. Move each end of the drive shaft in a circular motion (and also a reciprocate for inner one) and check the drive shaft joints for excessive wear or play. 3. This inner CV joint (inboard pivot joint) can be serviced if there is wear or play.
  • Page 38 CHAPTER 4 FINAL DRIVE LH800U-2D SERVICE MANUAL 2014.0 4.7 FRONT DRIVE AXLE DISASSEMBLY/ INSPECTION INNER CV JOINT DISASSEMBLY NOTE: The outer CV joint cannot be disassembled or repaired, if damage or faulty the drive axle assembly must be replace. 1. Open the clamps on both boot band ”A” and ”B” on the inner CV joint, then remove boot band ”B”.
  • Page 39 CHAPTER 4 FINAL DRIVE LH800U-2D SERVICE MANUAL 2014.0 replacement parts are available. 6. Clean the inner CV joint in solvent and thoroughly dry. 7. Inspect the interior of the inboard joint where the steel balls ride. Check for wear or damage and replace the joint if necessary.
  • Page 40 CHAPTER 4 FINAL DRIVE LH800U-2D SERVICE MANUAL 2014.0 4.8 REAR HUB EXPLODED VIEW 4.9 REAR HUB AND KNUCKLE REMOVAL/INSPECTION 1. Elevate rear end and safely support machine under main frame area. CAUTION: Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service...

  • Page 41: Rear Drive Shaft Removal

    CHAPTER 4 FINAL DRIVE LH800U-2D SERVICE MANUAL 2014.0 damage to the brake line. 5. Remove cotter pin, rear spindle nut, and washer. 6. Remove the upper and lower control arm bolts. 7. Slide the rear hub and knuckle from the rear drive axle.

  • Page 42: Rear Drive Shaft Installation

    CHAPTER 4 FINAL DRIVE LH800U-2D SERVICE MANUAL 2014.0 3. Pull the rear drive axle straight out of the frame. Use short sharp jerks to free the circlip from the gearcase. The circlip holds the axle in the gearcase. 4. Inspect the axle splines and cv boots for any damage.
  • Page 43 CHAPTER 4 FINAL DRIVE LH800U-2D SERVICE MANUAL 2014.0 4. Lift knuckle into place and install bolt to upper and lower control arm. Torque bolt to 44 ft.lbs (60 Nm). 5. Install the washer and the spindle retainer nut. 6. Install brake caliper using new bolts. (Apply Loctite™...
  • Page 44 CHAPTER 4 FINAL DRIVE LH800U-2D SERVICE MANUAL 2014.0 NOTES CHAPTER 4 FINAL DRIVE. 4- 13...
  • Page 45 CHAPTER 5 BRAKES LH800U-2D SERVICE MANUAL 2014.0 CHAPTER 5 BRAKES WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each ATV model for spare parts information and service. NOTE: Also See Chapter 2 for Maintenance Information.

  • Page 46: Specifications

    CHAPTER 5 BRAKES LH800U-2D SERVICE MANUAL 2014.0 5.1 SPECIFICATIONS Front Brake Caliper Item Standard Service Limit Brake Pad Friction material 0.157"/ 4mm 0.04"/ 1mm Thickness B rake Disc Thickness 0.150- 0.164"/3.810- 4.166mm 0.140"/ 3.556mm Brake Disc Thickness Variance 0.002 "/ .051mm Between Measurements Brake Disc Runout 0.005 "/ .127mm...
  • Page 47 CHAPTER 5 BRAKES LH800U-2D SERVICE MANUAL 2014.0 l Make sure atmospheric vent on reservoir is unobstructed. l Adjust foot brake after pad service. l Test for brake drag after any brake system service and investigate cause if brake drag is evident.
  • Page 48 CHAPTER 5 BRAKES LH800U-2D SERVICE MANUAL 2014.0 bleed brakes during regular maintenance. 1. Clean reservoir cover thoroughly. 2. Remove cover from reservoir. 3. If changing fluid, remove old fluid from reservoir with a brake fluid pump or similar tool. 4. Add brake fluid up to the indicated MAX level on the reservoir.

  • Page 49: Parking Brake Adjustment

    CHAPTER 5 BRAKES LH800U-2D SERVICE MANUAL 2014.0 hoses and lines for wear or abrasion. Replace hose if w ear or abrasion is found. 5.6 PARKING BRAKE AND BRAKE LINE INSPECTION 1. Inspect the spring on the parking brake lever assembly. 2.
  • Page 50 CHAPTER 5 BRAKES LH800U-2D SERVICE MANUAL 2014.0 5. Back the adjustment bolt (B) out 1/4 turn. 6. Tighten the jam nut (A) while holding the adjustment nut (B) in place. 5.8 PARKING BRAKE REAR CALIPER REMOVAL / INSTALL Park Brake Caliper Disassembly / Pad Inspection NOTE: Do not get oil, grease, or fluid on the park brake pads.
  • Page 51 CHAPTER 5 BRAKES LH800U-2D SERVICE MANUAL 2014.0 5.9 FRONT PAD REMOVAL / INSPECTION / INSTALLATION NOTE: The brake pads should be replaced as a set REMOVAL 1. Elevate and support front of UTV safely. CAUTION: Use care when supporting vehicle so that it does not tip or fall.
  • Page 52 CHAPTER 5 BRAKES LH800U-2D SERVICE MANUAL 2014.0 of All Season Grease, and install rubber dust boots. 2. Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other. Be sure pads and disc are free of dirt or grease.
  • Page 53 CHAPTER 5 BRAKES LH800U-2D SERVICE MANUAL 2014.0 3. Mount dial indicator as shown to measure disc runout on the dial indicator. Replace the disc if runout exceeds specifications. Brake Disc Runout Service Limit 0.005" (0.127 mm) REMOVAL/ REPLACEMENT 1. Removal caliper and hub. Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent.
  • Page 54 CHAPTER 5 BRAKES LH800U-2D SERVICE MANUAL 2014.0 18 ft. lbs. (25 Nm ) 2. Install brake hose and tighten to specified torque. Banjo Bolt Torque: 18 ft. lbs. (25 Nm) NOTE: If new brake pads are installed, it is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise.
  • Page 55 CHAPTER 5 BRAKES LH800U-2D SERVICE MANUAL 2014.0 Service Limit 0.3/64"(1 mm) INSTALLATION 1. Install new pads in caliper body. 2. Install caliper and torque mounting bolts. Brake Caliper Torque: 18 ft. lbs. (25 Nm ) 3. Turn adjuster screw back in finger tight using a hex wrench.
  • Page 56 CHAPTER 5 BRAKES LH800U-2D SERVICE MANUAL 2014.0 8. Install brake hose and tighten to specified torque. Banjo Bolt Torque: 18 ft. lbs. (25 Nm) 9. Bleed. 10. Field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes.
  • Page 57 CHAPTER 5 BRAKES LH800U-2D SERVICE MANUAL 2014.0 NOTES CHAPTER 5 BRAKES PAGE. 5- 13...

  • Page 58: Transmission

    CHAPTER 6 TRANSMISSION LH800U-2D SERVICE MANUAL CHAPTER 6 TRANSMISSION 6.1 GEARBOX DISASSEMBLY TRANSMISSION EXPLODED VIEW CHAPTER 6 TRANSMISSION. 6-...
  • Page 59 CHAPTER 6 TRANSMISSION LH800U-2D SERVICE MANUAL NUT M8 SPRING WASHER WASHER 8 ENGAGEMENT C SHIFT BRACKET CIRCLIP 25 CIRCLIP 11 WASHER 25.5B GEAR SHIFT COMPONENT BEARING 25X29X13 BOLT M6X16 DRIVEN GEAR, REVERSE COVER WASHER 25.5A SPRING DRIVEN GEAR, LOW SPEED O-RING 13.2X1.8 SIDE SHAFT STOP SWING LEVER, GEAR SHIFT...
  • Page 60 CHAPTER 6 TRANSMISSION LH800U-2D SERVICE MANUAL !Fig 4(page 1). Important: Before staring any operation on the gearbox make sure electric sensor of the gear consent A is protected (if mounted). Never clean the gearbox with a high pressure water jet.!Fig 1.(page 1). Fig 4 4.
  • Page 61 CHAPTER 6 TRANSMISSION LH800U-2D SERVICE MANUAL Fig 7 Fig 10 7. Hit alternately, the shift drum. 10. Remove the oil drain plug A and let the oil at A and shift shaft at B to remove the shift drain from the gearbox. housing cover.
  • Page 62 CHAPTER 6 TRANSMISSION LH800U-2D SERVICE MANUAL Fig 13 Fig 16 13. Remove the 4WD coupling running bushing 16. Remove the fork shaft B by a screws A B, then remove the electromagnet A. (M5), then remove the Selector fork C, !Fig 14.(page 3) Spring D, Spring E, Fork pole F.
  • Page 63 CHAPTER 6 TRANSMISSION LH800U-2D SERVICE MANUAL Fig 19 Fig 22 19. Remove the D20 lock snap ring, then 22. Remove the right semi-housing D. !Fig 23.(page 4). the 4WD fixed coupling bushing A. !Fig 20.(page 4). Fig 23 Fig 20 23.
  • Page 64 CHAPTER 6 TRANSMISSION LH800U-2D SERVICE MANUAL Table 1.Two Semi-Housing Components 25. Remove the safety ring F !Fig 27.(page 5). A Primary input drive shaft B Reverse gear shaft C Intermediate shaft D Shift fork E Shift fork rod F Shift drum G Output drive shaft !Fig 25.(page 5) Fig 27...
  • Page 65 CHAPTER 6 TRANSMISSION LH800U-2D SERVICE MANUAL 28. Remove the safety ring X, the clearance 6.2 GEARBOX ASSEMBLY washer Y, and the gear Z. !Fig 30.(page 6). 1. Use a scraper to remove all the sealant residue from the coupling surfaces of the semi-housing. !Fig 32.(page 6).
  • Page 66 CHAPTER 6 TRANSMISSION LH800U-2D SERVICE MANUAL Important: clean the coupling surfaces Mount following components carefully with degreaser liquid. on the input drive shaft H: 2. Mount oil seals to its limit stop. a The bearing G. !Fig 33(page 7). b The fast gear running gear A. c The Clearance washer d Use the pliers to put the safety snap ring C 0n the shaft.
  • Page 67 CHAPTER 6 TRANSMISSION LH800U-2D SERVICE MANUAL Fig 37 Fig 39 h Mount the bearing I to its limit stop Note: During the assembly, it is not !Fig 38(page 8). necessary to adjust the components. All the swivel rings and the clearances have been calculated 4.
  • Page 68 CHAPTER 6 TRANSMISSION LH800U-2D SERVICE MANUAL The engagement G with the convexity The waveform spring H The engagement O with the convexity The Clearance washer I j The Roller cage J slow gear running gear K, with the convexity for gear at the bottom. !Fig 42(page 9).
  • Page 69 CHAPTER 6 TRANSMISSION LH800U-2D SERVICE MANUAL Fig 46 Fig 48 6. Put the output drive shaft F and the 8. Put shift drum B into their seats. then, cut intermediate shaft E as an assembly, as the apophysis E of selector fork G in the shown, then put them to their seats.
  • Page 70 CHAPTER 6 TRANSMISSION LH800U-2D SERVICE MANUAL Fig 51 Fig 54 11. Turn the shafts manually and make 15. Make sure that the two centring pins A are sure they run smoothly and are free in their correct position. from impediments. Important: if damaged, replace the centring 12.
  • Page 71 CHAPTER 6 TRANSMISSION LH800U-2D SERVICE MANUAL Spring 4WD coupling running bushing !Fig 60(page 8). Fig 57 18. Insert 4WD drive shaft B along with the two already mounted bearing. Note: The end with a hole inward. Fig 60 !Fig 58(page 12) 20.
  • Page 72 CHAPTER 6 TRANSMISSION LH800U-2D SERVICE MANUAL Fig 63 Fig 66 The assembly is as shown in fig 64(page 13). 25. Mount the gasket X and the 4WD cover Y. !Fig 67(page 13). Fig 64 23. Use the Fork shaft B to drill through spring C spring F Fork pole E selector Fig 67 fork to fasten them on the 4WD coupling...
  • Page 73 CHAPTER 6 TRANSMISSION LH800U-2D SERVICE MANUAL Fig 69 Fig 72 28. Apply Loctite 510 sealant evenly on Table 4. Shift Housing Components the support surface of 4WD gearbox. Shift housing cover !Fig 70(page 14). Limit pole O-ring Shift shaft Driving gear Driven gear Spring Shift cam !Fig 73(page 14)
  • Page 74 CHAPTER 6 TRANSMISSION LH800U-2D SERVICE MANUAL 32. Mount the shift shaft D. !Fig 75(page 15). Fig 78 36. Apply Loctite 510 sealant evenly on Fig 75 the fringe of shift housing cover 33. Mount the shift cam E, then mount A, then, Assemble the shift housing cover A.
  • Page 75 CHAPTER 6 TRANSMISSION LH800U-2D SERVICE MANUAL Fig 80 Fig 83 38. Tighten the four screws M6 L16 41. Mount the selector lever J. Then to a torque of 20Nm. tighten the self-locking nut K to a torque of 30Nm. Note: There is a screw fasten the lubricating oil duct !Fig 84(page 16).
  • Page 76 CHAPTER 6 TRANSMISSION SERVICE MANUAL 2010.0 CHAPTER 6 TRANSMISSION PAGE. 6- 19...

  • Page 77: Electrical

    CHAPTER 8 ELECTRICAL LH800U-2D SERVICE MANUAL 2014.0 CHAPTER 8 ELECTRICAL 8.1. WIRING DIAGRAM 8.2. STARTING SYSTEM (1). Engine Starting Conditions 8.3. CHARGING SYSTEM 8.4. LIGHTING AND SIGNAL SYSTEM [1]. Head Light [2]. Tail Light [3]. Turn Signal Light [4]. HAZARD LAMP 8.5.

  • Page 78: Wiring Diagram

    CHAPTER 8 ELECTRICAL LH800U-2D SERVICE MANUAL 2014.0 8.1. WIRING DIAGRAM CHAPTER     8             ELECTRICAL       PAGE.   8-­‐   2    ...

  • Page 79: Starting System

    CHAPTER 8 ELECTRICAL LH800U-2D SERVICE MANUAL 2014.0 8.2. STARTING SYSTEM When the main switch is turned to the “3” position, the terminal “30” is connected to the terminals “19” and “AC”. The glow plugs become red-hot, and at the same time, the glow plug indicator also lights on。 When the main switch is then turned to the “2”...
  • Page 80 CHAPTER 8 ELECTRICAL LH800U-2D SERVICE MANUAL 2014.0 (1). Engine Starting Conditions When the following conditions become complete, electric current (12V) reaches starter S terminal through starter relay from main switch 50 terminal, and the engine can be started. (Neutral : Condition Symptom Probable Cause...

  • Page 81: Charging System

    CHAPTER 8 ELECTRICAL LH800U-2D SERVICE MANUAL 2014.0 3. CHARGING SYSTEM The charge system supplies electric power for various electrical devices and also charges the battery while the engine runs. It consists of a AC dynamo . （1） When the engine working the Charging warning indicator will turn off.
  • Page 82 CHAPTER 8 ELECTRICAL LH800U-2D SERVICE MANUAL 2014.0 8.4. LIGHTING AND SIGNAL SYSTEM The lighting system consists of light switch, head lights etc.. LIGHTING SYSTEM Symptom Probable Cause Solution Head light Does Fuse blown (10A) Replace Bulb blown Replace Light Relay blown Replace Wiring harness Repair or...
  • Page 83 CHAPTER 8 ELECTRICAL LH800U-2D SERVICE MANUAL 2014.0 8.5. THE LED METER 1. Coolant temperature meter 13. Reverse indicator light 2. Speedometer 14: Neutral indicator light 3. Engine rpm meter 15. L GEAR POSITION 4. Engine working hour counter 16. H GEAR POSITION 5.

  • Page 84: Troubleshooting

    CHAPTER 8 ELECTRICAL LH800U-2D SERVICE MANUAL 2014.0 8.6. TROUBLESHOOTING Symptom Probable Cause Solution All Electrical Battery Recharge or Replace Equipments Do discharged defective Operate Battery positive Repair or Replace cable disconnected or improperly connected Battery negative Repair or Replace cable disconnected or improperly connected...
  • Page 85 CHAPTER 8 ELECTRICAL LH800U-2D SERVICE MANUAL 2014.0 CHARGING SYSTEM Symptom Probable Cause Solution Charging Lamp Wiring harness Repair or Replace Does Not Light disconnected when Main improperly connected Switch (between main switch AC Turned ON terminal and panel board, between panel board and dynamo) Dynamo defective Repair or Replace...
  • Page 86 CHAPTER 8 ELECTRICAL LH800U-2D SERVICE MANUAL 2014.0 Running connected (between panel board and oil pressure switch) Circuit in panel board Replace defective Symptom Probable Cause Solution Fuel Gauge Fuel gauge defective Repair Does Not Fuel level sensor Replace Function defective Wiring harness Repair or disconnected or...
  • Page 87 CHAPTER 8 ELECTRICAL LH800U-2D SERVICE MANUAL 2014.0 7. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Battery Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing Antidote: External: Flush with water. lnternal: Drink large quantities of water or milk.
  • Page 88 CHAPTER 8 ELECTRICAL LH800U-2D SERVICE MANUAL 2014.0 Removing and Installing Battery Removing 1. Park the vehicle safely. 2. Raise passenger seat. 3. Disconnect all black negative cables (A) from battery first. 4. Slide back rubber protective cover disconnect all red positive cables. 5.
  • Page 89 CHAPTER 8 ELECTRICAL LH800U-2D SERVICE MANUAL 2014.0 (2) Main Switch Main Switch 1. Remove the steering wheel and the meter panel. 2. Disconnect the 4P connector (1) and remove the main switch (2). 3. Perform the following checks. Connector Voltage 1.
  • Page 90 CHAPTER 8 ELECTRICAL LH800U-2D SERVICE MANUAL 2014.0 Position 1. Set and hold the main switch key at the PREHEAT position. 2. Measure the resistance with an ohmmeter across the 30 terminal and the 19 terminal, and measure the resistance across the 30 terminal and the AC terminal.
  • Page 91 CHAPTER 8 ELECTRICAL LH800U-2D SERVICE MANUAL 2014.0 Glow Plug Continuity Disconnect the lead from the glow plugs. Measure the resistance between the glow plug terminal and the chassis. If 0 ohm is indicated, the screw at the tip of the glow plug and the housing are short-circuited.
  • Page 92 CHAPTER 8 ELECTRICAL LH800U-2D SERVICE MANUAL 2014.0 .ENGINE OIL PRESSURE LAMP When the engine oil pressure has dropped, the engine oil pressure switch is activated to let the current flow from the main switch and to light up the lamp. Oil Pressure Switch Gauge 1.
  • Page 93 CHAPTER 8 ELECTRICAL LH800U-2D SERVICE MANUAL 2014.0 Indicate the temperature of the engine （6） “A” the coolant temperature 90±3 “B” the coolant temperature 100±2 5. Thermo switch Remove the thermo switch from the radiator. lConnect the pocket tester (ΩX1) to the thermo switch.
  • Page 94 CHAPTER 8 ELECTRICAL LH800U-2D SERVICE MANUAL 2014.0 (7) Engine meter System Speed Speed Sensor on the Transmission Out Put Shaft. Operation Instructions of LCD Meter and Speed Sensor Main Technical Parameter： Item Code Vol value Unit Operating voltage 5-20 Operating current ≤15 Operating distance 1mm≤D≤8mm...
  • Page 95 CHAPTER 8 ELECTRICAL LH800U-2D SERVICE MANUAL 2014.0 (8) GEAR POSITION INDICATOR SWITCH TEST Switch table CHAPTER     8             ELECTRICAL       PAGE.   8-­‐   19  ...

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