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Golden Dragon XML6125CLE Repair Manual

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Table of Contents

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Summary of Contents for Golden Dragon XML6125CLE

  • Page 2 Catalogue is being compiled. The specifications or procedures in this catalogue may not be in accordance with specific objects. Golden Dragon has the right to modify them without notification in advance. Any detail should be subject to the modified parts should there be any modification.
  • Page 3 Chapter Schedule of Service Manual  The following table shows the numbers of all chapters contained in this Manual in relation to the repair data of various relevant types of bus systems. Chapter Model XML6125CLE General Instructions XML6125CLE Electric drive system XML6125CLE Transmission shaft...
  • Page 4 General Instructions GI-1 Overview  ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ General precautions GI-2 Key safety precautions General repair rules General cleaning rules  ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ How to use the Repair Manual GI-5 Operating instructions Definitions of directions Bus identity information  ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ General technical specifications of repair GI-8 Disassembly procedure requirements Assembly procedure requirements...
  • Page 5 1. Key safety precautions Improper or incorrect operations may cause troubles and accidents and thus personal injuries and (or) property losses. Please consult your local distributor of Golden Dragon if you have any doubts on the repair and maintenance of the bus.
  • Page 6  Check and record necessary items and statuses according to the Manual.  Replace all damaged or excessively worn-out components or assemblies.  Always use original Golden Dragon components.  Observe the assembly and disassembly regulations specified in the Manual to avoid damaging the...
  • Page 7 General Instructions GI-4 3. General cleaning rules  Choose a proper cleaning method according to relevant requirements so that the cleaning requirements are satisfied and no component is damaged. Cleaning methods include steam cleaning, pressure cleaning, light oil cleaning, acid or alkali solution cleaning, neutral medium cleaning, trichloroethylene cleaning, Magnus solution cleaning, etc.
  • Page 8 General Instructions GI-5 How to use the Repair Manual  The Repair Manual is compiled to guide the repair work of the bus. Some simple repair methods are not included herein, e.g. the simple installation and removal of components. Only those important methods that require guidance will be introduced herein.
  • Page 9 制造年月 Manufacture date 厦门金龙旅行车有限公司 Xiamen Golden Dragon Bus Co., Ltd. (3) Chassis S/N: chassis S/N is engraved on the frame close to the right front wheel. (4) Engine S/N: engine model and S/N are engraved on the engine set. Please refer to the corresponding Engine Operation Manual.
  • Page 10 GI-7 General Instructions GI-6126J12-01 General technical specifications of repair  1. Disassembly procedure requirements  Before disassembly of any component, please take full considerations, park the bus on an even and safe place, place the gearlever at the neutral position, flame out, disconnect the power supply switch and wedge the front and rear wheels.
  • Page 11 GI-8 General Instructions GI-6126J12-01 接管 卡套螺母 卡套 垫圈 扩口螺母 与管子的扩口构成密封面 在 螺 纹 处 用 填料密封 3. Pipeline Connecting Methods 铰接头 卡套式接头 垫圈 Hinge joint Bite-type connector Washer 卡套 卡套螺母 接管 Clip Bite-type nut Take-over 扩口螺母 与管子的扩口构成密封面 在螺纹处用填料密封 Flared nut Form a sealing face with flare of the Seal the thread with stuffing pipe...
  • Page 12 GI-9 General Instructions GI-6126J12-01 additional sealants;  Install pipe thread components after the requirements are satisfied. 5. Thread sealant adhesive application specifications  Sealant adhesive designation: JB260 thread sealant adhesive.  Evenly apply one 3 to 5mm-wide and 2 to 3mm-high coating in the axial direction along the full length of the thread of the bolt.
  • Page 13 GI-10 General Instructions GI-6126J12-01 Troubleshooting flow chart  1. Confirm the troubles reported by the user 2. Initial inspection 3．Routine system inspection 4．Read and check relevant technical Identify the 6. Recheck the problem trouble 7. Repair and check repair conditions Flow chart description Confirm the troubles reported by the user: the first step is to know as more information as possible from the user.
  • Page 14 GI-11 General Instructions GI-6126J12-01 5-2. It is necessary to carry out troubleshooting on site. Please refer to the Repair Manual, relevant schematic diagrams, system descriptions and operation instructions and check if the system is working in certain extreme environmental conditions (high temperature, humidity and pollution) and special procedures.
  • Page 15 GI-12 General Instructions GI-6126J12-01 Introduction of bus oils and fluids  1. Bus lubricants  Engine lubricating oil Lubricating oils influence the main working properties of the engine. a) Viscosity and viscosity-temperature characteristic: viscosity refers to the extent of shearing force between layers of flowing lubricating oils; viscosity-temperature characteristic refers to the changes of viscosity of lubricating oils with the changes of temperature.
  • Page 16 GI-13 General Instructions GI-6126J12-01 d) For instance: 10W/30 indicates that the engine oil can be used in a cold weather (engine that can be normally started at -25℃) and also be used where there is a high thermal load. Selection of lubricating oils a) Lubricating oils that fit in with the engine’s working conditions and has a proper viscosity shall be adopted.
  • Page 17 GI-14 General Instructions GI-6126J12-01 1-16...
  • Page 18 GI-15 General Instructions GI-6126J12-01 1-17...
  • Page 19 GI-16 General Instructions GI-6126J12-01  Bus gear oil The transmission gears of the manual transmission and the main reducer in the driving axle shall be lubricated with gear oils. Lubricating oils influence the main working properties of the engine. a) Viscosity and temperature-viscosity characteristic: gear oils with a high viscosity are good for lubrication, sealing, vibration reduction and noise reduction but will easily cause higher internal friction forces and thus reduce transmission efficiency.
  • Page 20 GI-17 General Instructions GI-6126J12-01 a low temperature. It reflects the minimum environmental temperature where gear oils are used. c) Resistance to wear: it is the ability of gear oils to keep oil films free of damage. Such ability is particularly important to gear oils. Brand and specification of gear oils Standards comparable to API (American Petroleum Institute) standards are adopted in China, i.e.
  • Page 21 GI-18 General Instructions GI-6126J12-01 spoil the properties of the working medium of the hydraulic system and thus cause the system to malfunction. For that reason, a certain number of kilfoams shall be added in hydraulic oils to increase their working stability. Types and scope of application of hydraulic oils a) L-HL hydraulic oil is a type of general-purpose lubricating oil for industrial machine tools and applicable to the low-pressure hydraulic system and transmission unit of machine tools...
  • Page 22 GI-19 General Instructions GI-6126J12-01 Calcium-based lubricating grease has fat and lime as the raw material and has four consistency designations of 1, 2, 3 and 4. Calcium-based lubricating grease is applicable within a temperature range of -10℃ to 60℃. Its advantage is high water resistance. It is applicable to the parts with a high temperature and easily get contact with water.
  • Page 23 GI-20 General Instructions GI-6126J12-01 b) Alcohol ether brake fluids may be adopted where there is a dry climate. The temperature properties of the brake fluid shall be determined according to atmospheric temperature and brake intensity; c) Grease brake fluids shall be adopted where it is wet and rainy. The temperature properties of the brake fluid shall be determined according to atmospheric temperature and brake intensity.
  • Page 24 GI-21 General Instructions GI-6126J12-01 Table of standard screw fastening torques  Unit: N. m) Mechanical property grade Bolt size Grade 4.6 Grade 5.6 Grade 8.8 Grade 10.9 Thread Screw pitch specification (mm) 2.5-5.5 3.0-6.0 6-12 5.0-11.0 17-28 8.0-15.0 1.25 5.5-11.5 7.0-14.0 16-26 14.3-24.7...
  • Page 25 Bus model definitions  Various parts of the bus model code are defined as follows Model: XML 6 J12 Self-defined code Golden Dragon Product series Main data code: nominal length 12m Bus type code: 6 indicates passenger bus Factory brand: Golden...
  • Page 27 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. Contents 1. Overview .................................. 5 2. Towing ..................................5 3. Emergency handling ..............................6 4. Safety operation guide: ............................7 4.1. Safety precautions for emergency repairs inside the station or on the road: ..........8 4.2.
  • Page 28 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 7.5.6. Troubleshooting method for insulation failure ................49 7.5.7. Troubleshooting method for derating mode ..................49 8. Instructions on the use of meters .......................... 50 8.1. Instructions on the use of megohmmeter: ....................50 8.2.
  • Page 29 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 10.1.2.1.3. Tools for use: ......................71 10.1.2.1.4. CO300 MCU consumable parts list: ................. 71 10.1.2.2. CO300 other maintenance parts replacement operation specifications: ......72 10.1.2.2.1. Replace the water pipe joint ..................72 10.1.2.2.2. Replace the grounding screw ................... 72 10.1.2.2.3.
  • Page 30 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 10.3.3. CO150 MCU service tools list ......................86 11. Maintenance items .............................. 87 11.1. Motor maintenance items ........................87 11.2. MCU maintenance items .......................... 88 11.3. VMUmaintenance items ........................... 88 11.4. Maintenance items for high-voltage power line (phase line) ..............89 11.5.
  • Page 31 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 1. Overview The electric drive products of Dana (Beijing / Shandong) Electric Motor Co., Ltd. can cover the application of 6-18m electric bus, trucks, off road machines and other equipments. The products have good safety, high reliability, high efficiency and energy saving, and are the ideal drive system of electric vehicle.
  • Page 32 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 3. Emergency handling When the vehicle is in an emergency, move the vehicle to a safe place as soon as possible,then turn off the Key switch to 0FF and cut off the 24V low-voltage main power supply. Flooding: Turn off the SecretKey and disconnect the 24V low-voltage main power switch Tow the car out of the water and to an open space for drainage...
  • Page 33 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 4. Safety operation guide: The E-drived vehicles are high-voltage equipments. When diagnosing vehicle faults, it is often necessary to contact the vehicle's high-voltage equipment, so, it is necessary to operate in accordance with this "safe operation guide" to avoid personal injury or death.
  • Page 34 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 4.1. Safety precautions for emergency repairs inside the station or on the road: Maintenance and inspection steps: 1. The personnel responsible for troubleshooting of vehicles must be employed with certificates before handling the products of our company;...
  • Page 35 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 4.2. Precautions on electrical safety: The maintenance of E-drive products must be completed by qualified professionals. The customer is responsible for ensuring that all operators have received professional training and wear protective gear to ensure personal safety.
  • Page 36 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 4.3. Product circumstance and cooling requirements: E-drive products have certain requirements on the circumstance and cooling, see the following table for details: Item Requirements Remarks Coolant temperature -40 ° C to 85 ° C Not higher than 65 °...
  • Page 37 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. Note: Before filling, rinse the cooling circuit with deionized water (remove impurities). Glycol must contain some type of active corrosion inhibitor. Glycol must comply with the standard corresponding to its application (light ASTM D3306 type III or heavy ASTM D6210 type III). Coolant composition is 60% glycol: 40% deionized water (minimum 50% glycol: 50% deionized water to ensure proper corrosion resistance).
  • Page 38 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 5. Working principle of BEV: After power-up, the accelerator pedal, brake pedal, drive selector or instrument command is sent to the VMU. The VMUsends commands to the MCUand BMS at the same time. The BMS commands the battery group to transmit power to the MCUand other vehicle equipments according to the VMU command.
  • Page 39 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 5.2. Working mode of E-drive system: Drive: Driver step on the accelerator pedal, the operation signal transmited to the VMU, then the signal from VMU to theMCU. The MCU controls the forward or reverse rotation of the motor to drive the vehicle forward (D position) or reverse (R position).
  • Page 40 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 6.ODIN software installation and use: Load and install the ODIN software package provided by the company. The installation steps are shown as follows: (you can find all the details of installation and ues from :TG-0001 TM4 ODIN 4 Technical Guide.pdf) 6.1.
  • Page 41 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. Select all, the content that says "Installed" can be left unselected, click "Next>", as shown in the figure above: Install the components we just selected, click "Next>", as shown in the figure above: Select “I accept the license agreement”...
  • Page 42 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. Click the "Next>" button to install the component. If other prompts or a component is not successfully installed in this process, you can skip it temporarily. After the installation is complete, the completion interface pops up, as shown in the figure above: Click "Finish"...
  • Page 43 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 6.2.2. Installation of ODIN Now start to install ODIN: After the "Installation Environment" is completed, the following dialog box appears: Click "Next>" to start installing ODIN: as shown in the figure above Select all the functional components of ODIN (some components can be selected according to the actual situation), click "Next>", as shown in the figure above 电话...
  • Page 44 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. When the license association and installation page occurs, click “Skip” , as shown in the figure above: The associated operation will be performed later by a specialist after the installation is complete Click "Next>" to continue installing ODIN, as shown in the figure above: 电话...
  • Page 45 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. Click "Install" to begin installation of TM4 ODIN4: as shown in the figure above Select "Automatically close applications and attempt to restart after setup is complete" and click "OK", as shown in the figure above: 电话...
  • Page 46 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. It prompts the lack of the “Sentinel Key" twice, then Click "OK". As shown in the figure above; The installation of the software license will performed later. The installation of ODIN continues and creates 2 shortcuts on the desktop. Then it will prompt "No matching feature found"...
  • Page 47 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 6.2.3. Installation of sofeware license Install the sofeware license now: （You can find all the details of installation and ues from :TG-0001 TM4 ODIN 4 Technical Guide.pdf） Double-click the ODIN icon on the desktop to open ODIN (either odin1 or 2 is OK): The system prompts a missing Sentinel Key and reports an error, then Click "OK"...
  • Page 48 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. Send the copied content to Dana TM4 Beijing by email and wait for the reply from DEMCO. Save the attached file in the email on your PC, return to the License Manager interface, and install the newly downloaded license.
  • Page 49 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. Click "Open" to locked the license to install, as shown in the figure above: Finally click "Install" to finish, as shown in the figure above: The system prompts "The license is valid" and the software license installation is successful till this time, as shown in the figure above;...
  • Page 50 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. Close the License Manager interface, open ODIN, and check whether ODIN is activated, as shown in the figure above: Find the “Options” button from the toolbar,click it, as shown in the figure above: 电话...
  • Page 51 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. You can change the system language between Chinese and English. After selecting, Click "OK" to load. As shown in the figure above: Then we do some configuration in the system file column, check the box in front of “Display error and warning displayed on the message panel”.
  • Page 52 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 6.2.4. CAN case driver installation Find the CAN case driver Kvaser software package and double-click to start loading. Click “Next”inside the pop-up dialog box, as shown in the figure below. The dialog window Kvaser CAN Drivers Setup pops up and selects “Next”, as shown in the figure below 电话...
  • Page 53 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. The dialog window Kvaser CAN Drivers Setup pops up and selects NEXT, as shown in the figure below The dialog window Kvaser CAN Drivers Setup pops up, then select Install, as shown in the figure below When the dialog window Kvaser CAN Drivers Setup pops up, after the progress bar is full, then click Close, as shown in the figure below.
  • Page 54 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. CAN case driver installation is complete 电话 Tel： 010－69596333 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co. Ltd 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 2-28...
  • Page 55 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 6.3. Use of ODIN: 6.3.1. Odin's position in the E-drive system architecture 电话 Tel： 010－69596333 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co. Ltd 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 2-29...
  • Page 56 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 6.3.2. Device connection Note: When opening Odin, it is best to use the right button select “run service with administrator privileges” Operating procedures: Device connection status: After entering the TM4 ODIN interface, check whether the Device Disconnect status mark is green (if it is connected, you can directly read the data).
  • Page 57 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. Click Configuration in the TM4 ODIN interface to find the Device Package. Click the down arrow in the Device Package dialog window. After you find the required program, click Apply. If there is no required program in the arrow under the Device Package Configuration dialog window, go to the required software folder provided by DEMCo, find the required program and double-click to install it.
  • Page 58 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 电话 Tel： 010－69596333 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co. Ltd 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 2-32...
  • Page 59 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 6.3.3. Fault records(sysfile) reading: Functions: Use the host computer to read the faults that have occurred Operating procedures: Find the fault log in the Sysfile at the bottom right of the ODIN interface, as shown in the figure below: If the interface is too small, you can drag it to the blank area of the interface and select the drag area, as shown in the figure below: Select the drag area...
  • Page 60 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 6.3.4. GDD file collection Functions: All system events recorded, including power on and off, system warning and fault information The most important basis for failure analysis and solving When troubleshooting, if conditions permit, collect Csinfo as soon as possible. When collecting Csinfo, it is best to collect it when the fault recurs GDD includes the following: Sysfile...
  • Page 61 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. The generated compressed file is added to the fault report summary form, and a template of the fault report summary form is provided by the after-sales department. 电话 Tel： 010－69596333 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co. Ltd 北京市通州区宋庄...
  • Page 62 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. (find more details from:TG-0127 TM4 CAN Spector Technical 6.3.5. Logging of CAN messages: Guide.pdf) Functions: Used to view and collect CAN messages on the CAN bus: Select CAN channel and communication baud rate, Collect CAN messages and save them in BLF format, Import and view blf format message files, Switch the data display mode and manually send message to the bus.
  • Page 63 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. Select Continuous Log in the bottom of the TM4 CAN Spector interface, set Msg Per File ( ) value to more than 30,000, and select the save path in Destination. As shown in the figure below: After confirming the above configuration, click the Play button to start collection 电话...
  • Page 64 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. (find more details from:TG-0009 TM4 Data Logger Technical Guide.pdf) 6.3.6 Data collection: Functions: It is designed to monitor the behaviour of selected items and log this behavior for short or long periods at a configurable level of granularity.
  • Page 65 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. Right-click on the blank space below Name to add Axis, as shown in the figure below: In the TM4 Data Logeger interface, find the items you want to monitor under the Items Explorer, as shown in the figure below: Drag the selected item into the established Axis, and click Start, as shown in the figure below: 电话...
  • Page 66 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. （find more details in chapter5.7 from： TG-0001 TM4 ODIN 4 Technical Guide.pdf） 6.3.7. Graph collection Functions: It is used to collect the system status in a short time for accurate analysis. High collection frequency (12kHz) You can collect the status of a specific event according to requirements (Trigger) Related parameters;...
  • Page 67 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. In the upper right of the interface, find the required parameters under the Items Explorer and drag them into the Axis under Graph config1 (right-click to build the Axis as required), as shown in the figure below: Configure the trigger conditions at the bottom left of ODIN and adjust Frequency to the maximum.
  • Page 68 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. After the trigger, use the mouse right button to click the curve part, and click the last item (Save Image And Csv Data As..) below to save, as shown in the figure below: 电话...
  • Page 69 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 6.3.8. Program flashing Precautions: When flashing programs, pay attention to the power-on and power-off time. It is recommended to wait 5-10 seconds after power-off to ensure that the device is completely powered off, and then power-on again to perform the flashing operation.
  • Page 70 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 7. Troubleshooting of common problems: 7.1. Circuit & control principles of high-voltage pre-charge circuit 7.2. Relay function and name: K1 (pre-charge relay) K2 (high-voltage main positive contactor) K3 (high-voltage main negative contactor) optional 7.2.1.
  • Page 71 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 7.3. Pre-charge fault troubleshooting method: Troubleshooting steps Use a multimeter, adjust to the DC voltage range (the range can reach 1000V). When one person starts the vehicle, the other person uses the multimeter to measure the DC bus voltage of the MCU. The vehicle can be powered on normally only when it reaches 95% of the normal voltage.
  • Page 72 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 7.4. Troubleshooting method for vehicle insulation faults Note: When repairing and maintaining high-voltage components, shut down and wait for 3-5 minutes before proceeding, and wait for the capacitors to discharge. 500V range shall be used to measure the insulation resistance of MCU, and 1000V or above shall not be used for measurement.
  • Page 73 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 7.5. Troubleshooting of drive system 7.5.1. MCU communication timeout / offline Fault code and name: Error-MCU communication timeout / offline Verify that the power supply of the MCU and the VMU, and whether the CAN joint are loose or withdrawn. In the state of key switch off and On, verify whether there is 24V voltage between E / F and L / M.
  • Page 74 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 7.5.3. Troubleshooting method for undervoltage faults: Fault code and name: 0x310A Error-High power battery voltage reached the low limit Static fault: Verify that the pre-charge voltage is met. If it is, check whether the main positive relay does not engage. Check whether the pre-charge voltage is met.
  • Page 75 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 7.5.6. Troubleshooting method for insulation failure Fault code and name: 0x320E Error-Motor Control Machine 0x0E-Insulation to chassis fault Static failure If the high-voltage on the vehicle reports this fault, first check whether the E-drive system has an insulation short circuit, please check as follows Whether the phase cable is broken and put-up- iron with the body or shielding layer Whether there is water or water drops inside the motor and controller...
  • Page 76 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 8. Instructions on the use of meters 8.1. Instructions on the use of megohmmeter: Usage and precautions of insulation resistance tester: Insulation resistance meters, also known as tramegger or megohmmeters, are special instruments used to measure large resistance and insulation resistance.
  • Page 77 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. and install the battery. 1. Measuring continuity: Set the range to continuity test, short the red and black test leads, and the multimeter will beeps, which indicating that the continuity is normal. 2. Measure the voltage: set the range to the DC voltage range (DC), connect the red and black test leads to the positive and negative poles of the power supply for voltage measurement, and the AC voltage range (AC) measurement is the same.
  • Page 78 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 9. Maintenance Manual on motor spare parts replacement 9.1.MD series 3-phase motor 9.1.1.MD series 3-phase motor structure diagram Figure (1) 电话 Tel： 010－69596333 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co. Ltd 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 2-52...
  • Page 79 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 9.1.2. MD series 3-phase motor repair spare parts list Part No. Part name Quantity Purpose Plate-15 upper baffle For dust protection at the front oil seal Plate-16 lower baffle For dust protection at the front oil seal HW-1742 Hex flange bolts For fixing the upper and lower baffles...
  • Page 80 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. Note: The lower baffles must be installed first before installing the upper baffle, so that the upper baffle presses the lower baffle at the joint. 2.Tools for use Fixed value torque wrench 10-50Nm, ratchet wrench, No. 13 sleeve, 3.
  • Page 81 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 3. List of maintenance parts: Quantit Maintenance part replacement Part number of Name of maintenance y per maintenance part part standard unit —— Nameplate Breakage and deformation HW-1968 Rivet Must be replaced after disassembly; 9.1.3.4.
  • Page 82 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. damage and serious corrosion, and replace if necessary. Step 5: Use a cable socket wrench to remove the cable gland cover, remove the cables that need to be replaced, and then remove the cable gland base. Step 6: Use a cable socket wrench to install the new cable gland base to the junction box with torque of 25Nm.
  • Page 83 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 9.1.3.6. Operation specifications for other maintenance parts replacement: (Figure 8) 1. Steps: see the diagram (Figure 8) Step 1: Replace the damage warning sign , paste a new warning sign. Step 2: Remove the grounding screw. Use a fixed torque wrench to tighten the new grounding screw. The tightening torque is 17 ±...
  • Page 84 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 9.2.MD series 6-phase motor 9.2.1.MD series 6-phase motor structure diagram Figure (1) 电话 Tel： 010－69596333 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co. Ltd 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 2-58...
  • Page 85 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 9.2.2. MD series 6-phase motor maintenance spare parts list Quantity per Part No. Part name Purpose unit Plate-15 Upper baffle For dust protection at the front oil seal Plate-16 Lower baffle For dust protection at the front oil seal HW-1742 Hex flange bolts For fixing the upper and lower baffles...
  • Page 86 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 9.2.3. Replacement method of maintenance parts of MD 6-phase motor 9.2.3.1. Operation specifications for flanges and related parts replacement: 1. Steps: see the diagram (Figure 2) Step 1: Use a ratchet wrench and a sleeve to remove the upper and lower baffles, and check for serious deformation and damage.
  • Page 87 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 9.2.3.3. Operation specifications for nameplates and related parts replacement: 1. Steps: see the diagram (Figure 4) Step 1: Use needle-nose pliers to remove the rivet, and then remove the nameplate (if the nameplate is directly attached to the motor with 3M glue, it can be removed directly with a flat screwdriver).
  • Page 88 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 9.2.3.5. Operation specifications for phase cables and related parts replacement: 1. Steps: see the diagram (Figure 6) Step 1: Use a ratchet wrench to remove the 8 hex flange bolts fixed on the phase cover, check whether the screw threads are damaged and severely rusted, and replace if necessary.
  • Page 89 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. NP-0041 High voltage sign The character is not clear; 3316-0565 Junction box cover Deformation and damage; BNAEB048 Hex flange bolts Thread damage and corrosion; 3310-0001 Sealing ring Must be replaced after disassembly; Screw and flat washer HW-2316 Thread damage and corrosion;...
  • Page 90 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 9.3. HD series 9-phase motor 9.3.1. HD series 9-phase motor structure diagram 电话 Tel： 010－69596333 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co. Ltd 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 2-64...
  • Page 91 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 9.3.2. HD series 9-phase motor maintenance spare parts list Part No. Part name Quantity Purpose Plate-11 Upper baffle For front oil seal protection Plate-12 Lower baffle For front oil seal protection GB/T5783 M10X16-8.8 Hex flange bolts For fixing the upper and lower baffles GB/T97.1-2002-TC 10...
  • Page 92 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 3. List of maintenance parts: Quantit Part number of Name of maintenance y per Maintenance part replacement standard maintenance part part unit Plate-11 Upper baffle Severe deformation and damage; Plate-12 Lower baffle Severe deformation and damage; GB/T5783 Hex flange bolts No damage to the thread and corrosion;...
  • Page 93 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 9.3.3.3. Operation specifications for phase cables and related parts replacement: 1. Steps: see the diagram (Figure 4) Step 1: Use a hex wrench to unscrew the cover screw and flat butterfly combination screw corresponding to the phase cable, check whether the cover screw is damaged and rusted, and replace if necessary.
  • Page 94 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. Figure (5) 2.Tools for use: Fixed value torque wrench 5-20Nm, fixed value torque wrench 20-100Nm, ratchet wrench, 13mm sleeve, 18mm sleeve 3. List of maintenance parts: Part number Name of part Quantity Maintenance part replacement standard 3354-0002 Warning sign The handwriting is not clear and legible;...
  • Page 95 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 10. Maintenance manual on MCU spare parts replacement 10.1.CO300 MCU 10.1.1. Structure diagram of CO300 MCU Figure (1) 电话 Tel： 010－69596333 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co. Ltd 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 2-69...
  • Page 96 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 10.1.1.1. CO300 MCU maintenance spare parts list Part No. Part name Quantity per unit Purpose Way for users to install positive and HW-1734 Screw cover 2 pcs negative cables HW-1754 O-ring 2 pcs Sealing between screw cover and the case HW-1994 Combination screws...
  • Page 97 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. Step 1: Use a socket wrench to loosen the two HW-1734 caps, and then unscrew the stuffing caps manually ; Step 2: Use a hexagonal wrench, loosen the two HW-1944 combination screws which fixes the positive cable; Step 3: Use the special spanner to loose the cable gland cover, and then remove the positive cable;...
  • Page 98 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 10.1.2.2. CO300 other maintenance parts replacement operation specifications: 10.1.2.2.1. Replace the water pipe joint Step 1: Use the special tool for the water pipe joint to remove the water pipe joint and remove the water pipe joint assembly.
  • Page 99 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 10.1.2.2.4. Tools for use: Fixed value torque wrench 10-50Nm, water pipe joint tightening tool, 14 # sleeve, sleeve conversion joint, ratchet wrench 10.1.2.2.5. List of other consumable parts of CO300: Part number of Name of maintenance Quantity Maintenance part replacement...
  • Page 100 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 10.2. CO200 MCU 10.2.1. Structure diagram of CO200 MCU 电话 Tel： 010－69596333 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co. Ltd 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 2-74...
  • Page 101 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 10.2.1.1. CO200 MCU maintenance spare parts list Part No. Part name Quantity Purpose Seal to prevent foreign objects entering the 3327-0256 Cover of junction box internal parts of the controller HW-3311 Hex flange bolts Terminal box cover fastening screws Seal to prevent foreign objects entering the 3327-0257...
  • Page 102 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 10.2.2.1. Phase cover, DC cover and phase cable replacement operation specifications: Figure (5) 10.2.2.1.1. Remove 6 phase cables Step 1: Use a socket wrench to remove the 12 HW-3311 hexagon flange bolts which fixes cover assembly; Step 2: Check that the surface of the phase end cover is not scratched, the seal is not damaged, and it is not deformed.
  • Page 103 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 10.2.2.1.2. Installation of phase cables Step 1: Check the appearance of the phase cable. The surface should be free from damage, no rust on the surface of the terminal, and no surface corrosion. Step 2: Remove the cable gland base from the cable line, and then apply a small amount of FN-0088 grease evenly on the surface of the fixed O-ring.
  • Page 104 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. Step 7: Tighten the cable gland and base, tightening torque 12 ± 2Nm Step 8: Repeat steps 1-7 to complete the installation of the negative cable. Step 9: Check whether any foreign matter in the DC cover plate has entered the controller cavity; Step 10: If the cover is deformed or the sealing gasket is damaged, a new phase cover needs to be replaced.
  • Page 105 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 10.2.2.2. Replacement of other maintenance parts of CO200 MCU: Figure (6) 10.2.2.2.1. Replace the water pipe joint Step 1: Use the special tool for the water pipe joint to remove the water pipe joint Step 2: Replace the new water pipe joint, check that the seal ring is not leaked or damaged, and use FN-0088 grease to apply on the outer circle Step 3: Manually screw the water pipe joint in threaded hole.
  • Page 106 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 10.2.2.2.4. Tools for use: Fixed value torque wrench 10-50Nm, water pipe joint tightening tool, 14mm sleeve, barrel converter, ratchet wrench 10.2.2.2.5. List of other consumable parts of CO200: Part number Name of part Quantity Maintenance part replacement standard No scoring, cracking or damage on the surface of the...
  • Page 107 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 10.3.CO150 MCU 10.3.1. Structure diagram of CO150 MCU Stuffy cover HW-1896 Warning sign NP-0039 Combination Hexagon socket screwsHW-2227 head cap screws HW-3144 Phase cable WH-0537-01 DC side cover Combination 3327-0209 Hex flange bolts screws HW-2102 HW-3311 Positive...
  • Page 108 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 10.3.1.1. CO150 MCU maintenance spare parts list Quantit Part No. Part name y per Purpose unit Seal the internal parts to prevent foreign HW-1896 Stuffy cover objects from entering the control HW-2227 combination screw Phase cable fastening screws Seal the internal parts to prevent foreign 3327-0209...
  • Page 109 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. Step 3: Use an external hex wrench to remove the three HW-2227 combination screws of the phase terminal; Step 4: Use a special tool for removing the phase cable, loosen the phase cable gland and the fixed base, and remove the phase cable.
  • Page 110 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 10.3.2.1.4. Steps for replacing and installing positive and negative cables: Step 1: Check the appearance of the positive and negative cables. The surface should be free from damage, and no rust or surface corrosion on the lug surface. Step 2: Remove the cable fixing base connected to the housing from the cable line, and then apply a small amount of FN-0088 grease evenly on the surface of the fixed O-ring.
  • Page 111 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 10.3.2.2. Replacement of other maintenance parts of CO150 MCU: Water pipe joint assembly AM-0012 Including: water pipe joint Water pipe joint assembly 3328-0408 AM-0012 O-ring Including: water pipe joint HW-1660 3328-0408 O-ring HW-1660 Hex flange bolts HW-3311 Figure (2)
  • Page 112 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 10.3.2.2.4. Tools for use: Fixed value torque wrench 10-50Nm, water pipe joint tightening tool,14mm sleeve, barrel adapter, ratchet wrench 10.3.2.2.5. List of other consumable parts of CO150: Quanti Part number of Name of maintenance part ty per Maintenance part replacement standard maintenance part...
  • Page 113 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 11. Maintenance items The first warranty period for all maintenance projects is 5,000 kilometers. 11.1. Motor maintenance items Maintenance Maintenanc Technical requirements Tool Operation specification content e interval Visually inspect the machine for The whole machine is complete, Visual Every...
  • Page 114 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 11.2. MCU maintenance items Maintenance Technical requirements Tool Operation specification Maintenance interval content The whole machine is Visually inspect the machine complete, no signs of Visual inspection appearance If it is damaged, Every 50,000 KM collision and damage it needs to be replaced .
  • Page 115 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 11.4. Maintenance items for high-voltage power cable (phase cable) Maintenance Maintenan Technical requirements Tool Operation specification content ce interval The wiring harness is complete, the outer insulation layer has no Visually inspect the wiring harness for signs of cracking, damage and Visual intactness, signs of skin peeling, damage,...
  • Page 116 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 11.5. High-voltage power line (DC bus) maintenance items Maintenance Maintenance Technical requirements Tool Operation specification content interval The wiring harness is Visually inspect the wiring harness for complete, and the outer intactness, signs of skin peeling, Every 5,000 insulation layer is free of Visual inspection...
  • Page 117 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 11.6. Maintenance items for motor and motor controller ground wires Maintenanc Maintenanc Technical requirements Tool Operation specification e content e interval Visually inspect whether the wiring Harness is complete, no Visual Every harness is complete, whether there are loosening, damage, etc.
  • Page 118 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 11.7. Low-voltage signal line maintenance items Maintenance Operation Maintenance Technical requirements Tool content specification interval a) Wiring harness complete, no skin breakage,damage. b) The air around circulates and is easy to dissipate heat no spikes or sharp objects around. a) ~ e) Visual c) The bending radius of cable is 8 times or more than inspection...
  • Page 119 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 11.8. Cooling system maintenance items Maintenance Maintenance Technical requirements Tool Operation specification interval content All the cooling pipe joints / Visual inspection of all cooling have no leaks, and the water pipe joints / transitions pipes are not cracked or without leaks, water pipes without Every 5,000...
  • Page 120 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 11.9. Insulation test items Maintenance Maintenance Technical requirements Tool Operation specification content interval Use insulation resistance meter with 500Vdc or 1000Vdc voltage range. Motor controller DC + or The test lead is touching the motor Every 60,000 DC- Insulation resistance Insulation...
  • Page 121 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 12.E-drive system service tools 12.1. List of tools: Tool name Quantity Unit Purpose Remarks Air gun For matching Phillips screwdrivers or sleeves Diagonal pliers For cutting straps Used to remove the motor side phase cable bolts; Hexagon wrench For removing DC bus bolts of MCU Needle-nose pliers...
  • Page 122 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. 12.2. Pictures of tools: (1) Pneumatic wrench (2) Diagonal pliers (3) Hexwrench (4) Needle-nose pliers (5) Magnetic picker (6) Phillips screwdriver (7) Open end wrench M6-M24mm (8) Socket M6-M24mm 电话 Tel： 010－69596333 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co. Ltd 北京市通州区宋庄...
  • Page 123 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. (9) (10) Socket M36mm, M50mm (11) Extractor tool (12) Lappgroup cable gland tool (13) Percussion ring spanner (14) Multimeter (15) Insulation resistance meter 电话 Tel： 010－69596333 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co. Ltd 北京市通州区宋庄...
  • Page 124 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. (16) Torque wrench 5-25Nm (17) Torque wrench 20-100Nm (18) Torque wrench 40-200Nm (19) Single-arm lifting machine 电话 Tel： 010－69596333 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co. Ltd 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 2-98...
  • Page 125 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co., Ltd. (20) Mobile hydraulic lift (21) Hydraulic lifting trolley 电话 Tel： 010－69596333 德纳（北京）电机有限公司 Dana (Beijing) Electric Motor Co. Ltd 北京市通州区宋庄 Songzhuang Tongzhou District Beijing 101118 2-99...
  • Page 127 Propeller shaft PP-1 DRIVE SHAFT  Drive shaft structure and working principle ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ PP-2 1. Drive shaft structure requirement 2. Concise machine draft  Settlement of common troubles ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ PP-4 1. Drive shaft vibration 2. Drive shaft abnormal noise  Drive shaft disassembly and assembly ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ PP-5 1.
  • Page 128 PP-2 Propeller shaft  Structure and working principles of transmission shaft 1. Requirements on structure of transmission shaft The transmission shaft is installed between the transmission and the rear axle and used to transmit the engine power from the transmission to the rear axle. ...
  • Page 129 Propeller shaft PP-3 of both shafts and that the universal coupling forks are within the same plane. 普通十字轴万向节 Ordinary cross shaft universal joint Cross shaft universal joint is a rigid non-constant-velocity universal coupling. When there is an angle between the driving shaft and driven shaft of a single cross shaft universal coupling, a differential angle will be caused so that the angular speeds of the driving and driven shafts are periodically different.
  • Page 130 PP-4 Propeller shaft 传动轴 Drive shaft 六角螺栓 Hex bolt 螺母 Nut 弹垫 Spring washer 万向节总成 Universal joint assy.
  • Page 131 Propeller shaft PP-5  Troubleshooting 1. Transmission shaft vibrations Cause Solution High-speed vibration: error of flange fork in Align to the aligning mark assembly direction Coupler needle roller bearing worn out Replace Drive shaft bent Replace Poor dynamic balance of drive shaft Adjust and correct Flange coupling bolt loosened Fasten with the required torque...
  • Page 132 PP-6 Propeller shaft  Removal and installation of drive shaft 1. Removal of drive shaft  Key points of removal Disconnect the drive shaft and flange disc at all coupling points. 1) Make aligning marks on the flange disc and joint fork 2) Remove nuts and bolts 3) Caution: park the bus on a level ground, pull up the parking brake and place wedges in front of the front...
  • Page 133 Propeller shaft PP-7  Separate the joint fork shaft and sliding fork 1) Strike the counter-cushion on the felt oil seal ring from the groove in the sliding fork; 2) Separate the joint fork shaft and sliding fork; 3) Remove the felt oil seal, retainer ring and felt inner race from the joint fork shaft.
  • Page 134 PP-8 Propeller shaft Install the cross shaft into the joint fork and then install universal joint bearing on the joint fork. Caution: pay attention to the position of the yellow lubrication fitting while installing the universal joint cross shaft onto the joint fork. Point it towards the inner side of the joint fork lug as indicated in the figure.
  • Page 135 Propeller shaft PP-9 Press the universal joint bearing into the joint fork so that is it located on the cross shaft journal. Caution: take care not to damage the sealing lips of universal joint bearing during installation. 4) Install the universal joint fork onto the cross shaft. Caution: align the phase arrow on the universal joint fork to the phase arrow on the sliding fork.
  • Page 136 PP-10 Propeller shaft  Inspection and repair Inspection item Standard value Limit value Solution Inspection method Transmission 0-0.6 Replace shaft {0.0393} damaged and bent Replace Welding seam crack Replace Sliding spline damaged 0.62-0.174 0.25 Replace {0.0025-0.0068} {0.0098} Sliding spline clearance Clearance 0.02-0.054 Replace needle...
  • Page 138 Repair Instructions A V N 7 5 , R L 7 5 A , R L 7 5 E , R L 7 5 E C , R L 8 0 A , R L 8 0 E , R L 8 2 A , R L 8 2 E C , R L 8 5 A , R L 8 5 E , R L 8 5 E C B u s e s...
  • Page 139 Copyright © ZF Friedrichshafen AG This document is protected by copyright. Complete or partial reproduction or distribution of this document is not permitted without the approval of ZF Friedrichshafen AG. Infringements lead to civil and criminal prosecution. This document is a translation of the German original.
  • Page 140 Table of Contents Preface ........................Document overview .......................... Safety ......................... Signal words and symbols ......................General safety instructions ......................Notes on Repairs and Assembly ................. General notes ............................Cleaning the ZF product ........................Dismantling the ZF product ......................Assembling the ZF product ......................

  • Page 141: Table Of Contents

    Table of Contents 9.3.2 Removing and dismantling lower control arm (RL 75 E, with molecular joint) ....9.3.3 Removing and dismantling upper control arm ................Removal of brake ..........................Remove and dismantle hub......................9.5.1 Removing hub (RL 75, RL 80, RL 82 and AVN 75, with compact bearing unit) ....
  • Page 142 Table of Contents 11.1.1 Conversion of length units ....................... 11.1.2 Conversion of mass units ......................... 11.1.3 Conversion of force units ......................... 11.1.4 Conversion of pressure units and units of stress ............... 11.1.5 Conversion of torque units ......................11.1.6 Conversion of temperature units ....................
  • Page 143 Preface Preface This documentation was developed for specialized staff trained in the operation of ZF products by ZF Friedrichshafen AG (hereinafter referred to as "ZF"). Object of documentation is a ZF product. State of design acc. to date of issue. The figures serve to illustrate the operation or the workflow and may deviate from your ZF product.
  • Page 144 Safety Safety Signal words and symbols This document contains particularly highlighted safety instructions which are marked with one of the following signal words depending on the severity of the danger. DANGER The signal word DANGER indicates a dangerous situation that, if not prevented, will lead to a severe injury or death.
  • Page 145 Safety General safety instructions Read all safety instructions and information. Failure to comply with safety instructions and information may lead to property damage, serious injuries or death. Intended use The ZF product is exclusively intended for the application as defined in the contract and as agreed on the time of delivery.
  • Page 146 Safety Handling of ZF product Unauthorized changes and modifications might impair functional security. Changes, modifications and applications are only permissible upon written approval by ZF Friedrichshafen AG. Observe the following when working on the ZF product: • Secure workspace. • Only carry out work at the unit when in a voltage-free state. •...
  • Page 147 Notes on Repairs and Assembly Notes on Repairs and Assembly General notes • Please read this documentation prior to starting repair or assembly work. • Prior to starting repair or assembly work, please find out whether ZF Service Information on the ZF product is available.
  • Page 148 Notes on Repairs and Assembly Sealing compound (refer to section Operating Sealing compound is only to be used when described as such in the work step supplies and auxiliary materials) . Please observe the manufacturer guidelines and processing instructions. Apply the sealing compound thinly and evenly. Keep oil ducts and oil bores free of sealing compound. When assembling the parts, no sealing compound must enter the oil ducts or oil bores.
  • Page 149 Notes on Repairs and Assembly • Single-use parts • Sealing rings • Safety plates • Shaft sealing rings Only replace with original ZF parts or ZF-approved parts. Please refer to the spare parts catalog for the ZF product. Reworking parts Authorized, specialized staff assess whether parts need to be reworked.
  • Page 150 Technical Data Technical Data Type plate The type plate contains the most important data. 1 Product designation 2 Parts list number 3 Serial number 4 Customer spec. number, if known to ZF 5 Number of List of Lubricants 6 Features The following data should be quoted when making inquiries or undertaking repairs: 1, 2, 3 Fig.
  • Page 151 Settings Settings Designation Dimensions Measuring Comment instrument Chapter/Section • axial clearance on steering 0.05 mm to Digital measuring Assembling steering knuckle and king knuckle 0.15 mm slide and digital pin (independent wheel suspension depth gage variant where king pin does not have a web), page •...
  • Page 152 Tightening Torques Tightening Torques Designation Tightening torque Measuring Comment instrument Chapter/Section • Torx screw M16 x 1.5 - 10.9 270 Nm Torque wrench Installing hub carrier (AVN 75), page • Installing hub (RL 75, RL 80, RL 82 and AVN 75, with compact bearing unit), page •...
  • Page 153 Tightening Torques Designation Tightening torque Measuring Comment instrument Chapter/Section • Assembling the steering arms (RL 75 EC and RL 82 EC), page • M36 x 1.5 hexagon slotted nut 600 Nm Torque wrench Installing control arm (RL 75 E, with molecular joint), page •...
  • Page 154 Workshop Equipment Workshop Equipment Special tools The required quantity is listed. Please inquire as to packaging unit before ordering. Figure Order no. Qty. Comment Designation Chapter/Section 5870.505.012 Test device • Clamping independent wheel suspension, page • Removing the track lever (independent wheel suspension variant), page •...
  • Page 155 Workshop Equipment Figure Order no. Qty. Comment Designation Chapter/Section 5870.350.000 Assembly truck • Clamping independent wheel suspension, page • Clamping RL 85, page • Clamping axle (variant with axle bridge), page • Dismantling the steering arms (RL 75 EC and RL 82 EC), page •...
  • Page 156 Workshop Equipment Figure Order no. Qty. Comment Designation Chapter/Section 5870.350.093 For AV 110, AV 133 and some RL-axles Fixture • Clamping axle (variant with axle bridge), page • Assembling axle housing, page AA02.244.885 Ø 25.8 mm, L = 29 mm Tapered ring •...
  • Page 157 Workshop Equipment Figure Order no. Qty. Comment Designation Chapter/Section • Dismantling hub (RL 75, RL 80, RL 82 and AVN 75, with compact bearing unit), page • Dismantling hub (RL 85, adjustable bearing), page AA01.312.325 Press-out device • Removing tie rod (variant with axle bridge), page 5870.080.052 Press-out device...
  • Page 158 Workshop Equipment Figure Order no. Qty. Comment Designation Chapter/Section AA02.293.799 Compression sleeve • Removing and dismantling the lower control arm (variant with tapered roller bearing), page • Removing and dismantling lower control arm (RL 75 E, with molecular joint), page •...
  • Page 159 Workshop Equipment Figure Order no. Qty. Comment Designation Chapter/Section 5870.401.136 Slotted nut wrench • Removing hub (RL 75, RL 80, RL 82 and AVN 75, with compact bearing unit), page • Installing hub (RL 75, RL 80, RL 82 and AVN 75, with compact bearing unit), page 5870.912.012 Centering device...
  • Page 160 Workshop Equipment Figure Order no. Qty. Comment Designation Chapter/Section 5870.300.019 Ø 56 mm to 110 mm Extracting device • Dismantling hub (RL 75, RL 80, RL 82 and AVN 75, with compact bearing unit), page • Dismantling hub (RL 85, adjustable bearing), page 5873.003.007 Clamping cylinder...
  • Page 161 Workshop Equipment Figure Order no. Qty. Comment Designation Chapter/Section 5870.285.028 Pull rod • Removing king pin and dismantling steering knuckle (independent suspension variant and example of king pin with web), page • Removing king pin and dismantling steering knuckle (variant with axle bridge and example of king pin without web), page AA02.042.372...
  • Page 162 Workshop Equipment Figure Order no. Qty. Comment Designation Chapter/Section 5870.650.001 Extracting device • Removing king pin and dismantling steering knuckle (variant with axle bridge and example of king pin without web), page 5870.055.107 Driver tool • Assembling steering knuckle and king pin (independent wheel suspension variant where king pin does not have a web), page...
  • Page 163 Workshop Equipment Figure Order no. Qty. Comment Designation Chapter/Section 5870.345.092 Press-in ring • Assembling the steering knuckle and installing the steering king pin (variant with axle bridge and steering knuckle as an example without web), page 5870.610.010 Use only in connection with insert.
  • Page 164 Workshop Equipment Figure Order no. Qty. Comment Designation Chapter/Section 5870.345.121 Support arbor • Assembling the hub (RL 75, RL 80, RL 82 and AVN 75, with compact bearing unit), page 5870.053.026 Driver tool • Assembling the hub (RL 75, RL 80, RL 82 and AVN 75, with compact bearing unit), page 5870.260.011...
  • Page 165 Workshop Equipment Figure Order no. Qty. Comment Designation Chapter/Section 5870.058.051 Driver tool • Assembling the hub (RL 85, adjustable bearing), page 5870.260.002 Length 160 mm Handle • Assembling the hub (RL 85, adjustable bearing), page 5870.058.089 Driver tool • Assembling the hub (RL 85, adjustable bearing), page 5870.651.070 Inner installer...
  • Page 166 Workshop Equipment Figure Order no. Qty. Comment Designation Chapter/Section 5870.230.005 0 to 50 N Spring balance • Installing hub (RL 85, adjustable mounting), page AA02.247.297 WAF 8 mm Socket wrench • Installing hub (RL 85, adjustable mounting), page AA00.249.031 alignment part •...
  • Page 167 Workshop Equipment Figure Order no. Qty. Comment Designation Chapter/Section 5870.100.060 Press together using press- in mandrel Compression sleeve • Installing the upper control arm, page • Assembling the steering arms (RL 75 EC and RL 82 EC), page AA01.003.764 Assembly fixture •...
  • Page 168 Workshop Equipment Figure 2 Order no. Comment Designation 5870.203.030 0.6 Nm to 6.0 Nm Torque wrench 5870.203.031 1.0 Nm to 12 Nm Torque wrench 5870.203.032 3.0 Nm to 23 Nm Torque wrench 5870.203.033 5.0 Nm to 45 Nm Torque wrench 5870.203.034 10 Nm to 90 Nm Fig.
  • Page 169 Workshop Equipment Figure 2 Order no. Comment Designation 5870.900.016 90° angled, contains the sizes: Set of external pliers A11, A21, A31, A41 Fig. 6 5870.970.001 Jaw width 80 mm Two-armed extractor Throat depth 100 mm 5870.970.002 Jaw width 120 mm Two-armed extractor Throat depth 125 mm 5870.970.003...
  • Page 170 Workshop Equipment Figure 2 Order no. Comment Designation AA02,000,695 Load-bearing capacity 2,000 kg Round sling Effective length 2 m Fig. 10 5870.281.047 Lifting chain Fig. 11 5870.221.500 230V Hot-air blower 5870.221.501 115V Hot-air blower Fig. 12 5870.345.071 Pry bar Fig. 13 5870.280.004 Plastic hammer 5870.280.006...
  • Page 171 Workshop Equipment Figure 2 Order no. Comment Designation 5870.650.004 Striker Fig. 15 5870.200.055 Magnetic holder Fig. 16 5870.200.057 Dial gage Fig. 17 5870.200.066 Consisting of two pieces Set of parallel gage blocks Height 70 mm 5870.200.067 Consisting of two pieces Set of parallel gage blocks Height 100 mm Fig.
  • Page 172 Workshop Equipment Figure 2 Order no. Comment Designation 5870.200.109 Length 150 mm Digital caliper gage Fig. 19 5870.200.072 Length 200 mm Digital depth gage 5870.200.114 Length 300 mm Digital depth gage Fig. 20 Tab. 2 Fixture Comment Requirement Crane with precision hoist Load-bearing capacity min.
  • Page 173 Workshop Equipment Operating supplies and auxiliary materials Order no. Manufacturer name Comment Designation Chapter/Section 0671.190.180 Renolit LX‑NHU 2 400 g. package Grease • Installing hub (RL 75, RL 80, RL 82 and AVN 75, with compact bearing unit), page • 0666.690.191 Phoenix spirit Assembling the hub (RL 85, adjustable bearing),...
  • Page 174 Preparatory Activities Preparatory Activities Clamping ZF product Risk of injury due to uncontrolled motion of the load. Death or serious injury possible. ð Only use the suspension points intended for transportation purposes. ð Only use secure, permitted, and tested means of transport, chain hoist, and lifting equipment with sufficient load capacity and suitable lifting technology.
  • Page 175 Preparatory Activities 8.1.2 Clamping RL 85 Special tools: • 5870.350.094 Fixture • 5870.350.063 Clamping plate • 5870.350.000 Assembly truck • 5870.350.098 Fixture Fix RL 85 with 5870.350.094 [Fixture], and 5870.350.063 [Clamping plate ] on 5870.350.000 [Assembly truck]. Fix RL 85 E with 5870.350.098 [Fixture] on 5870.350.000 [Assembly truck].
  • Page 176 Dismantling Dismantling Removing and dismantling attachments 9.1.1 Removing attachments (independent wheel suspension variant) Unfasten hexagon screw and remove air spring. Fig. 24 Unfasten hexagon nut and remove releasing parts. Fig. 25 9.1.2 Dismantling the steering arms (RL 75 EC and RL 82 EC) Special tools: •...
  • Page 177 Dismantling Slide AA02.244.885 [Tapered ring] and AA02.244.886 [Tapered ring] into bores on steering arm. Fix steering arm with 5870.350.110 [Supporting plate] on 5870.350.000 [Assembly truck]. Fig. 26 Heat hexagon nut. Loosen hexagon nut. Press out and remove bearing bolt with two- armed extractor.
  • Page 178 Dismantling 9.1.3 Removing tie rod (variant with axle bridge) Special tools: • AA01.312.325 Press-out device • 5870.080.052 Press-out device Secure tie rod with crane. Remove cotter pin. Fig. 29 Unfasten hexagon slotted nut. Fig. 30 EN 4474.751.104a - 2018-06 4-41...
  • Page 179 Dismantling Preload AA01.312.325 [Press-out device] and unfasten tie rod by striking against 5870.080.052 [Press-out device], and remove Fig. 31 9.1.4 Dismantling axle bridge Unfasten hexagon nut and remove releasing parts. Fig. 32 Fasten two hexagon nuts to the air spring and lock them.
  • Page 180 Dismantling Loosen cap screws. Using plastic hammer, unfasten and remove spring carrier from below. Pull cylindrical pin out of bore. Fig. 34 Secure axle bridge to crane. Unfasten hexagon screws and remove axle bridge. Fig. 35 Removing the track lever 9.2.1 Removing the track lever (independent wheel suspension variant) Special tools:...
  • Page 181 Dismantling Apply compressed air to brake cylinder with 5870.505.012 [Test device] and AA02.257.341 [Screw coupling] at 8 bar +2 bar. à Hub/axle secured to prevent twisting. Secure axle half to wheel stud with 5870.350.101 [Clamping bracket] to 5870.350.000 [Assembly truck]. Loosen hexagon screws and remove the track lever.
  • Page 182 Dismantling Heat hexagon nut. Loosen hexagon nut. Fig. 38 Fix control arm to crane. Press down bolt with 5870.100.059 [Assembly fixture] and two- armed extractor, and remove it. Fig. 39 Preload joint with hydraulic press, 5870.506.134 [Press-in bush], and AA02.293.799 [Compression sleeve]. Disengage retaining ring.

  • Page 183: Removing And Dismantling Lower Control Arm (Rl 75 E, With Molecular Joint)

    Dismantling Remove scrapers with 5870.400.001 [Offset screwdriver]. Remove the tapered roller bearings. Force out bearing outer rings. Fig. 41 9.3.2 Removing and dismantling lower control arm (RL 75 E, with molecular joint) Special tools: • 5870.080.052 Press-out device • 5870.506.134 Press-in bush •...

  • Page 184: Removing And Dismantling Upper Control Arm

    Dismantling Preload 5870.080.052 [Press-out device] using hexagon screw (1). Unfasten the control arm by striking the pin (2) of 5870.080.052 [Press-out device] and remove it. Fig. 43 Preload joint (2) with hydraulic press, 5870.506.134 [Press-in bush], and AA02.293.799 [Compression sleeve]. Disengage retaining ring (1).
  • Page 185 Dismantling Secure upper control arm to crane. Support upper control arm. Heat hexagon nut. Loosen hexagon nut. Fig. 45 Press down bolt with 5870.100.059 [Assembly fixture] and two- armed extractor, and remove it. Fig. 46 Preload joint with hydraulic press, 5870.506.134 [Press-in bush], and AA02.293.799 [Compression sleeve].

  • Page 186: Removal Of Brake

    Dismantling Remove scrapers with 5870.400.001 [Offset screwdriver]. Remove the tapered roller bearings. Force out bearing outer rings. Fig. 48 Removal of brake Special tools: • AA01.137.137 Eyebolt • 5870.204.002 Eyebolt Observe the specifications of the brake manufacturer. Loosen locknuts. Remove brake cylinder. Fig.
  • Page 187 Dismantling Remove the bracket. Fig. 50 Remove metal sheet. Fig. 51 Depending on variant, remove steel clip or plastic clip. Fig. 52 EN 4474.751.104a - 2018-06 4-50...
  • Page 188 Dismantling Remove rubber cap. Turn adjuster in counterclockwise direction manually until contact is obtained. Fig. 53 Remove spring split pin. Remove disk (1) and pin (2). Remove lining bracket (3). Fig. 54 Remove contacts (1). Fig. 55 EN 4474.751.104a - 2018-06 4-51...

  • Page 189: Remove And Dismantle Hub

    Dismantling Remove brake lining set. Fig. 56 Fix brake caliper with AA01.137.137 [Eyebolt], 5870.204.002 [Eyebolt], and crane. Unfasten screwed connection on brake caliper. Remove brake caliper. Fig. 57 Remove and dismantle hub. 9.5.1 Removing hub (RL 75, RL 80, RL 82 and AVN 75, with compact bearing unit) Special tools: •...
  • Page 190 Dismantling Loosen hexagon screws. Remove cover. Fig. 58 Remove O‑ring (1). Fig. 59 Support hub on a wheel stud from below. Loosen bolted connection of the brake disk with AA01.266.187 [Plug insert] and do not remove. à The brake disk will be removed later. Unlock slotted nut.

  • Page 191: Dismantling Hub (Rl 75, Rl 80, Rl 82 And Avn 75, With Compact Bearing Unit)

    Dismantling Use AA01.395.095 [Load carrying fixture] to fix the hub to the crane. Loosen slotted nut with 5870.401.136 [Slotted nut wrench] and 5870.912.012 [Centering device]. Remove hub from steering knuckle. 9.5.2 Dismantling hub (RL 75, RL 80, RL 82 and AVN 75, with compact bearing unit) Special tools: •...
  • Page 192 Dismantling Remove impulse disc with three-armed extractor. Fig. 63 Remove inner ring of shaft seal with 5870.400.001 [Offset screwdriver]. Fig. 64 Remove retaining ring (1). Fig. 65 EN 4474.751.104a - 2018-06 4-55...
  • Page 193 Dismantling Remove bearing inner ring with 5870.300.020 [Extracting device] and 5870.300.019 [Extracting device]. Remove shaft seal from bearing inner ring. Fig. 66 Press tapered roller bearing and shaft seal from the hub. Fig. 67 Do not mix up bearing outer rings. Use suitable appliances to tie together bearing outer ring and tapered roller bearing.

  • Page 194: Removing Hub (Rl 85, Adjustable Bearing)

    Dismantling 9.5.3 Removing hub (RL 85, adjustable bearing) Special tools: • AA01.395.095 Load carrying fixture Loosen cap screws. Remove cover. Fig. 68 Unfasten cap screw on locking nut. Fig. 69 EN 4474.751.104a - 2018-06 4-57...

  • Page 195: Dismantling Hub (Rl 85, Adjustable Bearing)

    Dismantling Use AA01.395.095 [Load carrying fixture] to fix the hub to the crane. Unfasten clamping nut. Remove supporting ring. Pull hub off steering knuckle and remove releasing components. Fig. 70 9.5.4 Dismantling hub (RL 85, adjustable bearing) Special tools: • 5870.400.001 Offset screwdriver •...
  • Page 196 Dismantling Remove the tapered roller bearing. Fig. 72 Remove impulse disc with three-armed extractor. Fig. 73 Remove the bearing outer rings with 5870.300.020 [Extracting device] and 5870.300.019 [Extracting device]. Fig. 74 EN 4474.751.104a - 2018-06 4-59...

  • Page 197: Removing King Pin And Dismantling Steering Knuckle

    Dismantling Risk of crushing due to hydraulic tool. Slight to moderate injury possible. ð Do not reach into danger area. Use press to fix hub. Do not transmit force through the brake disk. Place cloth or similar item under the brake disk.
  • Page 198 Dismantling Unfasten the lubricating nipple. Unfasten the lower lubricating nipple. Fig. 76 Remove retaining ring. Pull the seal holder out of the bore. Remove the lower seal holder. Fig. 77 Secure steering knuckle support to the crane. Working upwards from bottom, press out king pin using 5873.003.007 [Clamping cylinder], 5870.287.010 [Pump], 5870.285.027 [Pressure plate] and...

  • Page 199: Removing King Pin And Dismantling Steering Knuckle (Variant With Axle Bridge And Example Of King Pin Without Web)

    Dismantling Remove the axial roller bearing. Fig. 79 Drive components out of both bores using AA02.042.372 [Guidance] and 5870.260.003 [Handle]. Fig. 80 9.6.2 Removing king pin and dismantling steering knuckle (variant with axle bridge and example of king pin without web) Special tools: •...
  • Page 200 Dismantling Unfasten the lubricating nipple. Unfasten the lower lubricating nipple. Fig. 81 Remove retaining ring. Fig. 82 Pull seal holder out of bore with 5870.650.001 [Extracting device] and M10 x 1 screw. Remove the lower seal holder. Fig. 83 EN 4474.751.104a - 2018-06 4-63...
  • Page 201 Dismantling Secure steering knuckle to crane. Working upwards from bottom, press out king pin using 5873.003.007 [Clamping cylinder], 5870.287.010 [Pump], 5870.285.027 [Pressure plate] and 5870.285.028 [Pull rod] and remove it. Remove steering knuckle and disk. Fig. 84 Remove the axial roller bearing. Fig.

  • Page 202: Removing Tachometer And Steering Stop

    Dismantling Removing tachometer and steering stop Pull tachometer out of steering knuckle. Fig. 87 Pull bush out of steering knuckle. Fig. 88 Loosen hexagon nut. Remove stop screw. Fig. 89 EN 4474.751.104a - 2018-06 4-65...

  • Page 203: Removing The Hub Carrier (Avn 75)

    Dismantling Removing the hub carrier (AVN 75) Loosen Torx screws (1) and remove hub carrier. Remove O-ring from hub carrier. Fig. 90 EN 4474.751.104a - 2018-06 4-66...

  • Page 204: Assembly

    Assembly Assembly 10.1 Installing hub carrier (AVN 75) Insert O‑ring (1) in hub carrier. Fig. 91 Slide hub carrier into axle bridge and secure with Torx screws (1). Tightening torque: 270 Nm Fig. 92 10.2 Assembling steering knuckle and installing king pin There are various variants of the illustrated ZF units in various combinations.

  • Page 205: Assembling Steering Knuckle And King Pin (Independent Wheel Suspension Variant Where King Pin Does Not Have A Web)

    Assembly Damage due to inappropriate handling possible. ð Note that operational steps depend upon the variant being worked upon. 10.2.1 Assembling steering knuckle and king pin (independent wheel suspension variant where king pin does not have a web) Special tools: •...
  • Page 206 Assembly Adjusting the axial clearance of the steering knuckle Press gage block against the axial bearing. Set the depth gage on the gage block to zero. Fig. 95 Press the gage block against the upper bore of the steering knuckle. Measure dimension from axial bearing to gage block.
  • Page 207 Assembly Dimension C = e.g. 8.9 mm Calculate thickness s of shim for axial clearance on steering knuckle 0.05 mm to 0.15 mm. Calculation example: s = dimension A + dimension C – dimension B – axial clearance (mean value) s = 81 mm + 8.9 mm –...
  • Page 208 Assembly To enable the king pin to be installed, the temperature difference between these components must be at least 120 °C. Risk of burn injuries due to contact with hot or cold surface. Slight to moderate injury possible. ð Wear protective gloves. Fig.
  • Page 209 Assembly Check to ensure that the full circumference of the sealing lip of the sealing ring protrudes downwards. Fig. 102 Insert sealing ring with AA02.042.372 [Guidance] and 5870.260.003 [Handle] until contact is obtained. On variant with bush, install bush with recess pointing downwards.
  • Page 210 Assembly Install needle sleeves with nomenclature facing upwards. Drive in needle sleeve with AA02.042.372 [Guidance] and 5870.260.003 [Handle]. Remove packaging sleeve. Drive in needle sleeve until contact is obtained. Install second needle sleeve. Fig. 105 Install O-ring in the seal holder. Install seal holder in steering knuckle with tab facing towards tachometer.

  • Page 211: Assembling The Steering Knuckle And Installing The Steering King Pin (Variant With Axle Bridge And Steering Knuckle As An Example Without Web)

    Assembly 10.2.2 Assembling the steering knuckle and installing the steering king pin (variant with axle bridge and steering knuckle as an example without web) Special tools: • 5870.055.107 Driver tool • 5870.260.003 Handle • AA01.046.851 Assembly fixture • 5870.345.092 Press-in ring •...
  • Page 212 Assembly Install the axial roller bearing in the steering knuckle with AA01.046.851 [Assembly fixture]. Fig. 110 Adjusting the axial clearance of the steering knuckle Press gage block against the axial bearing. Set the depth gage on the gage block to zero.
  • Page 213 Assembly Measure height of axle stub. Dimension B = e. g. 87.45 mm Fig. 113 Measure height of gage block. Dimension C = e.g. 8.9 mm Calculate thickness s of shim for axial clearance on steering knuckle 0.05 mm to 0.15 mm. Calculation example: s = dimension A + dimension C –...
  • Page 214 Assembly Insert retaining ring. Fig. 115 Secure steering knuckle to crane. Slowly slide steering knuckle over axle stub. Slide in calculated shim for axial clearance of steering knuckle. On RL 85 slide disk above knuckle. On all other axles, insert disk below knuckle.
  • Page 215 Assembly To enable the king pin to be installed, the temperature difference between these components must be at least 120 °C. Risk of burn injuries due to contact with hot or cold surface. Slight to moderate injury possible. ð Wear protective gloves. Fig.
  • Page 216 Assembly Install O-ring in the seal holder. Fig. 120 Install seal holder in the steering knuckle. Insert retaining ring. Install the lower seal holder. Fig. 121 Screw in the top and bottom lubricating nipples and tighten by hand. Fig. 122 EN 4474.751.104a - 2018-06 4-79...

  • Page 217: Assemble And Install Hub

    Assembly 10.3 Assemble and install hub 10.3.1 Assembling the hub (RL 75, RL 80, RL 82 and AVN 75, with compact bearing unit) Special tools: • 5870.610.010 Assembly fixture • 5870.610.002 Insert • 5870.050.003 Driver tool • 5870.260.004 Handle • 5870.345.121 Support arbor •...
  • Page 218 Assembly Install 96 g of grease (1) in acc. with ZF List of Lubricants TE‑ML 12 in compact bearing unit (4). Press grease also from outside (Pfeile) into the space between bearing inner ring and bearing cage. 40_020226_01 Fig. 125 1 Grease 2 O‑ring 3 Retaining ring...
  • Page 219 Assembly Place the hub onto the bearing inner ring at the brake disk side. Place the outer bearing inner ring into the hub. Using a hand press, gently press down on the bearing inner ring and rotate the hub several times.
  • Page 220 Assembly Use 5870.048.317 [Driver tool] and 5870.345.121 [Support arbor] to insert the cassette-type seal at the brake disk side. Fig. 130 Press impulse disc until flush. Fig. 131 Place brake disk on hydraulic press with hub reaching through. Put hub onto the brake disk. Bolt in Torx screws and tighten manually with AA01.266.187 [Plug insert].

  • Page 221: Installing Hub (Rl 75, Rl 80, Rl 82 And Avn 75, With Compact Bearing Unit)

    Assembly Grease O‑ring (1) and insert it into the annular groove on the compact bearing. Fig. 133 10.3.2 Installing hub (RL 75, RL 80, RL 82 and AVN 75, with compact bearing unit) Special tools: • 5870.651.099 Inner installer • AA01.395.095 Load carrying fixture •...
  • Page 222 Assembly Use AA01.395.095 [Load carrying fixture] to fix the hub to the crane. Push hub carefully onto the hub carrier. Bolt on slotted nut with the chamfer showing outwards. Use 5870.401.136 [Slotted nut wrench] and 5870.912.012 [Centering device] to tighten the slotted nut.
  • Page 223 Assembly Secure slotted nut with locking plate (1). Fig. 136 Insert O‑ring (1). Fig. 137 Slide cover into hub. Screw in and tighten hexagon screws. Tightening torque: 100 Nm Fig. 138 EN 4474.751.104a - 2018-06 4-86...

  • Page 224: Assembling The Hub (Rl 85, Adjustable Bearing)

    Assembly 10.3.3 Assembling the hub (RL 85, adjustable bearing) Special tools: • 5870.610.010 Assembly fixture • 5870.610.002 Insert • 5870.058.051 Driver tool • 5870.260.002 Handle • 5870.058.089 Driver tool • 5870.651.070 Inner installer • 5870.048.295 Driver tool Operating supplies and auxiliary materials: •...
  • Page 225 Assembly Use the tools only with hubs where wheel studs have already been installed. Use 5870.610.010 [Assembly fixture] and 5870.610.002 [Insert] to install the wheel studs. Fig. 140 Press small bearing outer ring into hub until contact is obtained using 5870.058.051 [Driver tool] and 5870.260.002 [Handle].

  • Page 226: Installing Hub (Rl 85, Adjustable Mounting)

    Assembly Slide 5870.651.070 [Inner installer] onto bearing inner ring. Carry out the following two work steps immediately one after the other. Apply 0666.690.191 [Phoenix spirit] to the outer diameter of the shaft seal. Insert shaft seal with seal lip facing towards grease chamber using 5870.048.295 [Driver tool].
  • Page 227 Assembly Use AA01.395.095 [Load carrying fixture] to fix the hub to the crane. Slide hub firmly onto knuckle. Fig. 145 (refer to Slide greased tapered roller bearing section Assembling the hub (RL 85, adjustable bearing), page 87) onto knuckle. Fig. 146 Slide on supporting ring.
  • Page 228 Assembly Wind thread onto wheel stud. Uniformly pull thread with 5870.230.005 [Spring balance] and establish how much force is required to turn the hub. Force F = e.g. 25 N Rolling moment of hub (without shaft seal) 2 Nm to 5 Nm. Calculation example: [Nm] = r [m] x F [N] total...

  • Page 229: Installing Tachometer And Mounting Steering Stop

    Assembly Apply 0666.790.033 [Loctite 574] to surface (1) of cover. Fig. 150 Fix cover with cylindrical screws. Tightening torque: 23 Nm Fig. 151 10.4 Installing tachometer and mounting steering stop Operating supplies and auxiliary materials: • 0671.190.065 UNIREX N3 EN 4474.751.104a - 2018-06 4-92...
  • Page 230 Assembly Slide bush into knuckle. Fig. 152 For the installation position refer to the current spare parts lists. Apply a thin layer of 0671.190.065 [UNIREX N3] outside to the tachometer. Push speedometer into bush until contact is obtained. Fig. 153 On variant with hexagon nut, bolt hexagon nut to stop screw.

  • Page 231: Installing Brake

    Assembly 10.5 Installing brake Special tools: • AA01.137.137 Eyebolt • 5870.204.002 Eyebolt Operating supplies and auxiliary materials: • 0666.690.112 Loctite 649 Observe the specifications of the brake manufacturer. Use AA01.137.137 [Eyebolt], 5870.204.002 [Eyebolt] and crane to place the brake caliper onto the axle stub. Tighten screws once brake caliper is in lower limit stop position.
  • Page 232 Assembly Insert brake lining set into the brake caliper. Fig. 156 Install contacts (1) in brake linings from outside. Fig. 157 Attach lining bracket (3) into the brake. Press lining retainer bracket (3) downwards and push in bolts (2). Push disk (1) onto pin (2). Fix pin (2) with spring split pin.
  • Page 233 Assembly Attach steel clips. Fig. 159 Align cable with variant with steel clip (1) or variant with plastic clip (2). Fig. 160 EN 4474.751.104a - 2018-06 4-96...
  • Page 234 Assembly Clip in metal sheet. Fig. 161 Clip in the bracket. Fig. 162 Mount brake cylinder with the connections showing backwards to the brake caliper. Fix brake cylinder with new locknuts. Tightening torque: 195 Nm (±15 Nm) Fig. 163 EN 4474.751.104a - 2018-06 4-97...

  • Page 235: Assembling And Installing The Control Arms

    Assembly 10.6 Assembling and installing the control arms 10.6.1 Assembling the control arms (variant with retaining ring) Special tools: • AA00.249.031 alignment part • 5870.506.134 Press-in bush • AA02.293.799 Compression sleeve Always install completely new repair kits. Assembling control arms with joints Slide joint into control arm.

  • Page 236: Installing The Upper Control Arm

    Assembly Assembling control arm with ball joint and joints Install joints (2) as described above and secure with retaining rings (1). Slide ball joint (3) into control arm. On variant with spacer ring, place spacer ring centrally on ball joint. Install retaining ring as far as possible in bore so that opening 45°...
  • Page 237 Assembly Replace bearing outer rings with 5870.058.084 [Driver tool] and 5870.260.003 [Handle]. Fig. 167 Adjusting the rolling moment of the control arm bearing Slide the tapered roller bearings, shims and bush into bore with 5870.345.091 [Press-in mandrel]. Push on 5870.100.060 [Compression sleeve]. Tighten hex nut on 5870.345.091 [Press-in mandrel] and turn the 5870.345.091 [Press- in mandrel] several times during this...
  • Page 238 Assembly Insert and hold down the tapered roller bearings, the calculated shims and the bush. Fig. 170 Install the scraper with its sealing lip facing outwards, using AA01.003.764 [Assembly fixture]. Fig. 171 Install rings with large radius pointing inwards. Fig. 172 EN 4474.751.104a - 2018-06 4-101...

  • Page 239: Installing Lower Control Arm (Variant With Tapered Roller Bearing)

    Assembly Secure AA01.021.368 [Alignment fixture] to steering knuckle carrier. On opposing independent wheel suspension, secure the control arms to the AA01.021.368 [Alignment fixture] with a ratchet strap or similar. Screw internal part of 5870.000.097 [Mounting fixture] onto the bolt. Attach the control arms to the control arm carrier and pull the pin in the direction of travel.

  • Page 240: Installing Control Arm (Rl 75 E, With Molecular Joint)

    Assembly Screw internal part of 5870.000.097 [Mounting fixture] onto the bolt. Attach the control arm to the steering knuckle carrier and tighten bolt in direction of travel. Align surfaces of bolt WAF flush with control arm. Remove 5870.000.097 [Mounting fixture] . Slide washer onto bolt.

  • Page 241: Fitting The Track Lever

    Assembly 10.7 Fitting the track lever 10.7.1 Fitting the track lever (all axles with compact bearing units, e.g. independent wheel suspension) Special tools: • 5870.505.012 Test device • AA02.257.341 Screw coupling • 5870.350.101 Clamping bracket • 5870.350.000 Assembly truck Apply compressed air to brake cylinder with 5870.505.012 [Test device] and AA02.257.341 [Screw coupling] at 8 bar +2 bar.

  • Page 242: Assembling And Installing Attachment Parts

    Assembly 10.8 Assembling and installing attachment parts 10.8.1 Assembling axle housing Special tools: • 5870.350.093 Fixture • 5870.350.000 Assembly truck Operating supplies and auxiliary materials: • 0666.690.022 Loctite 262 Secure bracket with 5870.350.093 [Fixture] to 5870.350.000 [Assembly truck]. Secure axle bridge to crane. Apply 0666.690.022 [Loctite 262] to thread of hexagon screws.
  • Page 243 Assembly Install dowel pin in axle bridge. Using plastic hammer, drive spring carrier in until contact is obtained. Fig. 179 Apply 0666.690.022 [Loctite 262] to the threads of the cap screws. Secure spring carrier to axle bridge with cap screws. •...
  • Page 244 Assembly Fit shock absorber with disk (1) and joint ring (2). Push disk (5), joint ring (4) and disk (3) at the thread of the shock absorber. Fig. 182 Fix shock absorber with hexagon nut. Tightening torque: 90 Nm Fig. 183 Secure struts to axle bridge and spring carrier with hexagon bolts and washers.

  • Page 245: Installing The Tie Rod (Variant With Axle Bridge)

    Assembly 10.8.2 Installing the tie rod (variant with axle bridge) Degrease tapered hole and tapered pivot. Slide conical peg into tapered bore on track lever from below. Bolt on and tighten the hexagon slotted nut. Tightening torque: 250 Nm Fig. 184 Slide cotter pin into bore on conical peg.
  • Page 246 Assembly Replace bearing outer rings with 5870.058.084 [Driver tool] and 5870.260.003 [Handle]. Fig. 186 Adjusting the rolling moment of the steering arm bearing Slide the tapered roller bearings, shims and bush into bore with 5870.345.091 [Press-in mandrel]. Push on 5870.100.060 [Compression sleeve]. Tighten hexagon nut on 5870.345.091 [Press-in mandrel] and turn 5870.345.091 [Press-in mandrel] several...
  • Page 247 Assembly Insert and hold down the tapered roller bearings, the calculated shims and the bush. Fig. 189 Install the scraper with its sealing lip facing outwards, using AA01.003.764 [Assembly fixture]. Fig. 190 Install rings with large radius pointing inwards. Fig. 191 EN 4474.751.104a - 2018-06 4-110...

  • Page 248: Fitting Attachments (Variant For Independent Wheel Suspension)

    Assembly Bolt inner part of 5870.000.097 [Mounting fixture] onto the bearing bolt. Pull the bearing bolt into installation position upwards, i.e. from bottom to top. Remove 5870.000.097 [Mounting fixture] . Apply 0666.690.022 [Loctite 262] to thread of the hexagon nut. Screw hexagon nut onto bearing bolt with flat side pointing inwards and tighten.
  • Page 249 Assembly Fit shock absorber with disk (1) and joint ring (2). Push disk (5), joint ring (4) and disk (3) at the thread of the shock absorber. Fig. 194 Fix shock absorber with hexagon nut. Tightening torque: 90 Nm Fig. 195 Degrease all tapered bores and conical pegs.
  • Page 250 Assembly On variant with stabilizer, secure tie rod to bracket. Tightening torque: 220 Nm EN 4474.751.104a - 2018-06 4-113...

  • Page 251: Annex

    Annex Annex 11.1 Formulary and conversion tables 11.1.1 Conversion of length units Unit mile n mile 1 in 0.08333 0.02778 — — 25.4 0.0254 — 1 ft 0.33333 — — 304.8 0.3048 — 1 yd — — 914.4 0.9144 — 1 mile 63,360 5,280...

  • Page 252: Conversion Of Force Units

    Annex When cwt and tn are used without long or sh in front of it, this means long cwt and long tn in the UK, cwt and sh tn in the US. Further mass units: • 1 slug = 14.5939 kg = mass which is accelerated by 1 ft/s² by a force of 1 lbf. •...

  • Page 253: Conversion Of Torque Units

    Annex Unit N/m² μbar mbar N/mm 6,894.76 68,948 68.948 0.0689 0.00689 1 lbf/in 47.8803 478.8 0.4788 — — 1 lbf/ft — — — 154.443 15.4443 1 tonf/in Tab. 7 Pressure units and units of stress pound-force per square inch (psi) pound-force per square foot (psf) lbf/in lbf/ft...

  • Page 254: Conversion Of Temperature Units

    Annex 11.1.6 Conversion of temperature units Unit °C °F °R 1 °C K = 273 + °C °F = °C + 32 °R = °C + 491.7 1 °F °C = (°F – 32) °R = °F + 459.7 K = (°F – 32) + 273 1 °R °F = °R –...
  • Page 255 4-118...
  • Page 256 4-119...
  • Page 257 ZF Friedrichshafen AG ZF Aftermarket Donaustraße 71 94034 Passau Deutschland · Germany Telefon/Phone +49 851 494-0 www.zf.com/contact 4-120...
  • Page 259 REPAIR MANUAL ZF-DROP CENTER AXLE AV-132 II / AV-132 II T 5871.214.102 en...
  • Page 260 REPAIR MANUAL for ZF-Drop Center Axle AV-132 II / AV-132 II T I M P O R T A N T I N F O R M A T I O N : Due to the great variety of ZF units it is necessary to limit disassembly and reassembly manuals to a current ZF production unit.
  • Page 261 Chapter/Page T A B L E O F C O N T E N T S Preface General 0/2 … 3 Labeling of identification plate Contact pattern examples of Gleason tooth system 0/5 … 9 Conversion table 0/10 Denomination of standard dimensions 0/11 Tightening torques for screws 0/12...
  • Page 262 R E A S S E M B L Y 4/1 ... 6/8 Reassembly of input and differential 4/1 … 14 Determination of shim for suitable contact pattern 4/2 … 3 Setting of rolling torque of drive pinion bearing 4/4 … 5 Differential and crown wheel 4/6 …...

  • Page 263: Preface

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems PREFACE This documentation has been developed for specialized staff trained by ZF Friedrichshafen AG for repair and maintenance work to be done on ZF units. This manual describes a ZF series product with a design level valid at the date of edition.
  • Page 264 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems GENERAL The Service Manual covers all work required for disassembly and the relating reassembly. When repairing the unit, ensure utmost cleanliness and excellent workmanship. Dismantle the unit only if any damaged parts must be replaced.
  • Page 265 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Structure of the Service Manual The structure of this manual reflects the sequence of work steps for completely dismantling the removed unit.

  • Page 266: Labeling Of Identification Plate

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems LABELING OF IDENTIFICATION PLATE 1 = Unit type 2 = Unit serial number 3 = ZF parts list number 4 = Overall ratio 5 = Oil grade 6 = ZF List of Lubricants (e.g.

  • Page 267: Contact Pattern Examples Of Gleason Tooth System 0/5

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems CONTACT PATTERN EXAMPLES OF GLEASON TOOTH SYSTEM Field of application: These instructions are valid for all bevel gear sets in AV-132 (II) axles. (The setting specification is applicable for lapped spiral bevel gears.) Ideal contact pattern: Shot-peening edge...
  • Page 268 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems General: By shifting the pinion the contact pattern will be moved to the root or the top. Pinion mounting distance in +: = reduce pinion shim thickness →...
  • Page 269 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Dedendum tooth position: Coast side Drive side Contact pattern is too far within the crown wheel tooth root. Increase pinion distance towards crown wheel! Correction: I.e.
  • Page 270 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Addendum tooth position (1): Coast side Drive side Contact pattern is much too close to the crown wheel tooth top (acoustically extremely critical!). (At the crown wheel tooth top [drive], the contact pattern forms a V, and on the coast side it is completely located at tooth top.) Reduce pinion distance towards crown wheel!
  • Page 271 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Addendum tooth position (2): Drive side Coast side Contact pattern is much too close to the crown wheel tooth top (acoustically extremely critical!). Reduce pinion distance towards crown wheel! Correction: I.e.

  • Page 272: Conversion Table

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems VERGLEICHSTABELLE FÜR MASSEINHEITEN CONVERSION TABLE TABLEAU DE CONVERSION 25.40 mm 1 in ( inch) 1 kg ( kilogram ) 2.205 lb ( pounds ) 9.81 Nm ( 1 kpm ) 7.233 lbf x ft ( pound force foot) 1.356 Nm ( 0.138 kpm )

  • Page 273: Denomination Of Standard Dimensions

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems BEZEICHNUNG DER GESETZLICHEN EINHEITEN DENOMINATION OF STANDARD DIMENSIONS DENOMINATION DES DIMENSIONS STANDARDISEES Längenbezogene Masse in kg/m Flächenbezogene Masse in t/m Hinweis : Linear density in kg/m Areal density in t/m...
  • Page 274 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems TIGHTENING TORQUES FOR SCREWS (in Nm) ACC. TO ZF STANDARD 148 Friction coefficient: µ tot. = 0.12 for screws and nuts without subsequent treatment, as well as for phosphated nuts.
  • Page 275 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY AV-132 II / AV-132 II T 4472 037 020 Cons. Figure Designation Chapter/Fig. Order No. Assembly truck cpl.
  • Page 276 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY AV-132 II / AV-132 II T 4472 037 020 Cons. Figure Designation Chapter/Fig. Order No. 1/12 Load carrying fixture 6/15...
  • Page 277 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY AV-132 II / AV-132 II T 4472 037 020 Cons. Figure Designation Chapter/Fig. Order No. Rapid grip 5873 012 013 Basic tool...
  • Page 278 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY AV-132 II / AV-132 II T 4472 037 020 Cons. Figure Designation Chapter/Fig. Order No. Load carrying fixture 4/28 5/35...
  • Page 279 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY AV-132 II / AV-132 II T 4472 037 020 Cons. Figure Designation Chapter/Fig. Order No. 3/11 Slotted nut wrench 4/14...
  • Page 280 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY AV-132 II / AV-132 II T 4472 037 020 Cons. Figure Designation Chapter/Fig. Order No. 3/17 Inner extractor 5870 300 019...
  • Page 281 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY AV-132 II / AV-132 II T 4472 037 020 Cons. Figure Designation Chapter/Fig. Order No. 4/24 Locating pins M14x1.5...
  • Page 282 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY AV-132 II / AV-132 II T 4472 037 020 Cons. Figure Designation Chapter/Fig. Order No. Locating pin 4/23 AA00 622 210...
  • Page 283 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY AV-132 II / AV-132 II T 4472 037 020 Cons. Figure Designation Chapter/Fig. Order No. 4/42 Driver tool 5870 048 216...
  • Page 284 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY AV-132 II / AV-132 II T 4472 037 020 Cons. Figure Designation Chapter/Fig. Order No. 5/26 Driver tool 5/27...
  • Page 285 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY AV-132 II / AV-132 II T 4472 037 020 Cons. Figure Designation Chapter/Fig. Order No. Handle 5870 260 004 Location arbor...
  • Page 286 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY Cons. Figure Designation Chapter/Fig. Order No. Magnetic stand 5870 200 055 Universal Dial indicator 5870 200 057 Universal Gage blocks...
  • Page 287 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY Cons. Figure Designation Chapter/Fig. Order No. Torque wrench 5870 203 030 0.6 -6.0 Nm 5870 203 031 1.0 –...
  • Page 288 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY Cons. Figure Designation Chapter/Fig. Order No. Lifting chain 5870 281 047 Universal Pry bar 5870 345 071 Universal Striker...
  • Page 289 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY Cons. Figure Designation Chapter/Fig. Order No. Set of external pliers A1-A2-A3-A4 5870 900 015 Universal Set of external pliers A01-A02-A03-A04...
  • Page 290 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems COMMERCIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY Cons. Figure Designation Chapter/Fig. Order No. Three-armed puller 5870 971 001 Jaw width 85 mm Throat depth 65 mm 5870 971 002...

  • Page 291: Disassembly Of Mounting Parts 1/1

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems ZF-DROP CENTER AXLE AV-132 II / AV-132 II T Disassembly of mounting parts Longitudinal control arms, air springs and shock absorbers Loosen bolted connection on lower and upper longitudinal control arms (arrows 1 and 2) and remove the releasing longitudinal control arms.

  • Page 292: Brake Cylinder And Brake 1/2

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Brake cylinder and brake The brake manufacturer’s instructions and specifications are mandatory for any operations done on the brake system! The relating information is included in the repair, maintenance and service manuals of the component manufacturer!

  • Page 293: Hub 1/3

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Remove spring cotter from bolt (lining bracket). Pull bolt out of the hole. Mount load carrying fixture (S) to the hole of the brake caliper. (S) Load carrying fixture 5870 281 046 Figure 8...
  • Page 294 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Secure hub by means of load carrying fixture (S) and loosen slotted nut. Remove hub from hub carrier. (S) Load carrying fixture 5870 281 043 (S) Slotted nut wrench 5870 401 146...
  • Page 295 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Remove O-ring from compact bearing. Figure 15 Lever ABS-ring out of the hub hole and remove it. (S) Pry bar 5870 345 036 Figure 16 Disengage retaining ring.

  • Page 296: Disassembly Of Portal Drive 2/1

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Disassembly of portal drive Detach cable from the clamp (see arrow). Remove clamp from screen sheet. Then push out revolution counter towards the portal drive. Figure 1 Secure hub carrier by means of lifting device.

  • Page 297: Removal Of Portal Drive (Av-132 Ii)

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Remove output gear from the portal housing. Figure 5 Dismantle both bearing inner rings from output gear. (S) Rapid grip 5873 012 013 (S) Basic tool 5873 002 001...
  • Page 298 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Dismantling of portal drive Fix portal drive to the assembly truck. (S) Assembly truck 5870 350 000 (S) Fixture 5870 350 110 Loosen hexagon screws (see arrows).
  • Page 299 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Remove input gear, axial bearing and cup springs from portal housing. Figure 13 If required, remove retaining ring from input gear. Figure 14 Dismantle bearing outer ring from portal housing and remove the shim behind.
  • Page 300 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Carefully force hub-sided tapered roller bearing and shaft seal out of the hub using a suitable plate. Figure 19 If necessary, force out both bearing outer shells and remove wheel studs.
  • Page 301 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Disassembly of differential and input Differential and crown wheel Remove O-ring (see arrow). Remove differential from axle housing by means of lifting device.
  • Page 302 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Pull differential cover out of differential carrier using the extractor (S). (S) Extractor 5870 080 067 Figure 5 Take axle bevel gear and thrust washer (crown wheel side) out of the differential carrier.
  • Page 303 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Force out opposite differential pin. Then remove all single parts. Figure 9 Use striker (S) to force bearing outer ring out of the housing hole and remove the shim behind.
  • Page 304 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Drive pinion Loosen slotted nut. (S) Slotted nut wrench 5870 401 173 (S) Power wrench 5870 203 002 (S) Supporting device AA00 640 418 ...
  • Page 305 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Remove shim ring.  Mark installation position of shim ring → reassembly aid. Figure 15 Disassemble bearing inner ring from drive pinion. (S) Grab sleeve 5873 002 051 (S) Basic tool...
  • Page 306 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems If necessary, force out breather neck outwards. Figure 19 5-48 5871 214 102...

  • Page 307: Drive Pinion 3/3

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Reassembly of input and differential If either crown wheel or drive pinion is damaged, both parts (bevel gear set) having identical mating numbers must be jointly replaced! The following settings are described on the next pages: A = Bevel gear set contact pattern (chapter 4.1)

  • Page 308: Determination Of Shim For Suitable Contact Pattern 4/2

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Determination of shim for suitable contact pattern (bevel gear set) Take dimension I on the axle housing (arrow). Dimension I e.g......201.26 mm Figure 2 Figures 3 and 4 show the drive pinion.
  • Page 309 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Undercool the external bearing outer ring and insert it until contact is obtained. Figure 6 Insert the determined shim (e.g. thickness = 1.16 mm; figure 5) into the bearing hole.

  • Page 310: Setting Of Rolling Torque Of Drive Pinion Bearing 4/4

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Setting of rolling torque of drive pinion bearing (4 … 10 Nm) Fit bearing inner ring to the drive pinion until contact is obtained. ...
  • Page 311 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Heat input flange and fit it to the drive pinion. Wear protective gloves! Figure 13 Bolt on slotted nut and tighten it. Tightening torque = 1000 …...

  • Page 312: Differential And Crown Wheel 4/6

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Differential and crown wheel Prior to reassembly, oil the running surfaces of all parts within the differential with oil according to ZF List of Lubricants TE- ML 12.
  • Page 313 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Figure 20 Insert axle bevel gear into the differential carrier. Figure 21 Fix thrust washer in differential carrier cover using some grease. Figure 22 Radially align differential cover by means of locating pins (S) (2x, see arrows) and then press it into the differential carrier until...
  • Page 314 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Mount two locating pins (S). Heat crown wheel and bring it into contact position with the mounting face of the differential. (S) Locating pins (M14x1.5) 5870 204 025 Wear protective gloves!
  • Page 315 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Setting and check of backlash, determination of shim for differential bearing rolling torque and check of contact pattern Insert shim and bearing outer ring into the bearing hole until contact is obtained.
  • Page 316 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems To ensure an exact centering of the single parts, rotate bevel gear set in both directions several times. (S) Locking device 5870 240 002 Figure 31 Check backlash (e.g.
  • Page 317 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Determine shim for suitable differential bearing rolling torque (2.5 … 5.5 Nm) (figures 34 … 37). Determine dimension V from the upper front face of the test equipment (S) to the front face of the washer (S) (figure 29).
  • Page 318 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Determine dimension VIII (from mounting face of portal housing to front contact face of bearing outer ring). Dim. VIII e.g......27.84 mm (S) Straightedge 5870 200 022 Calculation example B:...

  • Page 319: Installation Of Shaft Seal (Input Flange) 4/13

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Rotate input flange in both directions several times. Then measure total rolling torque (pinion bearing and differential bearing) to check the differential bearing rolling torque. The total rolling torque depends on the ratio „i“...
  • Page 320 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Heat input flange and fit it to the pinion. Let parts cool down. Bolt on and tighten the slotted nut. Tightening torque see figure 14.

  • Page 321: Reassembly Of Portal Drive 5/1

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Reassembly of portal drive Mount longitudinal control arm bracket according to the description: 1. Position bracket on the housing. Turn in cylindrical screws with washers (arrow 1) and hand-tighten them (MA = 3 –...

  • Page 322: Setting And Installation Of Gears 5/2

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Setting and installation of gears 5.1.1 Input gear 2 3 4 5 8 9 10 11 Figure 3 Legend : Housing Cup spring (67.5 x 50.5 x 0.7) Housing disk (68 x 42 x 5)
  • Page 323 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Position single parts item 2 … 5 and item 8 … 11 in the portal housing by using the assembly fixture (S) (figure 5). (S) Assembly fixture 5870 345 103 2 …...

  • Page 324: Intermediate Gears 5/4

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems 5.1.2 Intermediate gears (axial play of bearing 0.01 … 0.05 mm)  When reusing already used intermediate gears/tapered roller bearings, observe the pairing and installation position of the single parts! According to our experience, the required axial play of the intermediate gear bearing is obtained when reusing the shims...
  • Page 325 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Position the intermediate gears together with bearing in the portal housing one after the other. While doing so, slightly lift the lower bearing by using a screw driver or similar.
  • Page 326 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Tighten the hexagon screws. Tightening torque (M14/10.9) = 185 Nm Figure 16 Position the dial indicator at one intermediate gear, use the pry bar (S) to lift the intermediate gear and check the axial play (0.01 …...
  • Page 327 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems 5.1.3 Output gear (axial play of bearing 0.00 … 0.03 mm) Press both bearing inner rings onto the output gear until contact is obtained.
  • Page 328 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Determine dimension III from mounting face to front contact face of bearing hole. Dim. III ......136.50 mm Figure 24 Determine dimension IV from mounting face to front contact face of bearing hole.
  • Page 329 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems If disassembled, support hub carrier evenly on the mounting face and press screen sheet onto the hub carrier. (S) Pressing device AA00 387 830 ...

  • Page 330: Mounting Of Portal Drive (Av-132 Ii)

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Mounting of portal drive (AV-132 II) Grease the O-ring (arrow 1) and mount it to the axle housing. Wet mounting face in the area without holes with sealing compound „Three Bond Silicone type 1207“...

  • Page 331: Revolution Counter

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Tighten Torx screws (arrow 2). Mount stub shaft to the portal drive. Grease the O-ring and fit it to the axle housing half (arrow 3). Bring portal drive and stub shaft into contact position with the axle housing half (arrow 3) and fix it by means of Torx screws (arrow 1).

  • Page 332: Reassembly Of Mounting Parts 6/1

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Reassembly of mounting parts Fit wheel studs to the hub. (S) Assembly fixture 5870 610 010 (S) Insert 5870 610 002 ...
  • Page 333 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Place the bearing inner ring at brake disk side (with groove for O-ring on inner diameter) onto the location arbor (S). (S) Location arbor 5870 345 121 Then hook the retaining ring into the annular groove of the...
  • Page 334 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Legend: 1 = Outer shaft seal (figure 10) 2 = Shaft seal at brake disk side (figure 11) 3 = Tapered roller bearing at brake disk side (figure 5) 4 = Outer tapered roller bearing (figure 6) 5 = Retaining ring (figure 5) ...
  • Page 335 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Wet both bearing areas on hub carrier evenly with grease for compact bearings (see assembly of compact bearing). Mount assembly aid (S) to the hub carrier. (S) Assembly aid 5870 651 085 Figure 13...
  • Page 336 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems If during the tightening process of the slotted nut (figure 16) no increase of the bearing rolling torque is noticeable, or if an axial play of the wheel bearing is detected, this may be caused by the disengagement of the retaining ring (see figure 8 …...

  • Page 337: Brake 6/6

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Grease O-ring (see arrow) and insert it into the annular groove of the flange shaft. Apply compact bearing grease to the flange shaft at the black- white line on the whole circumference (see assembly of compact bearing).
  • Page 338 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Bolt brake to hub carrier. Tightening torque (M16x1.5/10.9) = 270 Nm or (depending on the version) Tightening torque (M18x1.5/10.9) = 440 Nm ...

  • Page 339: Spring Carriers

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Spring carriers Position spring carriers at the portal drives by means of lifting device and fix them with washers and hexagon screws. Tightening torque (M20x1.5/10.9) = 620 Nm ...
  • Page 341 Suspension System SU-1 Air suspension control system & anti-roll bar  Air pipeline system of air suspension ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ SU-2 Outline of air suspension system Leveling system pipeline Front anti-roll bar system and leveling system Rear anti-roll bar system and leveling system ...
  • Page 342 SU-2 Suspension System Anti-roll bar & leveling system of air suspension  Outline of air suspension system Air spring, the elastic component of air suspension, which consists of a sealed rubber vessel filled with compressed air, realizes its elasticity by making use of the compressibility of air. When the load on the spring increases, the air is compressed and the air pressure rises, leading to increased spring stiffness, and vice versa.
  • Page 343 Suspension System SU-3 PART CODE PART NAME 4729000560 Solenoid valve 4341001250 Overflow valve 4325000200 Pipeline filter XML3500071N5F1 Connector body, 4-way protective valve JB982-22 Sealing washer XML3500351N5F0 Air intake connector, PVC valve 6125G02-2908501 Overflow valve to pipe filter PaG12*1.5 Pa11 tube (black) 12*1.5 6125G02-2908502 Pipe filter to solenoid valve GB3737.1-G12...
  • Page 344 SU-4 Suspension System  ECAS Electric control system WABCO Bus ECAS operation manual...
  • Page 345 Suspension System SU-5 CONTENTS 1. INTRODUCTION OF ECAS SYSTEM 1.1 Advantages of ECAS 1.2 Functions of ECAS system 2. COMPOSITION OF ECAS SYSTEM 3. INSTALLATION REQUIREMENTS AND TEST OF ALL ECAS SYSTEM COMPONENTS 3.1 Capacity requirements of air reservoir 3.2 Installation of height sensor 3.3 Installation of solenoid valve 3.4 Connection of cables 3.5 Installation of ECU...

  • Page 346: Introduction Of Ecas System

    SU-6 Suspension System Introduction of ECAS system ECAS is air suspension control system for vehicle. It uses solenoid valve to control the action of air bellow per the readings of sensor by means of electronic control unit (ECU).By working together with the switches, ECU can realize some other controls except normal driving height.

  • Page 347: Composition Of Ecas System

    Suspension System SU-7 special height II must be installed. Since the special height II is not limited by the speed, the vehicle shall not run for long at this height, otherwise, the components and traveling comfort can be subject to damage. ●...

  • Page 348: Installation Requirements And Test Of All Ecas System Components

    SU-8 Suspension System Electronic control unit (ECU), solenoid valve, height sensors, pressure sensor (optional), pressure switch, ECAS alarm light, indicators and functions selecting switches. Installation requirements and test of all ECAS system components 3.1 Limits on the capacity of air reservoir The air reservoir capacity shall be not less than 40L Pipeline filters and overflow valves must be installed before air reservoir 3.2 Installation of height sensor...

  • Page 349: Installation Of Ecu

    Suspension System SU-9 ECU can be powered by both the batteries and the ignition switch. Power supply voltage: max. 30V, min. 18V. ECU requires separate power supply and separate grounding (it shall be as far as possible from ground points of the other electric equipment) system.

  • Page 350: Parameters Setting Description

    SU-10 Suspension System Battery anode – terminal 30 Battery cathode – terminal 31 Diagnosis wire K Diagnosis wire L See the right figure 4.2.2 If there is no central socket meeting ISO9141, and no diagnosis socket satisfies ISO9141, please connect the diagnosis unit by coupling.

  • Page 351: Diagnosis Of Ecas System

    Suspension System SU-11 equipment, and save this height, which will be memorized by ECU as the min. height. Caution: - The input values of height sensor must be larger than 4 - The input values of height sensor must be less than 255 - Upper height limit must be larger than normal height plus height tolerance by 3 times plus 3.
  • Page 352 SU-12 Suspension System WABCO data Check all troubles Calibration values Height sensors evaluate the circuit, check all troubles RAM unit defects EUC/pressure sensor Calibration date of pressure sensor Relay of control valve ECU PIN8 of 2HSA right Short/open circuit to +UB height sensor ECU PIN26 of 2HSA left Short/open circuit to +UB...
  • Page 353 Suspension System SU-13 ECU pin15 of 3/2 solenoid Short/open circuit to +UB valve 2HSA left ECU pin13 of Short/open circuit to +UB 2/2 solenoid valve 2HSA right ECU pin31 of Short/open circuit to +UB 2/2 solenoid valve 2HSA left ECU pin12 of Short/open circuit to +UB 2/2 solenoid valve 1HSA right ECU pin30 of...
  • Page 354 SU-14 Suspension System Throttle valve ECU pin35 Grounding in short circuit of main passage 2HSA right height sensor Possible troubles during raising 2HSA left height sensor Possible troubles during raising 1HSA Possible troubles during raising 2HSA right height sensor Possible troubles during descending...

  • Page 355: How To Judge The Ecas System Is Working Properly

    Suspension System SU-15 How to judge if the ECAS system is working properly: When ignition switch is turned on, the alarm light and height indicator are illuminated for 2 seconds before flameout. Illumination of height indicator (yellow) indicates that the current height is not the normal height. If the vehicle is under efficient pressure, the yellow light shall be out when pressing the normal height resuming button.

  • Page 356: Repair Service Of Ecas

    SU-16 Suspension System Repair service of ECAS WABCO can supply comprehensive repair service for ECAS system, including repair and spare parts. When replacing ECU, the parameters shall be kept the same. So the information may be supplied by WABCO or vehicle manufacturer with no parameters setting error in new ECU.
  • Page 358 Steering System SR-1 Steering System  Structure & Working Principles of the Steering System ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ SR-2 Integrated power steering booster (steering gear) Hydraulic piping system of steering system  Technical specifications and parameters of the steering system ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ SR-6 Technical specifications of the steering system Tightening torques Installation and adjustment requirements of ZF 8098 steering gear ...
  • Page 359 SR-2 Steering System  Structure & Working Principles of the Steering System The bus needs to change its traveling direction from time to time. For that purpose, the driver has to operate one dedicated mechanism through which the wheels are deviated from the longitudinal axis of the bus by a certain angle.
  • Page 360 Steering System SR-3 Power Steering Gear Steering pitman arm Steering wheel Drag-link assembly, front Drag-link assembly, rear Middle rocker arm w/ bushing assembly Screw, self-tapping Spring washer Plane weasher Ignation switch Combination switch assembly Front cover Rear cover Dust boot, rubber Compression ring, dust boot Cotter pin Goose-neck grease nozzle...
  • Page 361 SR-4 Steering System pitman arm to turn. When the steering shaft stops turning, the driving valve will return to the middle position. Hydraulic piping system of steering system Steering booster oil pump is driven by the engine. The boosting oil pan supplies hydraulic oils via rubber hoses.
  • Page 362 Steering System SR-5 Joint, oil inlet, oil pump Transition connector, steering gear Sealing pad Hose clip (30) Hose clip (40) Straight thread connector Oil inlet pipe assembly, power steering Elbow connector Low-pressure oil pipeline assy., power steering Sealing washer...
  • Page 363 SR-6 Steering System  Technical specifications and parameters of the steering system 1. Technical specifications of the steering system Item Parameter Steering gear type ZF 8098957133 Number rotation 2.4~0~2.4 steering wheel Transmission ratio 20~17~20 Allowed drop arm swing ±47° angle Steering limiter type 0770 196 191 Steering relief valve and its...
  • Page 364 Steering System SR-7 Installation and fastening of the oil hose Ensure smooth transition and secure fastening of the steering oil hose. Adjustment of Hydraulic Steering stopper in steering 1) after install the steering to the vehicle, the steering drag link must have been installed and set Completed;...
  • Page 365 SR-8 Steering System Analysis and Troubleshooting of Common Malfunction  The common malfunctions with the steering system include unstable turning, too big clearances, one-sided turning or loosened turning wheels, as well as the deflective front axle which leads to malfunction of the steering wheel operation. In case the turning of the steering wheel is unstable, use a hydraulic jack to lift the front axle and check it as guided by the front wheels.
  • Page 366 Steering System SR-9 ● ● Excessive tyre wear Replace the tyre 4. Steering wheel off-tracking Malfunction Causes Troubleshooting Steering system Heavy steering ● Insufficient oil level in the steering gear ● Fill lubrication oil to its wheel operation specified level ●...
  • Page 367 SR-10 Steering System 6. Steering wheel’s failure to return Malfunction Causes Troubleshooting Steering system ● Adjust gear Steering wheel’s ● Difficult gear engagement engagement fail to return Front axle ● Check & adjust the front ● Excessive positive caster wheel positioning Early wear of tyre Malfunction Causes...
  • Page 368 Steering System SR-11 steering ● ● Loosened steering gear & its bracket; Check the steering gear gear sounds assembly bolts, tighten click or cluck the bolts with a torque of ● Loosened mechanical steering linkage; 90~110 N.m; ● Check whether there is ●...
  • Page 369 SR-12 Steering System  Assembly, disassembly and adjustment of steering system 1. Steering wheel and steering linkage  Removal of the steering wheel 1) Remove the horn button cover; 2) Remove the earth contact plate assembly; 3) Disconnect the horn wires, nuts and washers; 4) Take off the steering wheel;...
  • Page 370 Steering System SR-13  Disassembly of transmission shaft assembly of the steering system 1) Use long-nose pliers to take out the elastic retainer ring of the shaft; Caution: take protective measures for the threads at the head of the steering shaft. 2) Use a copper hammer or wooden hammer to strike as indicated in the Figure until the cross shaft and the bearing are detached from the bearing hole.
  • Page 371 SR-14 Steering System  Install the steering column pipe and steering shaft 1) Install the steering column pipe, steering shaft and sealing jacket; 2) Install the steering column onto the pedal bracket; 3) Install the wire clipping board 1. Screw 2.
  • Page 372 Steering System SR-15 3) Install the steering column protective cover; 4) Install the combined switch protective cover; Caution: ensure that the switch cover does not interfere with the adjusting nuts, key switches and combined switches.  Install the steering wheel 1) Turn the steering gear to the middle position (maintain straight travel), put on the steering wheel as shown in the figureand insert it into the spline;...
  • Page 373 SR-16 Steering System 2) Install the toothed washer and nut and fasten the nut. 3) With the front wheels being in the position they would be in straight travel, turn the steering wheel slightly to inspect its free gap; 4) Connect the lead wires of the horn brush and install the horn button cover; 5) In trial runs, ensure that the steering wheel operates normally without swinging, steering difficulty or deviation.
  • Page 374 Steering System SR-17 be applied with a coat of lubricating greases before assembly; 5) After installation of the steering transmission shaft assembly, please fully add lubricating greases into the grease nozzle; 2. Steering drag link  Removal of tie-rod and drag link 1) Remove the split pins at the front and rear ends of drag link and take off the slotted nut, and now the drag link assembly can be taken off.
  • Page 375 SR-18 Steering System 2) The link length shall be adjusted to satisfy the requirements on the position of lower pitman arm and the status of the steering wheels. Caution: Do not loosen the nuts in order to align the split pins. 3.
  • Page 376 Steering System SR-19 Initial inspection With respect to the steering problem, if you (service man) can confirm what users are actually relaying and ensure you are discussing a same issue with them, you will save a lot of time in handling problems. For example, if the customer tells you that steering is difficult, you should ascertain the specifics: is it left steering difficulty, right steering difficulty, pivot steering difficulty, intermittent steering difficulty or no boosting at all.
  • Page 377 SR-20 Steering System lead to poor performance Difficulty Front axle overload Reduce the front load. steering Bent or damaged kingpin or Repair or replace the damaged part. tie-rod Improper kingpin caster Adjust the kingpin caster as specified. Oil too hot with reduced Locate the cause of heat and address.
  • Page 378 Steering System SR-21 great Worn pin and joint in steering Check and replace the worn parts; spare travel of column universal joint and steering wheel damaged universal joint Loose universal joint sleeve Repair or replace the worn parts. Looseness between Check, repair or replace the damaged parts and steering gear support and the tighten the assembling bolts to the required torque.
  • Page 379 SR-22 Steering System Oil leakage of Worn or damaged sealing Replace the seals. steering gear elements after long use Worn or damaged sector shaft Replace the steering gear. or input shaft  Oil filling and air discharge of steering system The power steering system adopts Caution: A steering gear can only be filled with single brand of oil.
  • Page 380 Steering System SR-23  Appendix: User’s Manual of HERG centralized Lubrication System  附录：河谷集中润滑系统使用说明 1. HERG AP vehicles chassis instruction manual centralized lubrication system AP 型车辆底盘润滑系统 AP Lubrication System for Automotive Chassis 国家认可注册号 National Accreditated Registration No. 通过 ISO9001:2000 认证 With ISO9001:2000 authentication 使用说明书...
  • Page 381 SR-24 Steering System 追求卓越 创造精品 Strive for excellence and create finest products 目录 Contents 页数 Page number 一、用途与特性 I. Usages and Features 二、产品规格及技术参数 II. Specification and Technical Parameters of Products 7-24...
  • Page 382 Steering System SR-25 三、外形和安装尺寸 III. Outline and Mounting Dimensions 四、润滑油脂泵使用方法与调试 IV. Application Methods and Debugging of Grease Pump 五、车载程控器的说明 V. Description of In-vehicle Program Controller 六、维护与保养 VI. Maintenance 七、常见故障及排除方法 VII. Common Faults and Troubleshooting Method 八、附装箱单 VIII. Packing List 九、选购件 IX.
  • Page 383 SR-26 Steering System 一、用途与特性 I. Usages and Features AP 型系列电动润滑油脂泵是适应市场，满足客户要求，专为汽车底盘、轨道车辆、工程机械润滑引进生产制造 的。AP 型系列电动润滑油脂泵其额定输出压力 35-38kgf/cm ，与 AD 型容积式分配器组成润滑系统，也可与 35 型加压容积式分配器配套组成润滑油脂润滑系统。系统的压力适中，可将润滑油脂加压至 35-38kgf/cm 对润滑点 注入润滑，定量可靠；也可与抵抗式分配器组成抵抗式润滑系统，对各个润滑点进行按比例注脂润滑。 AP type series of electric grease pump is introduced and produced to cater to the market demands, and to respond to the requirements of customer specially for automotive chassis, railway vehicles, lubrication of engineering machinery.
  • Page 384 Steering System SR-27 二、产品规格及技术参数 II. Specification and Technical Parameters of Products 参数 吐出量 工作压力 油箱容积 使用电压 出油管规格 Parameters 使用油粘度 Discharge Operating Capacity of Service Specification Oil Viscosity Capacity Pressure Tank Voltage of outlet tube 型号 Model AP-32-300X DC24V NLGI-000.00 （M16×1.5） 或...
  • Page 385 SR-28 Steering System Type of motor 1=DC 12V 2=DC 24V 2=100~200cc. 3=200~300cc. 4=300~400cc. 润滑泵每分钟吐出量 Discharge capacity of lubricant pump per minute 2=100~200cc. 3=200~300cc. 4=300~400cc. 电动润滑油脂泵编号 Serial number for electric grease pump 例：AP-32-300X 代表吐出油量为 200~300cc/min，DC24V 不带压力开关、内藏卸压机构、3 升油箱的 AP 型电动 润滑油脂泵。 Eg. AP-32-300X suggests that the discharge capacity is 200~300cc/min, DC24V suggests AP-type electric grease pump without pressure switch, built-in pressure relief mechanism, and 3-L tank.
  • Page 386 Steering System SR-29 四、润滑油脂泵使用方法与调试 IV. Application Methods and Debugging of Grease Pump 1、确认与 AP 型润滑油脂泵连接的电源电压。 1. Confirm the power voltage connected to AP-type grease pump. 2、确认选用的 AP 型润滑泵内附有卸压机构。 2. Confirm that pressure relief mechanism is equipped on the selected AP-type grease pump. 3、安装时，为了获得更好的卸压效果，润滑泵安装在底盘的中间位置较为适宜，AD 型分配器安装时遇到有位...
  • Page 387 SR-30 Steering System ★ 建议：在时间不允许情况之时，支管可事先用油脂加油泵进行分别注满后在与分配器连接。 ★ Advice: If time does not permit, branch pipes can be connected to distributor after they are fully filled by grease pump in advance. 五、车载程控器的说明 V. Description of In-vehicle Program Controller 7-30...
  • Page 388 Steering System SR-31 （一）使用说明 (I) Direction for use 1、电路通电后，电源灯（黄色）亮，故障灯（红色）亮 2 秒钟就熄灭。系统自动进入间隔时间计时（如果上次 断电是故障状态，系统会先进入电机泵油计时） 。 1. After circuit is switched on, power indicator (yellow) is on, and fault indicator (red) will be on for 2 seconds and then off. The system automatically enters the state of timing the interval time (if the last power failure is fault state, the system will first enter the state of timing oil pumping of electric pump).
  • Page 389 SR-32 Steering System 4、有故障时，按 KEY0（消除报警）键消除故障输出，故障指示灯熄灭，系统复位，重新按设定的电机转动的 间隔时间开始计时。 4. In case of any failure, press KEY0 (DISALARM) to cancel fault output, fault indicator will then be off, system will be reset, and time will be re-counted according to the set rotation interval of motor. 5、按...
  • Page 390 Steering System SR-33 主电源 Main Power Supply 六、维护与保养 VI. Maintenance 1、为了润滑系统正常工作，务必使用清洁 000#~00#或 0#的润滑油脂，并保持润滑油脂的清洁 1. For the normal work of lubrication system, make sure to use 000#~00# or 0# lubricating grease and keep it clean. 2、每半年必须坚持油箱密封是否可靠，以免行车中混入沙泥与油脂里，造成油泵工作故障，吐出量减少和压力 不足。 2. Tightness of tank shall be checked every half year for reliability, to avoid mud and sand mixed in grease, which may cause pump failure decreased discharge and insufficient pressure.
  • Page 391 SR-34 Steering System 使用电压不对 使用正确的电压电源 Wrong service voltage Use correct supply voltage 按正确的电气接线图接线 接线错误 Wiring according to correct wiring Wiring error 电机不转 diagram Motor does not work 拆除底部齿轮泵清洗 吸入微细沙粒困死齿轮 Remove bottom gear pump for washing Gear is blocked due to sucking fine 此项必须由专业人士操作...
  • Page 392 Steering System SR-35 Little quantity of Oil suction is blocked Clean and wash filter screen of oil ingress of oil suction 溢流阀密封不好 取下溢流阀清洗 relief valve is poorly sealed Remove relief valve for washing 检查管路系统压力 系统压力不足 Check system pressure of pipeline Insufficient system pressure 压力开关失灵...
  • Page 393 SR-36 Steering System 九、选购件 IX. Optional Accessories 管外径 代号 Outer Code 油管接头 Diameter Oil Tube PA-4 Ø4 M8×1 Connector PA-10 Ø10 M16×1.5 管外径 代号 Outer Code Diameter 密封圈 Gasket Ring PB-4 Ø4 Ø4.1 Ø6 PB-10 Ø10 Ø10.2 Ø12 代号 固定双通接头 Code Fixed Double Passage Joint...
  • Page 394 Steering System SR-37 管外径 代号 Outer Code Diameter PD-406 Ø4 M8×1 M6×1 直通接头 PD-408 Ø4 M8×1 M8×1 Through PD-410 Ø4 M8×1 M10×1 Joint PD-1/8 Ø4 M8×1 R1/8 PD-1038 Ø10 M16×1.5 R3/8 PD-416 Ø4 M8×1 M16×1.5 PD-616 Ø6 M10×1 M16×1.5 管外径 代号...
  • Page 395 SR-38 Steering System 代号 Code PL-1/8 M8×1 R1/8 PL-1/8F M8×1 R1/8 直角接头 PL-406 M8×1 M6×1 Right-angle PL-406F M8×1 M6×0.75 Joint PL-408 M8×1 M8×1 PL-410 M8×1 M10×1 PL-412 M8×1 M12×1 PL-418 M8×1 R1/8 代号 Code 油管衬套 PT-4×2 Ø3.8 Ø2 Oil Tube Sleeve PT-4×2.5 Ø3.8 Ø2.5...
  • Page 396 Steering System SR-39 代号 材料 Code Materials 铜 GU-4T Ø4 Ø2 Copper 铜 GU-10T Ø10 Ø7 Copper 铝 GU-4L Ø4 Ø2 Aluminum 铝 GU-10L Ø10 Ø7 Aluminum 油管 Oil Tube 尼龙（带色） GU-4×2NA Ø4 Ø2 Nylon (color) 尼龙（带色） GU-10×7.5NA Ø10 Ø7.5 Nylon (color) 尼龙（带色）...
  • Page 397 SR-40 Steering System PC-1104 1Ø4 PC-1204 2Ø4 PC-1304 28.5 3Ø4 PC-1110 1Ø10 代号 Code PS-08Z M8×1 16.5 油塞 Oil Plug PS-16 M16×1.5 代号 Code 单边固定管夹 One-side fixed Tube Clip P0-16 Ø16.2 Ø19 内接双通接头 代号 Inner Two-Way Code 7-40...
  • Page 398 Steering System SR-41 Joint 2T-16-16 M16×1.5 M16×1.5 管径 代号 AL 接头 Outer Code Diameter AL Joint AL-16-16 Ø10 M16×1.5 M16×1.5 管径 代号 Outer AT 接头 Code Diameter AT Joint AT-16-16-10 Ø10 M16×1.5 M16×1.5 M10×1 代号 Code 定做 PH-7.5 Ø7.5 Ø11.5 波纹管...
  • Page 399 SR-42 Steering System 钢丝护套软管 Steel wire sheath hose 外钢丝编织布护套软管使用橡胶管，可在工作环境恶劣的场所使用，适用温度范围-20~80°C。 Outer sheath hose woven of steel wire shall be of rubber hose, it can be used in places of harsh working conditions, and the applicable temperature range is -20~80 °C. * 规格型号及技术参数 * Model and Technical Parameters 配管外径...
  • Page 400 Steering System SR-43 耐压软管使用复合橡胶材料软管，可在工作环境恶劣的场所下使用，适用温度范围-20~80°C。 Pressure hose uses hose of compounded rubber, can be used in places where the working conditions are poor, and applicable temperature range is -20~80 ° C. * 规格型号及技术参数 * Model and Technical Parameters 配套外径 d1 使用压力 最小变曲半径...
  • Page 401 SR-44 Steering System Outer Diameter Working Bending Radius of Pipe Pressure 可按用户要求定制 Can be customized in HSJ-4 ※※※ Ø4 Ø11 accordance with user requirement 压力开关 Pressure Switch  型号标记方法  Model Marking Method PS - 连接细牙螺纹：08=M8×1, 10=M10×1 Connect fine thread: 08=M8×1, 10=M10×1 压力（单位：kgf/cm ）...
  • Page 402 Steering System SR-45 GH-60 型手动加油枪 GH-60 Manual Oil Gun 十、润滑油补给装置 X. Lubricating Oil Supply Device 为保证润滑泵的正常工作，请及时补足油泵内的油量。本公司生产的 GH-60 型手动加油枪专门为补充油量设计， 方便、快捷、轻巧、实用。建议您随车配置。 In order to ensure the normal work of lubrication pump, please complement oil in pump timely. GH-60 manual oil gun of our company is specially designed for complementing oil, which is convenient, fast, indicator-weight and handy, and practical.
  • Page 403 SR-46 Steering System 2. CENTRALIZED LUBRICATION EQUIPMENT（AP-32-XML） PART CODE PART NAME SPEC AP-32-300X AP class electric grease pump PD-1016 Straight connector PT-10x6.5 Pipe bushing PB-10 Sealing ring PA-10 Oil pipe connector AD-2 AD type distributor PB-4 Sealing ring PA-4 Oil pipe connector PL-4** Square connector PD-4**...
  • Page 405 Break System BR-6125J93C-01 BR-1 Brake system Structure and working principles of brake system························································ BR-2 Structure outline Energy supply device of brake system Control and transmission devices of brake system Air brake chamber and brake Device for braking force adjustment—ABS Air pressure brake lines Automatic clearance adjusting arm Troubleshooting ···············································································································...
  • Page 406 BR-2 Brake System BR-6125J93C-01 Structure and working principles of brake system The driver, according to the road and traffic conditions and by a series of special devices provided in the car, forces the road to exert on the wheels an external force in a direction that is contrary to the car travel direction, so as to realize an enforced braking of the car.
  • Page 407 Break System BR-6125J93C-01 BR-3 whole vehicle will not be effected. 制动踏板力 制动踏板 制动器制动力 Brake pedal force Brake pedal Braking force of the brake 制动蹄 制动鼓 制动器制动力距 Brake shoe Brake drum Braking torque of the brake 车轮对地面的力 地面对车轮的制动力 Force exerted on the ground by the wheel Force exerted on the wheel by the ground Brake system classification by functions Service brake system: a special arrangement for making a traveling car to reduce the speed or even to stop,...
  • Page 408 BR-4 Brake System BR-6125J93C-01 the other lines from air pressure loss when one line is failed. 空气干燥器 Air dryer 再生储气筒 Regeneration air reservoir 空压机 Air compressor Air compressor In the figure is an air-cooled single-cylinder air compressor, which is driven by engine gear and provided with an air intake valve and an exhaust valve.
  • Page 409 Break System BR-6125J93C-01 BR-5 compressor into the cavity A via the port 1. Condense water may be produced due to the reduced temperature, which is discharged from the exhaust valve e via the passage C. The compressed air will pass the fine filter g of the drying filter and reaches the upper part of the drying filter b via the ring-passage h.
  • Page 410 BR-6 Brake System BR-6125J93C-01 The air pressure enters from the port 1 and reaches simultaneously chambers a, d and chambers b, c. When the pressure reaches the value for valve opening, the valves s, p, g, k will be opened and the compressed air will be transmitted via the ports 21, 22, 23, 24.
  • Page 411 Break System BR-6125J93C-01 BR-7 air from the rear air reservoir enters the port 11, goes into the cavity A via the upper valve e and the inlet clearance j in the upper valve body, and is transmitted through the port 21 to the relay valve of the rear braking line, which will open the rear braking air line to apply a brake on the rear wheels.
  • Page 412 BR-8 Brake System BR-6125J93C-01 行车位置 停车位置 膜片式制动气室 手制动阀 Driving position Parking position Diaphragm air brake chamber Hand brake valve ABS 阀 快放阀 ABS valve Quick release valve When the lever is at 0~10°, the intake valve m is fully opened and the exhaust valve n is closed, the air pressure comes in via the port 11 and leaves via the port 21 and the whole vehicle rear brake system is fully released.
  • Page 413 Break System BR-6125J93C-01 BR-9 Relay valve The relay valve is used to make the compressed air not to flow through the brake valve but to directly enter the air brake chamber via the relay valve so as to shorten the air supply route to reduce the brake hysteresis time. In the figure below, the valve gate leans on both the valve seat and the core tube, and both the intake and exhaust valves are closed.
  • Page 414 BR-10 Brake System BR-6125J93C-01 图形符号 梭阀工作原理图 a) Air intake of control port P1 Graphical symbol Schematic diagram of a shuttle valve b) Air intake of control port P2 Brake air chamber The air brake chamber is used to convert the air pressure energy into mechanical energy and to output the mechanical energy to the actuating device, making the brake to produce a brake torque.
  • Page 415 Break System BR-6125J93C-01 BR-11 coefficient φZ will reach its peak value: When the slip rate S continues to increase, the longitudinal adhesion coefficient φZ will continue to decrease; and the lateral adhesion coefficient φC will continues to fall since the very beginning. When the slip rate S is 100%, the wheels are blocked up and φZ will reduce to a lower point while the lateral adhesion coefficient φC will almost become zero.
  • Page 416 BR-12 Brake System BR-6125J93C-01 Working principle The automatic clearance adjusting arm is clearance induction adjusting device, which can enable a proper clearance between the brake drum and the brake shoe. The groove clearance of rack is corresponding to the normal clearance between the brake drum and the brake shoe.
  • Page 417 Break System BR-6125J93C-01 BR-13 Structural outline Name Name Name Housing Worm wheel shaft Front guard ring Yellow lubrication Worm wheel Bracket fitting Control arm Rear guard ring 8-13...
  • Page 418 BR-14 Brake System BR-6125J93C-01 Troubleshooting Insufficient brake force Cause Solution Grease or oil on the brake shoe Replace the liner. Bad contact between the brake drum and brake Calibration shoe liner Wheel brake and brake Improper liner material or smooth surfaced Calibration drum liner...
  • Page 419 Break System BR-6125J93C-01 BR-15 Brake screeches Cause Solution Improper liner material or smooth surfaced liner Replace the liner. Loosened liner rivet Replace the rivet or further tighten it. Contact of the liner rivet with the brake drum Replace the liner and rivet. Deformed or worn brake drum Repair or replace Foreign material between the brake drum and the liner...
  • Page 420 BR-16 Brake System BR-6125J93C-01 Use and maintenance of the parts of brake system Air dryer Breakdown structure diagram Inspection before dismantling Inspect the exhaust port for air leakage when the air compressor works. Make sure the exhaust port exhausts air at the moment as the air compressor stops. Inspect the water discharged from the exhaust port.
  • Page 421 Break System BR-6125J93C-01 BR-17 Four-way protective valve Disassembly To facilitate the re-installation, make a positional marks for each part before dismantling; Clamp tightly the four-way protective valve with a vice clamp with copper or aluminum protection. Remove the protective plug 15 on the valve bonnet 14 and take off the adjusting screw assembly 13 on the valve bonnet;...
  • Page 422 BR-18 Brake System BR-6125J93C-01 Tightness test Close the switches A1, A2, A3 and A4, open the switch A0. When the pressure in the gauge M0 is 1MPa, close the switch A0. Maintain the pressure for five minutes; inspect the tightness of the assembly. The permissible pressure drop is less than or equal to 10kPa.
  • Page 423 Break System BR-6125J93C-01 BR-19 Remove the middle piston 10 from the upper side of the lower body 14 and then remove the O-ring 9 and two pieces of O-rings 12 from the middle piston 10. 10) Use snap ring pliers to remove the retainer ring for holes 17 from the lower side of the lower body 14, and then remove the exhaust guide seat 16, bushing 4, cone spring 3 and valve assembly 2.
  • Page 424 BR-20 Brake System BR-6125J93C-01 Adjusting procedure Test device diagram Switch pressure gauge (above grade 0.4) 2, 4 Pressure gauges (above grade 0.4) 3, 5 Air reservoir Test piece 气源 Air supply 行车位置 Driving position Tightness test Set the lever at the parking position, open the switch 1, charge air via the port 11 to 800kPa and maintain the pressure for five minutes.
  • Page 425 Break System BR-6125J93C-01 BR-21 Breakdown structure diagram 1. Cover, air chamber 2. Clamp nut 3. Clamp bolt 4. Clamp 5. Spacer 6. Diaphragm 7. Push rod 8. Return spring 9. Air chamber T=拧紧力矩： 牛顿·米 （千克力·厘米， 磅力·英尺） T=tightening torque: N.m (Kgf.cm, lbf .ft) Key points of removal Before dismantling, make an alignment mark A on the air chamber, clamp and air chamber cover;...
  • Page 426 BR-22 Brake System BR-6125J93C-01 Breakdown structure diagram 1. Dust shield 2. Cotter pin 3. Slotted nut 4. Filter 5. Spring brake 6. Spring air chamber 7. Piston ring 8. Piston 9. O-ring 10. Retainer Plain Release ring washer bolt 13. Retainer 14.
  • Page 427 Break System BR-6125J93C-01 BR-23 Key points of assembly In assembling the spring brake chamber, piston ring, busing and O-rings must be replaced with new ones. Apply lubrication grease or oil on various parts. Silicon grease: The inner side of O-ring, bushing, piston ring and spring brake chamber.
  • Page 428 BR-24 Brake System BR-6125J93C-01 In reassembling the brake chamber, diaphragm should be replaced with a new one. Caution: The aligning marks on the brake chamber, yoke and spacer should be aligned. Insert the bolt from the side opposite to the exhaust port and use a nut to uniformly tighten the bolt with required torque 排气孔...
  • Page 429 Break System BR-6125J93C-01 BR-25 Automatic clearance adjusting arm Breakdown structure diagram 典型 Typical Name Name Name Rear guard ring Spring Thrust washer Housing Shaft sleeve Worm wheel shaft O-ring Bearing Transmission gear Spring Inner cover Thrust bearing Front guard ring Spring Spring Plug...
  • Page 430 BR-26 Brake System BR-6125J93C-01 Key points of removal Remove the automatic clearance adjusting arm Dismantling of pull-rod and spring components 1) Use dedicated tools to remove six screws. Caution: use dedicated impact driver and hammer in the event that the screw is fastened too tightly. 2) Remove the support and washer.
  • Page 431 Break System BR-6125J93C-01 BR-27 4) Remove the thrust bearing, O-ring, inner cover, spring and transmission gear. 5) Install dedicated tools. Mandrel and positioning ring. 心轴 Mandrel 定位环 Locating ring 6) Use a bench clamp to make slow turning till the bearing and worm-wheel shaft are removed.
  • Page 432 BR-28 Brake System BR-6125J93C-01 Key points of assembly Caution: In assembling, please apply sufficient lubricating grease to all parts. Assembly of worm-wheel shaft and worm wheel 1) Apply lubricating grease to the inside of housing and the whole worm wheel 2) Install the O-rings on both sides of worm wheel and insert the worm wheel with the projecting part into the front of housing.
  • Page 433 Break System BR-6125J93C-01 BR-29 8) Install the inner cover, spring and transmission gear. 9) Apply lubricating grease to the components to be installed in Step 7 and O-ring, thrust bearing and front guard ring. And install them in a sequence of front guard ring direction. 10) Set the housing on the bench clamp and use a dedicated tool and torque spanner to fasten the front guard ring.
  • Page 434 BR-30 Brake System BR-6125J93C-01 Assembly of rack and spring 1) Apply lubricating grease to the spring and rack and then install them in the housing. 2) Use the dedicated tool to install the rack while pushing the spring. Make sure visually that the rack and spring are installed as shown in the figure.
  • Page 435 Break System BR-6125J93C-01 BR-31 6) Apply lubricating grease to the washer, and then install it together with bracket onto the housing. Caution: Make sure the support groove is engaged with the rack claw. 7) Fasten the screws. 8) Install the grease nozzle. Grease filling Use a grease gun to supplement the grease till it overflows from the support clearance.
  • Page 436 BR-32 Brake System BR-6125J93C-01 6) If the control arm part of the bracket moves out of the scope, use the spanner to fasten or loosen dedicated tool hexagon spanner, adjust the assembly status. 7) Recheck after assembly so as to confirm whether it is proper or not. Ending 1) Use a punch or hammer to knock the rivet into the guard ring.
  • Page 437 Break System BR-6125J93C-01 BR-33 Routine maintenance Add lithium-base lubricating grease to the adjusting arm for every 20,000km travel. For every 20,000km travel, counterclockwise turn the square hexagon head of worm of adjusting arm, measure the brake release torque. Repeat it for three times, the adjusting arm assembly shall be replaced timely. Routine inspection Check if the automatic adjusting arm and fixing support are damaged, if the fixing support is securely fastened and if the control arm is fully released.
  • Page 438 BR-34 Brake System BR-6125J93C-01 If the camshaft bushing is worn If the air chamber is not securely positioned The ratchet wheel assembly is worn or if the spring is invalid 10. Braking force Disassembly of brake Front brake 1. Elastic retainer ring 10.
  • Page 439 Break System BR-6125J93C-01 BR-35 Place wooden wedges before and behind the rear wheels. Loosen the nuts of the front wheels. Use jacks to lift the front axle till the front wheels leave the ground; for the sake of safety, use split heads to support the front wheels.
  • Page 440 BR-36 Brake System BR-6125J93C-01 11) Remove the cotter pin, plain washer, washer and flat-headed pin. 平头销 Flat-headed pin 开口销 Cotter pin 平垫 Plain washer 弹簧垫 Spring washer 12) Remove the spring retainer ring 弹簧卡环 Spring retainer ring 13) Remove the adjusting arm. 14) Remove the camshaft sleeve, oil seal and brake camshaft.
  • Page 441 Break System BR-6125J93C-01 BR-37 Rear brake 1. Dust boot 10. Washer 19. Rivet, friction plate 2. Bolt 11. Brake adjusting arm 20. Brake friction plate 3. Rubber plug 12. Retainer ring 21. Retainer ring 4. Flat-headed pin 13. Camshaft bushing 22. Return spring 5.
  • Page 442 BR-38 Brake System BR-6125J93C-01 Use wooden wedges to block the front wheels from the front and ear. Loosen the nuts of outer rear wheels. Jack up the rear axle with a jack until the wheels are lifted off the ground. For the sake of safety, support the rear axle with a saddle.
  • Page 443 Break System BR-6125J93C-01 BR-39 12) Remove the cotter pin, plain washer, washer and flat-headed pin. 弹性挡圈 Elastic retainer ring 13) Remove the nut and air pipe and remove the air brake chamber from the air chamber support. 14) Remove the brake adjusting arm. Remove the elastic retainer ring and adjusting arm.
  • Page 444 BR-40 Brake System BR-6125J93C-01 Repair and replacement Brake friction plate Front brake Remove the rivets of friction plate. Remove the friction plate. Clean away the filths and rusts on the contact face of the brake shoe and friction plate. Place the new friction plate on the brake shoe and align the rivet holes Introduce a rivet through the rivet hole of the brake friction plate and fasten it.
  • Page 445 Break System BR-6125J93C-01 BR-41 Reinstall Front brake 1. Elastic retainer ring 8. Lock nut 15. Return spring 22. Steel lock wire 2. Adjusting arm 9. U-fork 16. Brake shoe 23. Brake air chamber 3. Grease nozzle 10. Flat-headed pin 17. Pin, return spring 24.
  • Page 446 BR-42 Brake System BR-6125J93C-01 Install the lock nut and U-fork on the pushrod of air chamber. Install the brake air chamber. Install the dust boot on the brake backing plate. 防尘罩 Dust boot 制动底板 Brake bottom plate Install the brake backing plate on the steering knuckle.。 Fasten the two queen bolts and two short bolts on the backing plate.
  • Page 447 Break System BR-6125J93C-01 BR-43 Install the shield on the camshaft and then the brake adjusting arm and retainer ring. 防尘罩 Dust boot 制动底板 Brake bottom plate Connect the pushrod U-fork and adjusting arm. Meanwhile, rotate the adjusting nut and the adjusting arm to align the U-fork to the adjusting arm hole.
  • Page 448 BR-44 Brake System BR-6125J93C-01 11) Use a dedicated tool to install the return spring. Caution: After the spring installation, use a proper tool to turn the spring to make it hang in the hook groove, ensuring its correct installation in the groove. 回位弹簧专用工具...
  • Page 449 Break System BR-6125J93C-01 BR-45 Rear brake 1. Air brake chamber (spring brake chamber) 9. Roller 17. Dust boot 26. Brake adjusting arm 2. Bracket, brake air chamber 10. Retainer ring 18. Positioning screw 27. Flat-headed pin 3. Grease nozzle 11. Pin shaft, roller 19.
  • Page 450 BR-46 Brake System BR-6125J93C-01 Install the brake backing plate on the rear axle shaft sleeve seat. Caution: The three bolts on the anchor pin shaft and camshaft each must be thin-head bolts to prevent any interference with the return spring. Directly install the support of brake air chamber.
  • Page 451 Break System BR-6125J93C-01 BR-47 Install the brake shoe assembly. Caution: Apply lubricating grease in the oil storage groove on the inner surface of bushing. 贮藏槽 Storage tank Caution: Don’t apply lubricating grease on the master anchor pin shaft. 蹄片轴 Brake shoe shaft Use a dedicated tool to install the return spring.
  • Page 452 BR-48 Brake System BR-6125J93C-01 14) Fasten the adjusting nut. 15) Measure the pre-tightening force of hub bearing and make sure the hub can rotate freely. Refer to the rear axle part for the measurement method. 16) Fix lock piece on the adjusting nut and apply sufficient grease on the outside of bearing. 17) Install the rear axle shaft.
  • Page 453 Break System BR-6125J93C-01 BR-49 Annex 1: Schematic diagram of braking pipelines Schematic diagram of the air pipeline in the braking system 8-49...
  • Page 454 BR-50 Brake System BR-6125J93C-01 General schematic diagram of brake system 8-50...
  • Page 455 Break System BR-6125J93C-01 BR-51 Schematic diagram of braking pipeline (35-00-01) Name Name Brake master valve Air intake connector, PVC valve Sealing washer Air reservoir assembly (40L) Screw plug, outer Hex. Clamp, air reservoir Straight bite-type pipe fitting Clamp bracket, air reservoir Hand valve assembly Automatic drain valve 4-way protective valve –...
  • Page 456 BR-52 Brake System BR-6125J93C-01 Schematic diagram of braking pipeline (35-00-02) Name Name Air reservoir assembly (30L) Connecting pipe, hand brake cylinder Air intake connector, PVC valve Bite-type rubber connector assembly Automatic drain valve Connecting pipe, air bellow tank Clamp, air reservoir Connecting pipe, air bellow cylinder Clamp bracket, air reservoir Pa11 tube (black) 12*1.5...
  • Page 457 Break System BR-6125J93C-01 BR-53 Schematic diagram of braking pipeline (35-00-03) Name Name Air dryer Combined elbow, bite-type Wire, air dryer Pa11 tube (brown) 12*1.5 Screw plug, outer Hex. Relay valve assembly M12 combined washer Relay valve assembly, differential Condenser Screw plug, outer Hex. Regeneration air reservoir Straight bite-type pipe fitting Automatic drain valve...
  • Page 458 BR-54 Brake System BR-6125J93C-01 Schematic diagram of leveling system pipeline Name Name Solenoid valve Pipe filter to solenoid valve Overflow valve Straight connector, bite-type Pipeline filter Combined elbow, bite-type Connector body, 4-way protective Intake connector, air bellow valve Sealing washer Sealing washer Air intake connector, PVC valve Intake pipe, right front air bellow...
  • Page 459 Break System BR-6125J93C-01 BR-55 Annex 2: Instructions of WABCO ABS for Commercial Vehicles Instructions of ABS/ASR “D” and “E” for Commercial Vehicles WABCO Ltd. (China) 8-55...
  • Page 460 BR-56 Brake System BR-6125J93C-01 1. Profile of ABS system ABS (Anti-lock braking system) is an electronic system supervising and controlling the vehicle speed during the braking. Its task is to prevent the wheel lock-up (especially on smooth road surface) caused by a too large braking force so as to maintain a lateral traction force even in full braking, thus ensuring a best driving stability, steering control and braking coordination of the main trailer, and also guaranteeing an optimal utilization of the braking friction force between the tires and the road surface and the vehicle...
  • Page 461 Break System BR-6125J93C-01 BR-57 6S/6M (6 sensors and 6 electromagnetic valves) 3. ABS working mechanism and installation of its components ABS working mechanism is as follows: the gear ring and sensor in coordination produce an induced voltage signal to ECU; the ECU receives and processes the electric signal and transmits an instruction signal to the electromagnetic valve;...
  • Page 462 BR-58 Brake System BR-6125J93C-01 8-58...
  • Page 463 Break System BR-6125J93C-01 BR-59 3.2.3 Sensor testing The induced voltage of the sensor should be tested after the gear ring and the sensor are installed. a) Use your hands to turn the wheel to 30 rpm; b) Use a multimeter to measure the voltage between the two poles of the sensor; c) When the wheel speed is greater than 30rpm, the sensor voltage should be larger than 0.20V and the ratio of the maximum induced voltage value to the minimum should be smaller or equal to 2.0.
  • Page 464 BR-60 Brake System BR-6125J93C-01 two-way single directional valve should have the intake port for foot valve point upward. 3.6 Lead connection In respect to Model D, for the wiring of 4S/4M basic version, refer to 841 801 151; for the wiring of 4S/4M ABS/ASR, refer to 841 801 277;...
  • Page 465 Break System BR-6125J93C-01 BR-61 (positioning switch); an engine control mode switch ((positioning switch); and a speed limit elimination switch (positioning switch). For Model E (ECU: 46 004 320 0, 446 003 705 0), two switches are optional: offroad function selector switch (reset switch, optional) and an ASR control mode altering switch (reset switch, optional).
  • Page 466 BR-62 Brake System BR-6125J93C-01 c) Listen for the sound cycle of ABS electromagnetic valve. The self-inspection sound numbers of electromagnetic valves are different and depending on the system configuration. For example, for Model D 4S/4M basic version, there will be six sounds in the self-inspection of electromagnetic valve while for Model E 4S/4M basic version, four sounds.
  • Page 467 Break System BR-6125J93C-01 BR-63 The diagnosis system of a diagnosis apparatus is mainly composed of the following parts: WABCO diagnosis apparatus; 446 300 320 0 Diagnosis line: 894 604 303 2 Model D diagnosis card: 446 300 732 0 Adapter for sensor inspection: 446 300 350 0 Procedure card for sensor inspection: 446 300 601 0 5.2 PC diagnosis Its functions include:...
  • Page 468 BR-64 Brake System BR-6125J93C-01 5.3.2 Trouble location a) After the diagnosis unit is successfully connected with the ABS system, press ERROR key for about one second. b) Release “ERROR” key and the troubles will be displayed in three groups of figures: Location 1 Location 2 Location 3...
  • Page 469 Break System BR-6125J93C-01 BR-65 8-65...
  • Page 470 BR-66 Brake System BR-6125J93C-01 8-66...
  • Page 471 Break System BR-6125J93C-01 BR-67 8-67...
  • Page 472 BR-68 Brake System BR-6125J93C-01 5.4.6 Procedure of flash code diagnosis Mode Procedure System response Operation Diagnosis Step 1: turn on the ignition There is no practical trouble Three possible responses: switch in ABS and no action is 1. ABS warning light is on needed instantly and then off, indicating the system is OK.
  • Page 473 Break System BR-6125J93C-01 BR-69 5.4.7 Flash code table First group of trouble flash codes Second group of trouble flash codes Number Failed parts Number Trouble location No trouble No trouble ABS electromagnetic valve Right front wheel Overlarge sensor clearance Left front wheel Open circuit or short circuit of sensor Right rear wheel Instable sensor signal...
  • Page 474 BR-70 Brake System BR-6125J93C-01 5.4.8 Trouble code table Trouble description Flash code Response Left front wheel sensor Sensor clearance ABS: wheel ABS is failed. ASR is failed. Improper tire Short circuit of storage battery power supply Short circuit of grounding Open circuit Short circuit Incorrect gear ring...
  • Page 475 Break System BR-6125J93C-01 BR-71 Sensor clearance ABS: wheel ABS is failed. ASR is failed. Improper tire Short circuit of storage battery power supply Short circuit of grounding Open circuit Short circuit Incorrect gear ring Looseness Wrong wiring Interrupted speed Abnormal speed (tremble) Too high frequency Right rear wheel sensor Sensor clearance...
  • Page 476 BR-72 Brake System BR-6125J93C-01 Short circuit of storage battery power Left front, right rear supply differential braking are failed. Electromagnetic valve of left right wheel ABS is failed. Open circuit of intake and exhaust valves Open circuit Short circuit of grounding Short circuit of storage battery power Right front,...
  • Page 477 Break System BR-6125J93C-01 BR-73 Diagonal 2, short circuit of storage ABS for left front, right rear and battery power supply right third axle is failed Diagonal 2 voltage, low voltage/open circuit Diagonal 2 grounding, open circuit The differential braking does not fail, but WL is on.
  • Page 478 BR-74 Brake System BR-6125J93C-01 5.4.9 Repair guide/trouble detection Repair guide/trouble detection The sensor signal is weak. Check the bearing for gear ring deflection. Push the sensor till it contacts the gear ring. The tooth number of the gear ring is different. Check the sensor wire harness and measure the DC voltage.
  • Page 479 Break System BR-6125J93C-01 BR-75 battery. Check the power line and its fuse to see if the voltage is too low. Check pin 12/17 to see if there is disconnection. Check the wire harnesses of electromagnetic valve to see if there is short circuit of grounding.
  • Page 480 BR-76 Brake System BR-6125J93C-01 Use of ABS Precautions during the application of ABS: It is strictly prohibited to wash the ECU with water. Do not use a multimeter to measure the ECU. When the storage battery is charged from an external high voltage source, disconnect the ABS. Turn off the power supply when dismantling any parts.
  • Page 481 Break System BR-6125J93C-01 BR-77 Appendix 1: List of ABS-D system parts Product name Code ECU (D-Basic) 446 004 310 0 ECU (4S/4M ABS/ASR) 446 004 416 0 ECU (6S/6M ABS/ASR) 416 003 413 0 Electromagnetic valve 472 195 018 0 ASR differential braking valve 472 170 606 0 Extension...
  • Page 482 BR-78 Brake System BR-6125J93C-01 Appendix 2: List of ABS-E system parts Product name Code ECU (E-Basic) 446 004 320 0 ECU (6S/6M ABS/ASR) 446 003 705 0 Electromagnetic valve 472 195 018 0 ASR differential braking valve 472 170 606 0 Extension wire 449 513 xxx 0...
  • Page 483 Break System BR-6125J93C-01 BR-79 8-79...
  • Page 484 BR-80 Brake System BR-6125J93C-01 ECU 插头视图 电磁阀共用接地 所有 ABS 部件只有一个中 诊断接口 View of ECU plugs Shared earth for solenoid Diagnosis joint 心接地 valves All ABS parts have only one central grounding 点火开关 片 式 保 险 根据 ： ISO/DIN ABS：通过 DBR-RELAY ABS 越野路面开关...
  • Page 485 Break System BR-6125J93C-01 BR-81 8-81...
  • Page 486 BR-82 Brake System BR-6125J93C-01 φ φ 接右前电磁阀 接右前转速传感器 35 漏斗形胶套 60 漏斗形胶套 Connect to the right front Connect to right front wheel Funnel gum cover, Ф 35 Funnel gum cover, Ф 60 solenoid valve speed sensor 接左前电磁阀 接左前转速传感器 技术要求 接底盘线束 Connect to the left front Connect to the left front Technical requirements...
  • Page 488 Wheel and Tyre WT-1 Wheel and tyre  Structure of wheel and tyre ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ WT-2 Structure of wheel Structure of tyre  Use and maintenance of tyre ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ WT-12 Principles for selection of tyres Operating precautions of tyres  Tyre troubleshooting ꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏꞏ WT-16 Trouble at tyre crown Trouble at tyre shoulder and tyre sidewall Trouble at tyre body...
  • Page 489 Wheel and Tyre WT-2  Structure of wheel and tyre Wheels are mainly used for the following purposes: Firstly, support the weight of the bus; secondly, buffer the impacts from the road surfaces; thirdly, generate towing forces and brake forces based on the adhesions between tyres and road surfaces.
  • Page 490 Wheel and Tyre WT-3 (a) Outer diameter (b) Width (c) Bead base (d) Hump (e) Wheel rim (f) Total width (g) Screw hole diameter (h) Screw hole center distance (i) Wheel shaft diameter (j) Base (k) Wheel rim center (l) Inflating valve (m) Distance from wheel rim center to base ...
  • Page 491 Wheel and Tyre WT-4  Tyre makeup Tyres with inner tube are made of cover tyre 1, inner tube 2 and lining band 3. Tyre without inner tube consists of only one cover tyre. Cover tyre: Cover tyre is the main part of a tyre and consists of tyre bead, buffer layer, tyre tread and ply cord layer.
  • Page 492 Wheel and Tyre WT-5 Tyre sidewall is the rubber layer on the side walls of the tyre body between tyre shoulder and tyre bead. It mainly works to connect and support the tyre body and protect the tyre body from mechanical damages. Tyre bead Tyre bead is the tyre part installed on the wheel rim and mainly works to prevent the tyre from being detached from the wheel rim.
  • Page 493 Wheel and Tyre WT-6 the tyre. It is not different from tube-containing tyres in other aspects. Tubeless tyres have the following advantages: Tubeless tyres are light in weight; The pressure of tubeless tyres decrease slowly in case of punctures and thus the tyre bead is not easily detached from the wheel rim base.
  • Page 494 Wheel and Tyre WT-7 There are transverse patterns, strip patters, block patters and mixed patterns. Patterns can also be divided into ordinary patterns and winter patterns according to the climatic conditions. Different pattern designs are closely related to different types of vehicles and different purposes of uses. There is also one “small platform”...
  • Page 495 Wheel and Tyre WT-8 BS specifications and marks: BS specifications and marks are normally adopted for trucks as follows: Tyre section breadth (B) has inch as the unit; Tyre structure: ‘R’ indicates radial tyre and ‘-’ indicates diagonal tyre; Wheel rim diameter (b) has inch as the unit; Eg: 9.00—20 Wheel rim diameter (20inch) Tyre structure: diagonal type...
  • Page 496 Wheel and Tyre WT-9  Tyre sidewall mark Radial tyre sidewall mark 层级代号 Ply rating code 生产厂家 Manufacturer 轮胎产地 Place of origin 美国交通部 DOT 编码 轮胎规格 欧洲经济委员会认证 ECE 代码 US Department of Transportation Tyre specifications ECE certification code DOT code 层级...
  • Page 497 Wheel and Tyre WT-10 Diagonal tyre sidewall mark Schedule of Chinese and English marks on tyre sidewall 序号 No. 英文字母 English 所示内容 Chinese ALL STEEL RADIAL 全钢丝子午线轮胎 REGROOVABLE 花纹可再刻轮胎（可翻新） STANDARD RIM 标准轮辋 TREAD 5PLIES STEEL CORD 胎面五层钢丝 SIDEWALL 1PLY STEEL CORD 胎侧一层钢丝...
  • Page 498 Wheel and Tyre WT-11 English Chinese ALL STEEL RADIAL Full-steel-cord radial tyre REGROOVABLE Tyre pattern re-gravable (recappable) STANDARD RIM Standard wheel rim TREAD 5PLIES STEEL CORD Tyre tread with five layers of steel coil bed SIDEWALL 1PLY STEEL CORD Tyre sideweel with 1 layer of steel coil bed E* ******* ECE certification code...
  • Page 499 Wheel and Tyre WT-12  Use and maintenance of tyre Principles for selection of tyres  The tyres selected must satisfy relevant state rules. The tyres recommended by the automobile manufacturer are normally adopted for different automobiles.  Tyres of an appropriate type (including specification, ply rating, speed level, etc) are selected according to the working conditions (automobile, load, route, road conditions and tyre position).
  • Page 500 Wheel and Tyre WT-13 tyre pressure and charge tyres to standard pressure after a traveling a distance of 2,000 to 3,000km. The internal pressures of double tyres shall be the same if they are adopted; The internal pressure had better be increased by 10% or so during high-speed traveling; The internal pressure of tyres may increase due to heating during traveling but will resume the original pressure after cooling down.
  • Page 501 Wheel and Tyre WT-14 Higher speed will increase driving force, braking force and eccentric force so that the tyre will be more likely to skid on the road and become worn out more rapidly with reduced service life; Higher traveling speed will apparently increase the chance of tyre deformation, increase the heat value and cause troubles more easily;...
  • Page 502 Wheel and Tyre WT-15 Preclude overloading and overspeed; Travel with care and at a low speed in special weather or environment (e.g. rainy, foggy, snowy, muddy and alley); Try to avoid severe impacts on the tyres when the bus is traveling on a road with poor surface conditions; Slow down before getting around a corner;...
  • Page 503 Wheel and Tyre WT-16  Tyre troubleshooting Other than the good driving habits of the driver, some of the most important factors that determine the soundness of the tyre include tyre pressure, load and speed. Various types of tyre faults and damages are caused by these three factors.
  • Page 504 Wheel and Tyre WT-17  Crown perforation Phenomena: the crown is perforated by a sharp object. In this case, the ply cords of the belt layer will be loosened and detached and one or multiple strands of the ply cords of the tyre body are broken for full-steel radial tyres.
  • Page 505 Wheel and Tyre WT-18 2. Trouble at tyre shoulder and tyre sidewall  Lateral bursting Phenomena: tyre sidewalls are burst in a “zipper manner” with a big scar and snapped steel ply cords. Cause: the tyre is severely overloaded or under-pressurized so that the tyre sidewall ply cords burst due to fatigue.
  • Page 506 Wheel and Tyre WT-19 3. Trouble at tyre body  Ply cords are loosened and cracked internally. Phenomena: tyre ply cord layer has a 1-shaped rupture. Cause: the tyre is subject to external impacts and damaged during loaded traveling. Ply cords are loosened and snapped due to overloading, under-pressure or excessive deflection of tyre body.
  • Page 507 Wheel and Tyre WT-20 pressure and strictly avoid overloading. Properly remove and install the tyre. Proper tools must be used for the installation and removal of tubeless tyres.  Toe rupture Phenomena: peripheral rupture of toe. Cause: overloading or improper driving so that the tyre body is excessively deflected and the ply cords are loosened and snapped.
  • Page 508 Wheel and Tyre WT-21  Toe breakage Phenomena: the ply cords on the inner side of the toe are peripherally snapped. Cause: sharp turns upon overload; under-pressure and overspeed of the bus so that the wheel rim presses against the tyre toe and the ply cords are broken. Precaution: maintain standard tyre pressure and strictly avoid overloading.
  • Page 509 Wheel and Tyre WT-22  Removal and assembly of wheels and tyres Warnings Violation of operating regulations may cause displacement of the tyre and/or wheel hub and thus explosion of the assembly. Such explosion may cause heavy casualties. Safety precautions for removal and assembly ...
  • Page 510 Wheel and Tyre WT-23 Use a dedicated tool to pry around the tyre gradually until the retainer ring is fully removed from the wheel hub groove; Turn the tyre assembly around so that the tyre bead on the other side is detached from the wheel hub and then lift up the wheel hub from the tyre.
  • Page 511 Introduction of Power Battery System CATL AFS STTG CATL Confidential 2019/12/17...
  • Page 512 Content Composition of Battery System Introduction of Battery System Hardware Introduction of Battery Management System (BMS)
  • Page 513 Chapter 1 Composition of Battery System CATL Confidential Page 3 2019/12/17...
  • Page 514 1.1 Composition of Power Battery System High voltage Box (S-Box) Battery Box Several (PACK) High/Low voltage wiring harness Cold plate, Several High- heating film voltage wiring （optional） &Low voltage wiring Thermal management accessories CATL Confidential Page 4 2019/12/17...
  • Page 515 1.2 The Location of Battery Box in the Vehicle （Example） ④ ③ ② ① Including 4 locations： ① Chassis（Classic） ② Rear（Classic） ③ Side of rear（Common） ④ Roof（Uncommon） CATL Confidential Page 5 2019/12/17...
  • Page 516 Chapter 2 Introduction of Battery System Hardware CATL Confidential Page 6 2019/12/17...
  • Page 517 2.1 Structure of Battery Box 1—HV positive pole 2—HV negative pole 3—heat input 4—heat output 5—LV input 6—LV output 7—Manual Service Disconnect Socket 8—Pressure Valve (Upper lid) 9—hook 10—Warning label（No tread on or touch HV） Two types of MSD With fuse Without fuse CATL Confidential Page 7 2019/12/17...
  • Page 518 Appendix-1：MSD MSD-A（ With Fuse） MSD-B（Without Fuse） CATL Confidential Page 8 2019/12/17...
  • Page 519 Appendix-2：Pressure Valve （Upper Lid） Inner side Outer side CATL Confidential Page 9 2019/12/17...
  • Page 520 2.2 Explosive View of Battery Box 1—Lid 2—Sealer 3—Cell supervision circuit（CSC） 4—Copper bar 5—Module 6—Box 7—Pressure valve Pressure valve CATL Confidential Page 10 2019/12/17...
  • Page 521 2.3 IP Level of Battery Box Level of protection：IP67 Standard：GB4208《Protection Level of Shell(IP code)》 Dust-proof Water-proof Level Level 6-Keep metal piece off the dangerous part 7-Prevent flooding effect in a short （Highest-6） time（Highest-8） • • Prevent metal piece with a diameter larger Static depth of water：＜1m •...
  • Page 522 2.4 Module 1—Aluminum bar 2—Temperature sampling line 3—Voltage sampling line 4—module’s general positive pole 5—module’s general negative pole CATL Confidential Page 12 2019/12/17...
  • Page 523 2.5 Explosive View of Module 1—Dielectric plate 2—Wiring harness plate 3—cell 4—side plate 5—end plate 6—baseplate CATL Confidential Page 13 2019/12/17...
  • Page 524 2.6 Connection Type of Cells（Example） Parallel connection P：Parallel connection S：Series connection Parallel connection CATL Confidential Page 14 2019/12/17...
  • Page 525 2.7 Cell 1—Positive column 2—Negative column 3—Vent 4—Shell（Al） 5—Dielectric plate CATL Confidential Page 15 2019/12/17...
  • Page 526 2.8 Anatomical Drawing of Cell 1—Positive pole（Al） 2—Negative pole（Cu） 3—Shell（Steel/Aluminum） 4—Separate membrane 5—Electrolyte DANGER Disassembly CATL Confidential Page 16 2019/12/17...
  • Page 527 2.9 S-Box 1—DC/DC power 11—LV input 2—Debugging interface 12—LV output 3—Vehicle LV 13—Battery positive pole 1 4—DC charge negative pole 14—Battery positive pole 2 5—Main loop negative pole 15—Battery negative pole1 6—Main loop positive pole 16—Battery negative pole2 7—DC charge positive pole 17—heat input 1 8—LV connector socket...
  • Page 528 2.10 Explosive View of S-Box（1） 1—Upper lid 2—Copper bar 3—Heater relay 4—Insulation column 5—Current sensor 6—MSD base 7—PDM 8—BMU 9—HVB（HV sampling plate，check if there is adhesion of EVC500, temperature of charging base） 10—HV relay CATL Confidential Page 18 2019/12/17...
  • Page 529 2.11 Explosive View of S-Box（2） 1—Upper lid 2—Backup power（BPM） 3—BPM installation component 4—Copper bar 5—Current sensor, Insulation column 6—Power distribution module （PDM） 7—Battery disconnect unit(BDU) 8—Battery management unit （BMU） 9—Box and connector 10—Manual Service Disconnect （MSD） CATL Confidential Page 19 2019/12/17...
  • Page 530 2.12 Battery Management Unit（BMU） BMU including power port、CAN communication interface. Three types of CAN communication which are C-CAN， A-CAN and CH-CAN 1，Communicate with CSCs through C-CAN, acquire voltage, temperature and working condition of each cell. When it meets the equilibrium condition, CSC will driven into equilibrium controlled by BMU through C-CAN 2，Communicate with HCU through A-CAN, which accept command of HCU and status information.
  • Page 531 2.13 Power Distribution Module（PDM） To distribute 24V DC LV power to battery management system (BMS). Distributable power and its priority: 24V DC charger>24V AC charger>24V lead-acid battery or DC/AC LV power CATL Confidential Page 21 2019/12/17...
  • Page 532 2.14 Cell Supervision Circuit（CSC） To supervise cell voltage and module temperature, and execute active equalizing function under the control of BMU. CATL Confidential Page 22 2019/12/17...
  • Page 533 2.15 Backup Power（BPM） An 18V DC LV backup power inside S-box. 5 LCO cell, the single cell voltage is 3.6V CATL Confidential Page 23 2019/12/17...
  • Page 534 2.16 The Hardware Relationship Diagram Current sensor ,relay, etc C-CAN 电 S-BOX 芯 Module Wiring harness Charging Lead-acid pile Heating accessory（optional） battery Several battery box C-CAN 电 芯 Module Wiring harness CATL Confidential Page 24 2019/12/17...
  • Page 535 Chapter 3 Introduction of Battery Management System (BMS) CATL Confidential Page 25 2019/12/17...
  • Page 536 3.1 BMS • Overcharge & overdischarge protection • Overcurrent, high/low temperature • Cell voltage equilibrium protection Safety • Active & passive balance mode • Multi-stage fault diagnosis protection Management • Balance SOC calculation SOC/SOH • SOH calculation management Inspection • Capacity integration Function •...
  • Page 537 3.2 Electrical Schematic Diagram（Example） CATL Confidential Page 27 2019/12/17...
  • Page 538 3.3 Principle Diagram of Battery Management System (BMS) CATL Confidential Page 28 2019/12/17...
  • Page 539 CODE FOR DAILY USE OF EV BATTERY SYSTEM CATL  AMD KongCF...
  • Page 540 SAFETY INSTRUCTIONS Please carefully read and observe the following safety instructions in order to protect the personal safety： The positive and The maintenance Wear insulating Any behavior of The positive and The working negative terminals personnel must gloves in operation damaging the batter negative terminals environment of the...
  • Page 541 EMERGENCY HANDLING Scenario - Traffic accident Step 1: Stop the vehicle stably, open the door, evacuate passengers, pull out the key, turn off the main power witch and if conditions permitting, disconnect the manual maintenance switch by professionals. Step 2: Handle the traffic accident according to relevant requirements of the national road traffic safety laws and egulations.
  • Page 542 EMERGENCY HANDLING Scenario - Fire Step 1: Rapidly evacuate people from the vehicle, and dial the alarm call, depending on the scene conditions. Step 2: Carry out the following operations if allowed, provided that personal PROMPT safety is protected: ① If the battery harness is smoking, use the carbon dioxide or dry powder extinguisher. If the fire is caused by charging anomaly, ②...
  • Page 543 EMERGENCY HANDLING Scenario - Vehicle wading in water Pay attention to the following items if the vehicle runs on the road with water: Depth Speed Time <=35cm <=10km/h <=10min The vehicle must not run on the road with the water depth more than 30cm Note...
  • Page 544 EMERGENCY HANDLING Scenario - immersion Pay attention to the following items if the vehicle accidentally falls into water or is immersed in water: 1. Do not turn on the power supply 2. Notify the auto brand dealer PROMPT If immersed in water for weather or special reasons, the vehicle must not be energized;...
  • Page 545 TERMINOLOGY Normally operating vehicle: refer to the vehicle which is operated, charged and discharged each day. Temporarily operating vehicle: refer to the vehicle which is not operated at the fixed frequency each month or not charged and discharged each day. Long-time stationary vehicle: refer to the vehicle which is not operated in more than 15 consecutive days.
  • Page 546 BATTERY TEMPERATURE CHARACTERISTICS -30℃~55℃ -40℃~55℃ 0~55℃ 25℃~45℃ Range of battery Range of battery Range of battery Range of the best battery work environment storage environment charging environment charging environment temperature temperature temperature temperature...
  • Page 547 CHECK BEFOR DRIVING Observe the dashboard of the vehicle and confirm that the battery system is in normal conditions without alarm.  If the SOC value is more than 50%, it means goods conditions are met for driving. It is recommended to fully ...
  • Page 548 REQUIREMENTS FOR NORMAL OPERATION OF VEHICLE The daily cumulative charging power should not exceed 1.5 times of the rated total power.  If there is the prompt for battery maintenance on the dashboard, please conduct “battery maintenance” as soon  as possible, to recover the normal conditions of the battery system.
  • Page 549 INSTRUCTIONS OF TEMPORARILY OPERATING VEHICLE The same as those of the normally operating vehicle. PROMPT If the air temperature is 0 °C or below, the vehicle should be charged as soon as possible after operation, in order to prevent the influence on operation as a result of long charging time in the case of too low temperature..
  • Page 550 INSTRUCTIONS OF LONG-TIME STATIONARY VEHICLE The best SOC range for battery storage is 50%~80%.  The battery system should be stored in the ventilated and dry place, free  from sunlight, rain or heat source. The vehicle should be fully charged once every three months. in order to ...
  • Page 551 INSTRUCTIONS OF CHARGER Use the charger conforming to the national standards.  Use the “Auto charge” function to charge the vehicle. Do not use the  “Manual charge” function. Do not pull out the charger when charging.
  • Page 552 BATTERY MAINTENANCE PROCEDURES Place: broad, flat and safe, with the charger Procedures: ① Adjust the battery capacity (SOC) to be 25% to 40%. ② Stop the vehicle stably, turn off the power supply (turn the key into the OFF position), and then turn on the power supply (turn the key into the ON position).
  • Page 553 INSTRUCTIONS OF ROUTINE INSPECTION The vehicle should be comprehensively inspected once a year in operation. Specific inspection items are as follows:  Whether the high/low-voltage harness and connector of the battery system are scratched, damaged or loose.  Whether the battery box or high-voltage box has sludge, crack or odor or is subject to deformation or expansion. ...
  • Page 554 INSTRUCTIONS OF ROUTINE INSPECTION A comprehensive inspection of the water-cooled unit is required before the summer season. The specific items are as follows:  Check if the liquid level of the expansion tank is normal (should be 2/3 or more liquid level). If it is not enough, please refill the liquid, and then check if the water circulation is normal.
  • Page 555 FUNCTIONS OF MANUAL MAINTENANCE SWITCH The manual maintenance switch is a kind of orange electrical  component which is used for manually cutting off the high-voltage line and achieving the function of safety protection (see the right figure). The manual maintenance switch should be disconnected before ...
  • Page 556 OPERATING REQUIREMENTS OF MANUAL MAINTENANCE SWITCH 1. Removal Procedures As shown in Fig. 1, press the clip indicated by the arrow A, using the thumb of the left hand. At the same time,  pull the handle of the maintenance switch in the direction indicated by the arrow B into the angle in Fig. 2, using the thumb of the right hand.
  • Page 557 OPERATING REQUIREMENTS OF MANUAL MAINTENANCE SWITCH 2. Installation Procedures As shown in Fig. 1, hold the handle of the upper cover of the maintenance switch, using the right hand, until a  90-degree angle is formed between the handle and maintenance switch. Carefully insert the upper cover into the base in the direction indicated by the arrow A.
  • Page 558 DAILY CHECK(INSTRUMENTS PANEL) Check SOC value，when the value is under30%，it’s  not appropriate to drive out until the SOC value is more than 50%. Check instrument panels, make sure if there is any  warning signal or not, the signal of “please maintenance” appears, routine maintenance should be done quickly.
  • Page 559 DAILY CHECK（BATTERY BOX） Check the outside of the box, if it is deformed or destroyed, open the box and check the module.  Check the window-shades of the box, if blocked, clear it timely.  Check if there is any dust, water or other liquid. If there is , clear it with dry cloth. ...
  • Page 560 DAILY CHECK（PACK） MSD is loose?Heating? Screw loose? Harness status Check the MSD, loose? Heating? Bolt loose?  Check if the PACK’s balance valve is normal or not.  Check if the PACK is deformed & destroyed or not.  Check if the harness is loose or not. ...
  • Page 561 DAILY CHECK（S-BOX） MSD status Check if the MSD is loose or heating.  Check if the terminal of the HV box is loose or heating.  Check if the HV box is deformed.  Check if the HV harness is aging or destroyed. ...
  • Page 562 ROUTINE MAINTENANCE Maintenance field requirement Close to the charging place so that the battery could be charged timely after maintenance. Maintenance operating processes 1. Keep the SOC value at the range of 25%~40%, if we don’t use it . 2. Please turn off the power supply before charging, then turn on the key, and turn off all electrical equipment like air- condition, radio and so on.
  • Page 563 NOTICE  It’s not advisable to drive or use any electrical equipment during the maintenance.  The high voltage electrical equipment will break off itself during the maintenance if you use it, if happens, you should restart maintenance operation.  If the warning alarm appears more than twice when the maintenance finished after one month, please call us for help.
  • Page 564 Thank you for watching! Any questions? Web: http://www.catlbattery.com Tel: 400-918-0889...
  • Page 565 Contemporary Amperex Technology Co.,Ltd. DOC NO. AFSP-OM-01 宁德时代新能源科技股份有限公司 VER. After-sale System Process FORM NO. QF-T-AFSP-A User Manual of E-BUS Power Battery System Contemporary Amperex Technology Co.,Limited After-sales Service File File Name： User Manual of E-BUS Power Battery System File NO.： AFSP-OM-01 File Liability：...
  • Page 566 Contemporary Amperex Technology Co.,Ltd. DOC NO. AFSP-OM-01 宁德时代新能源科技股份有限公司 VER. After-sale System Process FORM NO. QF-T-AFSP-A User Manual of E-BUS Power Battery System Contents Safety Instructions ..............................1 Emergency Handling ............................. 2 Terminology ................................3 Chapter 1 Operating Instructions ........................... 3 Battery Temperature Characteristics......................

  • Page 567: Safety Instructions

    Contemporary Amperex Technology Co.,Ltd. DOC NO. AFSP-OM-01 宁德时代新能源科技股份有限公司 VER. After-sale System Process FORM NO. QF-T-AFSP-A User Manual of E-BUS Power Battery System Safety Instructions Please carefully read and observe the following safety instructions in order to protect the personal safety： 1.

  • Page 568: Emergency Handling

    Contemporary Amperex Technology Co.,Ltd. DOC NO. AFSP-OM-01 宁德时代新能源科技股份有限公司 VER. After-sale System Process FORM NO. QF-T-AFSP-A User Manual of E-BUS Power Battery System 5. Any behavior of damaging the batter system, such as extrusion, puncturing and burning, will be prohibited. 6. The working environment of the battery system should be free from corrosive, explosive and destructive insulating gas or conductive dust.

  • Page 569: Terminology

    Contemporary Amperex Technology Co.,Ltd. DOC NO. AFSP-OM-01 宁德时代新能源科技股份有限公司 VER. After-sale System Process FORM NO. QF-T-AFSP-A User Manual of E-BUS Power Battery System Step 3: Notify the auto brand dealer to obtain the opinions on further handling Prompt If the fire is caused by charging anomaly, immediately turn off the power supply of the charger and then extinguish the fire (Scenario) vehicle wading in water Pay attention to the following items if the vehicle runs on the road with water...

  • Page 570: Battery Temperature Characteristics

    Contemporary Amperex Technology Co.,Ltd. DOC NO. AFSP-OM-01 宁德时代新能源科技股份有限公司 VER. After-sale System Process FORM NO. QF-T-AFSP-A User Manual of E-BUS Power Battery System Battery Temperature Characteristics Operating temperature: -35℃~65℃  Storage temperature: -35℃~65℃  Optimal charge and discharge temperature: 25℃~45℃  Check before Driving ...

  • Page 571: Instructions Of Long-Time Stationary Vehicle

    Contemporary Amperex Technology Co.,Ltd. DOC NO. AFSP-OM-01 宁德时代新能源科技股份有限公司 VER. After-sale System Process FORM NO. QF-T-AFSP-A User Manual of E-BUS Power Battery System Prompt If the air temperature is 0 °C or below, the vehicle should be charged as soon as possible after operation, in order to prevent the influence on operation as a result of long charging time in the case of too low temperature Instructions of Long-time Stationary Vehicle...

  • Page 572: Instructions Of Routine Inspection

    Contemporary Amperex Technology Co.,Ltd. DOC NO. AFSP-OM-01 宁德时代新能源科技股份有限公司 VER. After-sale System Process FORM NO. QF-T-AFSP-A User Manual of E-BUS Power Battery System Instructions of Routine Inspection 1.7.1 The vehicle should be comprehensively inspected once a year in operation. Specific inspection items are as follows: ...

  • Page 573: Operating Requirements Of Manual Maintenance Switch

    Contemporary Amperex Technology Co.,Ltd. DOC NO. AFSP-OM-01 宁德时代新能源科技股份有限公司 VER. After-sale System Process FORM NO. QF-T-AFSP-A User Manual of E-BUS Power Battery System Operating Requirements of Manual Maintenance Switch 1.9.1 Removal Procedures As shown in Fig. 1, press the clip indicated by the arrow A, using the thumb of the left hand. At the same time, pull the handle of the maintenance switch in the direction indicated by the arrow B into the angle in Fig.

  • Page 574: Chapter 2 Warranty Instructions

    Contemporary Amperex Technology Co.,Ltd. DOC NO. AFSP-OM-01 宁德时代新能源科技股份有限公司 VER. After-sale System Process FORM NO. QF-T-AFSP-A User Manual of E-BUS Power Battery System Chapter 2 Warranty Instructions Quality Warranty All provisions of this manual apply only to CATL power battery systems sold and used outside of mainland China If the battery is under the capacity warranty and the battery capacity is below the warranty capacity approved by a CATL-approved or authorized person, CATL agrees to provide repair or replacement service...

  • Page 575: Warranty Period

    Contemporary Amperex Technology Co.,Ltd. DOC NO. AFSP-OM-01 宁德时代新能源科技股份有限公司 VER. After-sale System Process FORM NO. QF-T-AFSP-A User Manual of E-BUS Power Battery System Warranty Period 2.1.1 Warranty Period for OEM Battery System 1. Starting date of the warranty period: to be agreed on by the battery manufacturer and vehicle manufacturer 2.

  • Page 576: Warranty Responsibility Exemption Range

    Contemporary Amperex Technology Co.,Ltd. DOC NO. AFSP-OM-01 宁德时代新能源科技股份有限公司 VER. After-sale System Process FORM NO. QF-T-AFSP-A User Manual of E-BUS Power Battery System Warranty Responsibility Exemption Range CATL will not provide warranty services in the following cases The product is damaged as a result of nonconformity to the requirements of <Battery User Manual> and <Vehicle Quality Warranty Manual>...
  • Page 577 11-1...
  • Page 578 Golden Dragon products. Golden Dragon has the right to modify them without notification in advance. Any detail should be subject to specific objects.
  • Page 579 目 录 CONTENTS POWER SUPPLY AND INTERNAL INSTRUMENT SYSTEM CAN ..................................1 ENGINE COMPARTMENT TEMPERATURE ALARM ......................................3 ELECTRIC COOLING FAN ................................................5 HORN ........................................................7 DRYER,CONDENSER,COOLING WATER PUMP ........................................9 FOUR IN ONE CONTROLLER ..............................................11 MOTOR CONTRILLER ................................................13 PRINCIPLE DIAGRAM OF HIGH VOLTAGE ELECTRIC ....................................
  • Page 580 11-4...
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  • Page 590 ≥ ≥ ≥ ≥ ≥ ≥ 11-14...
  • Page 591 11-15...
  • Page 592 494.07 (205.8) 444.52 506.7 The Min engaged lengh of thread is 12mm; +0.22 THRU (150.6) 61.8 (68.1) Screw grade:8.8; Toqure is 20Nm; Vent VMU interface Encoder interface Warning Product nameplate mounting position High-voltage battery interface (44) (143) 630.9 (35.5) 93.8 Cable gland 2-M25x1.5 733.8 816.3...
  • Page 593 11-17...
  • Page 594 Input+ pump Input- Insurance controller Input+ Main main motor+ motor Main motor relay Insurance Input- main motor- controller Precharge Precharge Input+ relay resistor 24V+ Input- DCDC 24V- AC relay Insurance Defrost+ Defrosting Insurance relay Defrost- GOLDEN DRAGON 11-18...
  • Page 595 11-19...
  • Page 596 charge work drive wake wake up battery charging socket 11-20...
  • Page 597 GOLDEN DRAGON 11-21...
  • Page 598 整车CAN1(外CAN) 120欧 CAN2(内CAN) 120欧 CAN2-H CAN2-L 120欧 Explain： 1. This drawing is hereby made for presentation. If any change is made, the design of the order shall prevail. 120欧 GOLDEN DRAGON 11-22...
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  • Page 603 （ ） GOLDEN DRAGON 11-27...
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