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DongFeng EQ1030T47D-820 Service Manual

Light commercial truck
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EQ1030T47D-820
Light Commercial Truck
Service Manual
PEOPLE'S REPUBLIC OF CHINA
DONGFENG AUTOMOBIL CO.,LTD.
2006, 6

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Summary of Contents for DongFeng EQ1030T47D-820

  • Page 1 EQ1030T47D-820 Light Commercial Truck Service Manual PEOPLE'S REPUBLIC OF CHINA DONGFENG AUTOMOBIL CO.,LTD. 2006, 6...
  • Page 2 General QD32 Engine Clutch Transmission Front Suspension Rear Axle & Rear Suspension Propeller Shaft & Differential Steering System Brake System Cab & Frame Electric System...

  • Page 3: Table Of Contents

    General Preventive Measures ..................GL-2 How to Use Manual ...................GL-3 Maintenance Specifications ..............GL-4 Grease Application Place and Schedule ..........GL-7 Main Adjusting Data ..................GL-8 Lubricant ......................GL-8 Capacity Data ....................GL-8 Fuel ........................GL-9 Engine Lubricant ..................GL-9 Gear Oil ......................GL-9 Transmission Gear Oil ................GL-10 Lubricating Grease ...................GL-10 Fluid for Brake and Clutch ..............GL-10...
  • Page 4 Please consult the local agency for the latest news. The informaion in this manual are correct before issuance, DONGFENG reserve the rights of changing any of the content without notice. Maintenance method varified due to different skill level, method, tools and available parts that serviceman adopts to.

  • Page 5: Preventive Measures

    General Preventive Measures See preventive measures below to get safe operation and suitable mainte- nance surely. These measures will not be repeated in the next pages. 1.Do not let engine run too long absolutely unless it is under special venti- lation to ensure that there is good ventilation in working area, no fire things there.

  • Page 6: How To Use Manual

    General 7.Before the check and assembly of a disassembled part, clean it first. 8.During the reassembling, oil seal, gasket, O-washer, lock washer and split pin should use the new one. 9.Replace the outer and inner rings of tapered roller bearing in whole set. 10.Arrange the disassembling procedures according to the part assembling order.

  • Page 7: Maintenance Specifications

    General Maintenance Specifications It is necessary for periodical inspection and maintenance of a vehicle to extend its service life, and improve on its power performance and fuel economy. So periodical inspection and maintenance should be carefully and maintenance should be carefully and strictly implemented in accordance with the following specifications so as to achiveve maximal economic and social benefits.

  • Page 8: Brake System

    General A—Dusty area B—Frequent start in short time C—Towing long trailer D—Long tome idle speed E—Extremely bad climate, high temperature or bitter cold area. Using Environment Maintenance Item Operation Maintenance Interval Oil and oil filter Replace Often All types Replace Often Fuel filter Replace...

  • Page 9: Suspension System

    General Steering system Maintenance Intervals( × 1,000km） Maintenance Items △ 4 8 12 16 20 24 28 32 36 40 Check the tightening condition of tie rod ends and drag link joints ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ Check the tightening condition of transition arm and driven arm ☆...

  • Page 10: Grease Application Place And Schedule

    General Axle & wheel Maintenance Intervals( × 1,000km） Maintenance Items △ 4 8 12 16 20 24 28 32 36 40 Clean front, rear axle assembly and wheel assembly ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ Check main reductor for oil leakage ☆...

  • Page 11: Main Adjusting Data

    General ☆—Running-in maintenance lubrication item ★— Normal driving lubricating item Lubricating interval mileage （× 1,000km） Place of lubricating △ 4 8 12 16 20 24 28 32 36 40 Slip yoke of steering drive shaft and spider bearing ☆ ★ ★...

  • Page 12: Fuel

    General Fuel The qualified light diesel oil specified by GB/T19147-2003 could be applied for in China, and the users choose different qualified light diesel oil according to the local temperature. 0# Light diesel oil Local temperature above 4 ℃ 10# Light diesel oil Local temperature above -5 ℃...

  • Page 13: Transmission Gear Oil

    General Transmission Gear Oil The manually operated gear oil API GL-4, 75W/90 is recommended. Lubricating Grease The compound lithium grease is recommended, but the general lithium grease could also be used. Fluid for Brake and Clutch The DOT4, 901-4 brake fluid is recommended. Note: Never use brake fluid with different quality or type.
  • Page 14 General Part Tightening torque (N.m) Transition output shaft and propeller shaft connecting 69~78 part Transition control flexible shaft fixed bracket and lon- 13~16 gitudinal member connecting part Fixed bolt of flexible shaft two ends ball joint 25~30 propeller shaft and rear axle connecting part 69~78 Brake pipe joint 15~22...
  • Page 15 Fan fixed bolt Push lever nut of brake thruster 16~22 As for the other torques not mentioned, please see the standard of DONGFENG EQB-37-1999. Note: No locking spacer, but to make sure the required tightening torque. When tightening during installing, make use of the oil to lubricate. Do not use the bolt with thread damaged.
  • Page 16 Clutch Precaution and Preparation ..............CL-1 Clutch System ..................... CL-3 Clutch Control System ................CL-4 Clutch Release Mechanism ..............CL-6 Clutch Driven Disc and Pressure Plate ..........CL-7 Service Data and Specifications .............. CL-9...

  • Page 17: Precaution And Preparation

    Clutch Clutch Precaution and Preparation Precaution: The DOT 4 901-4 compound brake fluid is recommended for the clutch hydraulic system. Dirty brake fluid is forbidden to use. Never let the brake fluid on paint, it may damage the paint coat. Use tools to assemble or disassemble the clutch pipeline.

  • Page 18: Clutch System

    Clutch Clutch System Clutch pedal bracket assy Dustproof 2.Rubber hose assy--oil reservoir to master pump 10.Front oil pipe assy Spacer Clutch master pump assy Clutch pedal welding assy 12.Rear oil pipe assy Clutch rear bent pipe bracket Pedal jacket Hose assy Clutch pedal shaft Gasket Clutch pedal return spring...
  • Page 19 Clutch Adjusting Clutch Pedal 1.Adjust the pedal height by means the spacing screw. Height of the clutch pedal H： 160~170mm 2.Adjust the clutch pedal free play by master cylinder push rod: Loose the locking nut when adjusting, turn the master cylinder push rod, then make the push rod withstand the spacer and screw off for 1/5~1/2 cir- cles, screw down the locking nut at last.

  • Page 20: Clutch Control System

    Clutch Clutch Control System Clutch master pump Oil intake joint Limit screw Dual wire clamp 12.Rubber cup Pump body 13.Piston Return spring Retainer ring Piston oil intake valve return spring seat Push rod thread fork Piston oil intake valve return spring Hex thin nut Piston oil intake valve oil seal Push rod spacer...
  • Page 21 Clutch Disassembly and assembly Push pistion into cylinder body with screwdriver when removing or tightening valve stopper screw. Align groove of piston assembly and valve stopper when installing valve stopper screw. Clutch slave pump Slave pump push rod nut Rubber cup Shield Pump body Push rod...

  • Page 22: Clutch Release Mechanism

    Clutch Clutch Release Mechanism Clutch driven disc Clutch cover and pressure plate Removel and installation Install retainer spring and spring holder. CL-6...

  • Page 23: Clutch Driven Disc And Pressure Plate

    Clutch Remove release bearing. Install release bearing with suitable tolerance. Inspection Check whether the release bearing has crackle and wear. The release bear- ing should run smoothly and noiselessly. Change it if necessary. Check whether the surface of the release bushing and release fork has wear, damage and corrosion.
  • Page 24 Clutch Clutch Driven Disc Check Check the wear of the driven disc; The wear limit between the friction facing and rivet head: 0.3mm. Check up the spline tooth gap and its deviation for the driven disc; 　 Check whether the driven disc has been burnt, discolored or polluted with oil or grease.

  • Page 25: Service Data And Specifications

    Clutch · Check whether the matching surface of the pressure plate and driven disc has deformation or damage. Change them if necessary. ·Adjust the unevenness of the diaphragm spring with tool. Flywheel check · Check whether the working surface of the flywheel is burnt or discolored. Remedy it with the emery paper.
  • Page 26 Clutch CL-10...
  • Page 27 Transmission Technical Performance Overview ............MT-1 Service and Maintenance Notes for Transmission ......MT-1 Trouble and Troubleshooting ..............MT-1 Disassembling Procedures and Notes for Transmission Assembly MT-2 Check and Repair ..................MT-11 Reassembling Procedures and Notes for Transmission Assembly MT-13...

  • Page 28: Technical Performance Overview

    Transmission Transmission Technical Performance Overview Structure pattern The 17G1A8-25 transmission is a mechanically manual transmission with 5 forward speeds and 1 reverse speed. All the forward speeds are synchromeshed. 5th speed is overdrive gear. All of them apply skew cylindrical gear engagement and the gear shifting is smooth.

  • Page 29: Disassembling Procedures And Notes For Transmission Assembly

    Transmission Trouble Phenomenon Probable case Judgement &Trouble shooting 1.Without the failure 1.Severe wear of interlock pin. of clutch,shifting is The gear couldn't 2.The fork head of internal speed difficult with serious be engaged prop- 1.Check the faulty area and remove the failure. selective rocker arm is sevrely worn pound or disengage- erly.
  • Page 30 Transmission Disassembling sequence and notes for transmission Disassembling sequence: 1.Clutch release bearing assembly 2.Clutch release fork shaft and release fork arm assembly 3.Clutch case connecting bolt, 9.8 grade 4.Clutch case 5.2nd shaft nut 6.Odometer flexible shaft sleeve sets 7.Connecting bolt, 9.8 grade 8.Rear cover 9.Odometer drive gear 10.Distance sleeve...
  • Page 31 Transmission 13.Self-locking spring and steel ball Take off 3 self-olcking springs and 3 self-lock steel balls from the transmission housing. 14.Elastic pin sets 15.Fork shaft (reverse~5 speed) Before disassembling, place all the fork shafts in neutral position. Push the rear end of rork shaft (reverse~5 speed) so that it moves forward. Then move the fork shaft backward to dismantle the shifting arm and shift- ing device.
  • Page 32 Transmission 18.Shifter fork 19.Retainer ring(countershaft rear bearing) 20.Countershaft rear centripetal ball bearing Strike the front end of countershaft with copper bar or hand hammer and move the countershaft backward 3mm. Remove the retainer ring, place special tools into the ring groove and dismount the bearing.
  • Page 33 Transmission 25.PTO coverplate bolt, 6.8 grade 　 26.PTO coverplate 　 27.Reverse shaft stop pin After removing the PTO coverplate, take off the reverse shaft gear stop pin from the transmission case. 28.Reverse shaft Knock the rear end of reverse shaft with an appropriate metal bar and strike it towards the interior of transmission case.
  • Page 34 Transmission Disassembling scheme and notes for 2nd shaft assembly and 1st shaft assembly Disassembling sequence of 2nd shaft assembly and 1st shaft assembly 1.Thrust washer 2.2nd shaft 5th speed gear 3.Retainer ring 4.Synchronizer gear ( 5th speed) MT-7...
  • Page 35 Transmission 5.Synchronizer assembly(reverse~5th speed) Remove the retainer ring and the synchronizer assembly,and then dis- mount the synchronizer spring,synchronizer gear sleeve,sliding block and synchronizer gear hub. Notes: As the dimension of each retainer ring matches the clearance of synchronizer gear hub respectively,do not mix the disassembled retainer rings.
  • Page 36 Transmission 14.Synchronizer gear ring(2nd speed) 15.Synchronizer assembly(1st speed~2nd speed) Remove the retainer ring and synchronizer assembly(1st speed~2nd speed) Notes: The disassembled retainer rings couldn't be mixed. 16.Synchronizer gear ring(1st speed) 17.2nd shaft 1st speed gear 18.Needle bearing(1st speed) 19.1st shaft centripetal ball bearing When disassembling, use bench press.
  • Page 37 Transmission Disassembling sequence for transmission shifter cover assembly Disassembling sequence: 1.Backing lightswitch 2.Elastic pin sets 3.Speed selective shaft external rocker arm sets 4.Speed selective shaft sets 5.Speed selective shaft adjusting shim 6.Oil seal 7.Elastic pin 8.Speed selective shaft sets 9.Oil seal 10.Flat washer 11.Speed selective shaft internal rocker arm 12.Flat washer...

  • Page 38: Check And Repair

    Transmission Check and Repair If wear of part, damage of part or other fault is found through inspec- tion, repair or replace it. 1.Thickness of shifter fork(mm) Standard Limit 10.0 2.Free length of self-locking spring(mm) Standard Limit 31.6 30.1 3.Clearance between,synchronizer gear ring and the end face of joint tooth (mm) Standard Limit...
  • Page 39 Transmission 6.2nd shaft radial runout(mm) Limit 7.Clearance between gear orifice and 2nd shaft(mm) Standard Limit 5th speed 0.05~0.08 8.Clearance between the liner and reverse gear shaft(mm) Standard Limit 0.04~0.08 9.Radial runout of centripetal ball(mm) Limit MT-12...

  • Page 40: Reassembling Procedures And Notes For Transmission Assembly

    Transmission Reassembling Procedures and Notes for Transmission Assembly Reassembling of 1st shaft and 2nd shaft assembly as showed in the figure Assembling sequence: 1.1st shaft centripetal ball bearing Use bench press when assembling. 2.Needle bearing(1st speed) 3.2nd shaft 1st speed gear 4.Synchronizer gear collar(1st~2nd speed) 5.Synchronizer assembly (1st~2nd speed) Mount it non-directional,select and fit the thickest snap ring...
  • Page 41 Transmission 6.Synchronizer gear ring(1st~2nd speed) 7.2nd shaft 2nd speed gear 8.Thrust washer and retainer ring After assembling,measure the distance X and select the fittest retainer ring from the table below. Distance X Retainer ring thickness(mm) 2.20~2.27 1.875 2.27~2.32 1.925 2.32~2.37 1.975 2.37~2.43 2.025...
  • Page 42 Transmission Reassembling of shifter cover assembly Assembling sequence: 1.Oil seal 2.Speed selective shaft sets 3.Speed selective shaft internal rocker arm 4.Flat washer 5.Speed selective shaft reverse stop spring 6.Flat wasger 7.Elastic pin 8.Oil seal 9.Flat washer 10.Speed selective shaft sets 11.Speed selective shaft external rocker arm sets 12.Elastic pin sets 13.Backing light switch...
  • Page 43 Transmission Reassembling and specifications for transmission assembly Assembling sequence: 1.Countershaft 2.Countershaft 5th speed gear Put the countershaft assembly and 5th speed gear together and mount them into the case with the 5th speed gear close to the rear end. 3.Reverse shaft gear assembly When assembling, be sure that the longer end of reverse shaft gear hub faces forward, and then insert the reverse shaft pin.
  • Page 44 Transmission 4.Reverse shaft 5.Reverse shaft stop pin 6.PTO Coverplate 7.Connecting bolt, 6.8 grade 8.2nd shaft assembly 9.Centripetal ball bearing(the rear of 2nd shaft) 10.1st shaft assembly First measure the distance x between the front end face of synchro- nizer gear hub(3rd speed~4th speed) and the front end face of housing. When the value of X is less than 53.85mm, mount 1st shaft centripe- tal ball bearing first, then install 1st shaft shim and retainer ring in sequence.
  • Page 45 Transmission 14.Shifter fork 15.Shifter fork shaft (1st speed~2nd speed) 16.Shifter fork shaft (3rd speed~4th speed) 17.Shifter fork shaft (reverse~5th speed) Before assembling, place the shifter fork shaft in neutral position. Mount 2 steel balls on the position between 1st~2nd speed shifter fork shaft and 3rd~4th speed shifter fork shaft.
  • Page 46 Transmission 22.Connecting bolt, 9.8 grade 23.Odometer shaft sleeve and odometer driven gear 24.Clutch case assembly Apply seal gum on the joint face of clutch case, the gum track must be continuous . 25.Clutch case connecting bolt, 10.9 grade 26.Ball-end supporter 27.Release fork and dust cover 28.Clutch release bearing assembly 29.2nd shaft nut...

  • Page 47: Front Suspension

    Front Suspension Notice & Preparation ................. FA-1 Front Suspension ..................FA-2 Driving Inspection and Repair ..............FA-3 Front Axle....................... FA-9 Hub & Brake Disc ..................FA-10 Steering Knuckle ..................FA-14 Front Independent Suspension ............. FA-16 Maintenance Data & Explanation ..........FA-25...
  • Page 48 Front suspension Notice When assembling the rubber part, the vehicle must be in curb weight, and the rubber part has to be screwed down after the wheels touched down the ground. Curb weight: the vehicle equipped with full fuel, coolant, oil, and spare tyre, jack, service tools, and parked on the level ground.
  • Page 49 Front suspension Front Suspension FA-2...
  • Page 50 Front suspension Riding Inspection and Repair Note: When assembling the rubber part, the vehicle must be in curb weight, and the rubber part has to be screwed down after the wheels touched down the ground. Curb weight: the vehicle equipped with full fuel, coolant, oil, and spare tyre, jack, service tools, and parked on the level ground.
  • Page 51 Front suspension Chck the upper and lower transverse arm ball head dust proof for any damage, crack, or loose. Warning: If any of the above situation has happened, replace the ball head pin in time and forbidden to drive the vehi- cle.
  • Page 52 Front suspension As for the front wheel bearing pretightening force adjustment, please take the reference of other chapter. Front wheel alignment Before check the front wheel alignment, do the fol- lowing primary inspection. Primary inspection 1.Check the tyre for wear, and the tyre pressure. (standard pressure: 530kPa) 2.Check the inside and outside radial runout of the wheel assembly.
  • Page 53 Front suspension After the test, if it is necessary to adjust the angle, please follow the steps below: First, check the upper and lower ball head pin for wear and looseness, the hub bearing for looseness, and the steering kunckle for deformation. Wheel camber (zero load) See "maintenance data &...
  • Page 54 Front suspension Thickness of the adjusting spacer: 1.0mm, 1.6mm, 3.2mm Don't use more than 3 spacers in the same place. When assemble the spacer, insert from top to bottom. The total thickness of the spacer should not be more than 9.6mm. The thickness difference of the same side of the front and rear end should not be more than 4.8mm.
  • Page 55 Front suspension Make sure that the middle tie rod has less than 35mm length turned into the left and right joint, this is to assure the same length of the middle tie rod left an right joint. (3) Use the moment wrench to tighten the lock nut to the required value.

  • Page 56: Front Axle

    Front suspension Front Axle Front wheel hub cover Brake disc Retainer ring Front wheel hub inner bearing assy Hex thin nut Front wheel hub oil seal assy Oil seal retainer 4.Antifriction spcer--steering knuckle Left dustproof assy--front brake Front wheel hub outer bearing assy Left steering knuckle Front wheel hub Wheel nut...

  • Page 57: Hub & Brake Disc

    Front suspension Hub & Brake Disc Disassembly and assembly Dismount the brake caliper assembly. The brake pipe need not to be dismount from the brake caliper, and pay attention not to depress the brake pedal to avoid piston extruded. Note: Never distort the brake pipe.
  • Page 58 Front suspension 3.Tighten the bearing locking nut to the required torque: 34~39N.m 4.Turn the hub for several times to set the bearing in correct position. 5.Tighten the bearing locking nut again to the required torque: 34~39N.m °. 6.Back the locking nut for 45 7.Install the adjusting cap and new cotter pin, and °...
  • Page 59 Front suspension 8.Measure the wheel hub bearing tightening force and shaft end clearance. Shaft end clearance: 0mm Bearing tightening force(at the hub bolt): Standard torque: 0.7~101N.m Spring balance read: 9.8~27.5N Repeat the above procedure until obtain the correct bearing tightening force. 9.Bend the cotter pin.
  • Page 60 Front suspension Assembly Use the proper tool to install the bearing outer ring into the hub. Smear some grease on the bearing tapered face. Smear some grease on the flange part of the oil seal and then install it in the hub. FA-13...

  • Page 61: Steering Knuckle

    Front suspension Steering Knuckle Disassembly Use special tool to dismount the steering tie-rod. Install the check nut on the check bolt in reverse to protect the bolt. Dismount the steering knuckle from the ball head connecting part. (1) Loose (Don't dismount) the upper and lower ball head pin clamp nut.
  • Page 62 Front suspension Inspection Steering knuckle Check the steering knuckle for any defprm, crack or damages by the method of magnetic test. Assembly Use the jack to lift the lower transverse arm, and install the upper and lower ball head pin and the steering knuckle.

  • Page 63: Front Independent Suspension

    Front suspension Front Independent Suspension Shock absorber assy Torsion bar fixing bar Upper arm shaft Lower arm shaft Inner side washer Lower transverse arm assy Rubber bush assy Rubber bush assy Big washer Limit block assy Upper transverse arm Bolt Bolt Rubber bush assy Round head pin assy...
  • Page 64 Front suspension Shock absorber Disassembly and assembly When disassembling and assembling the shock absorber, never let the oil or grease touch the rubber parts. Check Use the proper cleanser to wash all the parts except the non-metal parts, and then dry them with compressed air.
  • Page 65 Front suspension Disassemble the torsion bar adjusting arm from behind and draw out the torsion bar. Disassemble the torsion bar fixed arm. Check Check the torsion bar for any wear, deform, bend or any other damages. Check the parts serrating spline for crack, wear, distort or other danages. Assembly and adjustment Along the tightening direction to adjust the adjusting nut of the adjusting arm.

  • Page 66: Tightening Torque

    Front suspension 4.Install the torsion bar spring When install the torsion bar spring, please pay atten- tion to the mark on the end of the spring. Don't install in wrong direction. 5.Install the adjusting arm Make sure the vehicle is in no load. Make the same extending length of the fixed bolt and the extending length before disassembling, and then screw down.
  • Page 67 Front suspension (1) Shock vehicle front part up and down for 4~5 times to make the vehicle gesture is in correct height. (2) Measure the vehicle gesture value H. See "Wheel alignment" of "Maintenance data & explanation". (3) If the H is different from the required value, adjust the vehicle gesture. See "Wheel alignment"...
  • Page 68 Front suspension Check the A and B dimension after tightening. A=110mm B=32mm Assemble the upper ball head pin on the upper transverse arm. Assemble the upper fixed nut of the shock absorber. Tighten the upper transverse arm locking nut under the condition of wheel on ground, no load.
  • Page 69 Front suspension Install the upper transverse arm shaft and inside washer. Install the inside washer by using of the fillet of inside machined surface. Press the bush of the other end, and the bush must be pressed into the proper position. Tighten the nut for the moment.
  • Page 70 Front suspension Lower transverse arm Diasassembly and assembly Disassemble the lower fixed nut of the lower shock absorber bracket. Disassemble the torsion bar spring. See "Torsion bar spring disassembly". Disassemble the fixed nut of push rod. See "Disassembly and assembly of the push rod". Disassemble the lower transverse arm ball head pin from the steering knuckle.
  • Page 71 Front suspension Upper and lower ball head pin Disassemble and assemble Disassemble the upper and lower transverse arm. See "Steering knuckle". Check Shock at direction A (see the the right figure), and check the ball head pin. See "Maintenance data & explanation" for reference. If the torque A is not in the required range, replace the ball head pin.

  • Page 72: Maintenance Data & Explanation

    Front suspension Maintenance Data & Explanation Torsion bar spring Length mm 1000 Diameter mm 30 Shock absorber Diameter A mm 54 Diameter B mm 45 ±350 Recover risistance N 2250 ±200 Compression resistance N 1000 Check and adjustment Front alignment (no load) °25´~ °35´...
  • Page 73 Front suspension Vehicle gesture (no load) Lower transverse arm central height H mm 139~145 No load: full fuel, coolant, lubricant, and original tyre, jack and driver tool, vehicle is parked on the level ground. Ball head pin Upper ball head pin Lower ball head pin Swing force A (N) 19.6~122.6...
  • Page 74 Rear axle & Rear Suspension Precaution .....................RA-1 Rear Axle and Rear Suspension ..............RA-2 Rear Axle ......................RA-4 Rear Suspension ..................RA-9 Maintainance Data and Explaination ...........RA-13...

  • Page 75: Precaution

    Rear Axle & Rear Suspension Precaution: Assemble the rubber parts under the vacuum conditions, tighten them at last. No load: Full fuel, coolant and oil, equipped with spare tyre, jack, and driving tools. Use the tools to disassemble and assemble the brake pipes. Every time the suspension part is moved, the front wheel alignment must be checked, and adjust it if neces- sary.

  • Page 76: Rear Axle And Rear Suspension

    Rear Axle & Rear Suspension Rear Axle and Rear Suspension RA-2...
  • Page 77 Rear Axle & Rear Suspension Rear axle and rear suspension Check rear axle and rear suspension parts for any looseness, wear, or damage. Turn the left and right wheel to check if it is in normal con- dition. Retighten all the bolts and nuts to the required torque. Tightening torque: aim to the requirement of rear suspen- sion Check the shock absorber for leakage or other damage.

  • Page 78: Rear Axle

    Rear Axle & Rear Suspension Rear Axle Rear axle half axle Rubber seal gasket assy Dustproof Adjusting spacer Half axle outer oil seal seat Half axle inner oil seal assy Half outer oil seal assy Ventilation plug assy Half axle bearing seat Rear axle housing assy Half axle supporting bearing Seal washer...
  • Page 79 Rear Axle & Rear Suspension Disassemble 1.Disassemble the parking brake cable and brake pipe. 2.Disassemble the brake drum. 3.Remove the bearing lock nut. 4.Pull out the half axle by special tool. Be careful not damage the oil seal when pulling the half axle.
  • Page 80 Rear Axle & Rear Suspension 7.Remove the bearing lock nut by special tool. 8.Disassemble the wheel bearing, bearing cover and splash guard from the half axle. 9.Disassemble the grease seal ring from the bearing cover by a proper lever. 10.Use a brass bar to disassemble the outer ring of the wheel bearing.
  • Page 81 Rear Axle & Rear Suspension Check Half axle Check the half axle for any bend, crack, damage, wear or distort, replace if necessary. Wheel bearing Make sure if the bearing drive freely, without noise, crack, notch or wear. Rear axle housing Check the rear axle housing for distort or crack, replace if necessary.
  • Page 82 Rear Axle & Rear Suspension 7.Put lithium based lubricating grease into the flute of the axle end cover. 8.Put lubricating grease into the Spline slot of half shaft and wipe lubricating grease on the half shaft's surface where need to be lubricated. 9.Adjust clearance of axle end.

  • Page 83: Rear Suspension

    Rear Axle & Rear Suspension Rear Suspension Structure Summary RA-9...
  • Page 84 Rear Axle & Rear Suspension Shock Absorber Disassembly and assembly Loose the nut of uper and lower end to disassembly the shock absorber. Check If there are any oil leak, crack or distortion on shock absorber, it has to replace the shock absorber ass'y. If there are any crack or distortion on rubber sleeve, it has to replace the rubber sleeve Leaf Spring Disassembly and assembly...
  • Page 85 Rear Axle & Rear Suspension Check Check if there are any crack on leaf spring. If there are, replace the spring. Check if there are any abrasion, crack, distortion or damaged screw thread on front bracket, shackle, U type bolt and gasket. If there are any, replace the parts when necessary. Check if there are any distortion or craze on all sleeves, replace them when necessary.
  • Page 86 Rear Axle & Rear Suspension Rubber Cushion Block Disassembly rubber cushion block Make sure front mark is on the outside of vehicle as the picture showed. RA-12...

  • Page 87: Maintainance Data And Explaination

    Rear Axle & Rear Suspension Maintainance Data and Explaination Leaf Spring Thickness (mm) --Amount of piece Main spring: 7--3 Auxiliary spring: 14--2 Static deflection S: 101 Length L (mm) : 1200 Width (mm) : 70 Shock Absorber Work length (mm) : Min/Max: 338/548 Jouney (mm) : 210 ±350/600±130 Damp (N) : Extend/Compress: 2250...
  • Page 88 Rear Axle & Rear Suspension RA-14...
  • Page 89 Profeller Shaft and Differential Catalog Preperation ..................PD-1 Profeller Shaft ................PD-4 Maintainance .................. PD-9 Disassembly and Assembly............PD-10 Main Reducer ................PD-11 Disassembly ................. PD-12 Check.................... PD-17 Adjust ................... PD-18 Assembly..................PD-19 Maintainance Data and Explaination ........... PD-25...

  • Page 90: Preperation

    Profeller Shaft and Differential Preperation Special Tool 1.Differential fixing assistant tool： 1） Engine bracket 2） Seat 2.Differential assistant tool： Assembly driving axle 3.Flange spanner： Disassembly and assembly driving axle locking nut and drive gear locking 4.Differential bearing adjusting nut spanner： Adjust bearing preload and tooth sapce 5.Differential bearing adjusting nut spanner：...
  • Page 91 Profeller Shaft and Differential 8.Drive wimble gear assembly gauge： 1） Height gauge 2） Model shaft 9.Drive wimble gear assembly gauge： 1） Height gauge 2） Tightening clincher 10.Drive wimble gear inside track tension seat： 1） Tension implement 2） Seat Disassembly and assembly drive bearing rear taper bearing 11.Preload testing gauge：...
  • Page 92 Profeller Shaft and Differential 14.Revise gauge： Select bearing adjusting gasket 15.Differential bearing punch： Assembly inside taper bearing 16.Punch： Assembly rear bearing sleeve 17.Punch： Assembly front bearing sleeve 18.Punch： Assembly rear bearing sleeve 19.Bearing seat punch： Assembly bearing seat 20.Bearing punch： Assemble taper inside bearing 21.Bearing seat front oil seal punch：...

  • Page 93: Profeller Shaft

    Profeller Shaft and Differential Profeller Shaft Maintain of theVehicle Vibration on Profeller shaft If profeller shaft vibrates when the vehicle is in high speed, check the diameter run-out of the shaft first. . Lift rear axle. 2. Turn profeller shaft and check the diameter run-out amount of a certain point on it.
  • Page 94 Profeller Shaft and Differential 3.If diameter run-out amount exceeds the limited value, turn the connecting flange of the rear axle's one end for 180 degree, then assembly the profeller shaft. Diameter run-out amount refers to Maintainance data and Explaination.。 4.Check diameter run-out amount again, if it still exceeds the limited value, replace a new profeller shaft. 5.
  • Page 95 Profeller Shaft and Differential Check the Axial Freedom Degree of Cross Axle Replace the cross axle of profeller shaft if it's axial fredom degree exceeds the limited degree. Axial fredom degree amount refers to Maintainance data and Explaination. Disassembly Disassembly cross axle. 1.
  • Page 96 Profeller Shaft and Differential 4. Use the same approch to disassembly the other cross axle bearing. Mark the disassemblyed parts in order to keep their former positions in the later assemly. Assembly Cross axle 1. Assembly the cross axel bearing, and lay the recom- mendatory multi-purpose grease on the inner side of bear- ing.
  • Page 97 Profeller Shaft and Differential 4. Check agility and axial freedom degree of cross axle. Axial freedom degree refers to Maintainance data and Explaination. PD-8...

  • Page 98: Maintainance

    Profeller Shaft and Differential Maintainance Replace Front oil Seal Attention: For drive system, adjustable washers are used. Afer disassembly flange, the preload force of bearing has to be adjust. Therefore final gear needs to be checked. 1 .Disassembly profeller shaft. 2.

  • Page 99: Disassembly And Assembly

    Profeller Shaft and Differential Disassembly and Assembly Disassembly Disassembly profeller shaft After disassembly profeller shaft, stuff the ouput port of trassmition case with a plug. Disassembly axle casehalf shaft. (Refer to rear axle part) Attention： When disassembly profeller shaft,take care to aviod damaging splin, socket flange yoke and oil seal.
  • Page 100 Profeller Shaft and Differential Drive Gear 1.Hex nut 11.Rear asle final drive housing 21.Differential bearing 2.Flange 12.Flange nut 22.Stop spacer 3.Dust thround 13.Spring washer 23.Bolt 4.Oil seal ass'y 14.Gasket 24.Supporting washer 5.Driving conic gear bearing 15.Adjusting nut 25.Planetary gear 6.Adjusting gasket 16.Adjusting nut 26.Spring pin 7.Adjusting sleeve...
  • Page 101 Profeller Shaft and Differential Disasembly Pre-check Before disassembly drive differential, check the following: Preload force 1）Turn drive gear for several times to put bearing in its right position. 2） Use tool check the preload force. Clearance between driven gear and drive gear. Measure the clearance of main reduct gear at different points with a micrometer gauge.
  • Page 102 Profeller Shaft and Differential Differential 1 .Fixing main differential ass'y by tool. 2 .Mark the seat of hakf shaft bearing with paint or a special tool to avoid mistaking in reassembly. Since the bearing seat is linear bored in machining, it should be in its former position when reassembly it.
  • Page 103 Profeller Shaft and Differential 5. Disassembly differential housing ass'y by a tommy bar. Pay attention that seperate the outside track of bearing and taper in right and left respectively--in order not to mis- tacken them. 6. Diassembly nut of drive conic gear by tool. 7.
  • Page 104 Profeller Shaft and Differential 8. Take off drive conic gear, its rear inner conic bear- ing, bearing seat and adjusting gasket of bearing together. 9. Disassembly front oil seal and front conic bearing. 10.Disassembly outside track of gear bearing by a brass stick.
  • Page 105 Profeller Shaft and Differential Pay attention not to mistake left and right bering parts. 2 .Loose bolt of driven gear by tool. 3 .Knock driven gear by soft harmmer, then disassem- bly the gear from differential housing. 4 .Take off cross locking pin from the side of driven gear by punch.

  • Page 106: Check

    Profeller Shaft and Differential Check Driven Gear and Drive Gear Check whether there are any nicks, cracks or chippings, if there are some obvious damage, must replace the gears together. Differntial Housing Ass'y Check the assembly surface of differential hous- ing,bearing of half shaft, planetary gear, shaft of planetary gear and thrust washer.

  • Page 107: Adjust

    Profeller Shaft and Differential Adjusting Gear Contact Area To proof whether the driven conic gear and drive conic gear mesh correctly, the shape of contact area should be checked. If the hyperbola gear mesh mesh incorrectly, it will cause noise and shorten the duration of the gears. By checking the shape of contact area and adjust the gears to their best meshing position, it will reduce noise and increase the duration of the gears.

  • Page 108: Assembly

    Profeller Shaft and Differential Assembly Differential Housing 1. Assembly gear of half shaft, planetary gear, plane- tary gear set and thrust spacer. 2. Incert the planetary gaer shaf into differential hous- ing and contact it to the hole of locking pin. 3.
  • Page 109 Profeller Shaft and Differential 5. Put gear oil on the surface of gear and check the running situation of gear. 6. Put seal glue on differential housing and the surface of driven gear's contact area, then put the differential hous- ing on the main reducer driven gear.
  • Page 110 Profeller Shaft and Differential Differential Seat 1 .Assembly the outside track of front and rear bearing. 2 .Select adjusting gasket of drive gear. Refer to the explaination of adjusting. 3 .Assembly adjusting gasket of drive gear, insert the inner taper of drive gear's rear conic bearing by tool. 4.
  • Page 111 Profeller Shaft and Differential 5. Put universal grease in the cavum of oil seal' s lip. Assembly front oil seal. 6. Reassembly bearing gasket of drive gear, adjusting gasket of bearing and drive gear on gear seat. 7 .Knock connecting flange by soft hammer softly and assembly the flange on drive gear.
  • Page 112 Profeller Shaft and Differential 9 .Turn driver gear repeatly and measure the preload of the drive gear bearing. 10.Assembly the differential housing which has the outside track of half shaft bearing into the gear seat. 11.Turn adjusting gasket softly by special tool to lay the gasket on a suitable screw thread connecting position of gear seat.
  • Page 113 Profeller Shaft and Differential 13.Tighten the left and right gasket of half shaft bear- ing one by one and measure the windage and preload force of driven gear. Tighten the left and right gasket in turns to get the prescripive windage and preload force. When check preload force, turn the drive conic gear repeatly to lay bearing in the right position.

  • Page 114: Maintainance Data And Explaination

    Profeller Shaft and Differential Maintainance Data and Explaination Profeller Shaft General Explaination Wheelbase mm：2515 Rear wheel：Single wheel Type of rear axle：Single class hyperbola conic main reducer differential, punch jointing axle housing Type of profeller shaft：Single, open Amount of tie-in：2 Main Differential Gear ratio：4.875 （Provided by JMC）...
  • Page 115 Profeller Shaft and Differential PD-26...
  • Page 116 Steering System Notes ......................ST-1 Check With the Vehicle ................ST-2 Steering Wheel and Steering Column ............ ST-3 Steering Gear ....................ST-6 Steering Tie-rod ..................ST-7 Power Steering System ................ST-10 Maintenance Data and Explanation ............ST-11...

  • Page 117: Notes

    Steering System Steering System Notes ·Before disassembling, please clean external surface of the parts carefully. ·Disassemble the parts in a clean working area to prevent any dirt and other objects from entering. 　 ·Put the disassembled parts in order for later reassembling. ·Clean the parts by using nylon or soft paper, normal shop cloth will cause some remains on the parts to interfere the movement.

  • Page 118: Check With The Vehicle

    Steering System Tool Name Brief Description Installing the steering gear on it Accessories, bracket and steering gear casing Adjusting the preload of worm bearing Torque connecting end Check with the Vehicle Check the free play of the steering wheel ·Measure the free play when steering wheel is in central position (driving straight).

  • Page 119: Steering Wheel And Steering Column

    Steering System Steering Wheel and Steering Column Steering Wheel ·Remove the horn button. ·Disassembling the steering wheel by using special tools. ST-3...

  • Page 120: Steering Column

    Steering System ·When installing the steering wheel, apply a layer of multi-purposed grease on the whole surface (two parts) of the automatic return-back pin of steering indicator and touch point of the horn. ·Install the steering wheel on the column shaft at the central position. ·After installing, turn the steering wheel, make sure to have a smooth movement and the same turning cycles on both left and right side at the central position.
  • Page 121 Steering System ·Install the spring lock ring on the upper shaft with tools. Steering Lock a) Remove the lock screw with a clamp. b) Tightening the lock screw. Notes: Pay attention to whether the position of the steering lock mechanism is correctly located.

  • Page 122: Steering Gear

    Steering System Steering Gear Hex neck bolt Duct clip Spring washer Steering screw lever Hex nut Cylinder pin Side cover 29.O rubber sealing ring Torsion bar O rubber sealing ring Valve pocket Retaining nut Needle bearing Adjusting bolt Cylinder pin Retaining ring Imput shaft High pressure sealing ring...

  • Page 123: Steering Tie-Rod

    Steering System Steering Tie-rod Disassembly and assembly 1.Remove the cotter pin and nut from the tie-rod connecting part, and then make use of proper tool to separate steering knuckle arm from tie-rod. ST-7...
  • Page 124 Steering System 2.Make use of proper tool to release the ball pin connection part like connecting pull rod, etc. 3.Remove the drag link from the steeringdrop arm by use of tools. 4.Remove the fixed bolt of front and rear limit bracket. Intermediate pull rod and tie-rod 1.When disassemble the tir-rod ball head connection, adjust the pull rod length.
  • Page 125 Steering System Check Ball head pin assembly 1.Check the ball head pin travel. If there is damage, too large axial clearance or hard move of the ball head pin, replace the ball head pin assembly. Transverse swing force(measuring point: cotter pin) A: See "Maintenance data and explanation".

  • Page 126: Power Steering System

    Steering System Power Steering System Steering oil pump assy Steering gear oil intake hose assy Steering oil pump bracket Straight joint Bolt Throat hoop Bolt Dual pipe clip upper bracket Oil reservoir assy Steel pipe clip backing ring Oil pump intake pipe assy Steering gear oil intake pipe assy Clip Steering gear oil return pipe assy...

  • Page 127: Maintenance Data And Explanation

    Steering System Maintenance Data and Explanation Basic parameter Steering gear drive ratio: 23~26 Steering wheel turning circle: 4.3 Check and adjust Steering wheel Steering wheel axial clearance (mm): 0 Steering wheel free travel (mm): 10~40 Steering column: Steering column length L (mm): 484 Connecting rod mechanism Ball head pin assy Transverse swing force (measuring point: cotter pin) N:...
  • Page 128 Steering System ST-12...
  • Page 129 Brake System Attentions .....................BR-1 Check and Adjust ..................BR-2 Exhaust ......................BR-3 Brake Pipe ....................BR-4 Brake Pedal and Bracket ................BR-6 Brake Booster ....................BR-8 Vacuum Pipe ....................BR-11 Front Brake ....................BR-12 Rear Brake ....................BR-13 Parking Brake System ................BR-14...

  • Page 130: Attentions

    Brake System Attentions Use brake liquid of "901-4" to meet the requirements of DOT4. May use other brand liquids which meet the requirements of DOT4, but two kinds of liquids are not allowed to mix up for use. Do not reuse the exhausted and unclean liquid. Be careful not to spray the liquid to the painted area, this will damage the painting surface.

  • Page 131: Check And Adjust

    Brake System Check and Adjust Check the brake liquid level Check the level of the reservoir, it should be between "MAX" and "MIN". If the level of the liquid is too low, check whether the brake system is leaking. If the brake warning light is till on when releasing the hand brake rod, check whether the parking brake control system is adjusted to the right position.

  • Page 132: Exhaust

    Brake System Exhaust Note: Monitor the level of the liquid in process of exhausting. Add new liquid of "901-4" in to the reservoir to assure it is always full during the whole process. Place a container under the main pump to avoid liquid coming out.

  • Page 133: Brake Pipe

    Brake System Brake Pipe 1.Oil brake pipe assy 12.Brake hose assy 2.Oil brake pipe assy 13.Straight joint 3.Three line straight joint 14.Single pipe clip 4.Oil brake pipe assy 15.2nd oil brake pipe assy 5.1st oil brake pipe assy 16.Brake hose assy 6.Three way joint 17.Oil brake hose assy 7.Front three way bracket assy...
  • Page 134 Brake System Disassembly Note: Be careful not spray the brake liquid on the painted area, otherwise it will damage the painting surface; if it dose, clean it immediately with clean water. Avoid bending, twisting and stretching of all the hoses too much when disassembling.

  • Page 135: Brake Pedal And Bracket

    Brake System Brake Pedal and Pracket Disassemble and assemble 1.Pedal bracket assy 2.Support shaft 3.Brake lamp switch assy 4.Return spring 5.Brake pedal 6.Rubber mat 7.Vaccum booster with brake master pump Assembly Check the following items of the pedal: Whether the pedal is bent. Whether the pin is damaged.
  • Page 136 Brake System Adjustment Check the free height from pedal to reinforced plate. Free height 169~175 mm Note: The booster rod couldn't be in a pressed position when assembling the booster head pin. Adjust the pedal height if necessary. Adjustment 1.Loosen the lock nut, turn on the booster rod to adjust the pedal height, then tighten the nut.

  • Page 137: Brake Booster

    Brake System Brake Booster Brake master pump with vacuum booster 1.Oil reservoir assy 2.Front chamber oil pipe assy 3.Rear chamber oil pipe assy 4.Vacuum booster with brake master pump assy 5.Nylon pipe with one-way valve assy BR-8...
  • Page 138 Brake System Driving Inspection Control check Shut down the engine and depress the pedal for several times for any travel change. Press down the brake pedal, start the engine, if the pedal slowly down a litle, it is nornal. Sealing check Start the engine for one or two minutes then shut off.
  • Page 139 Brake System Assembly Note: Be careful not bend the brake pipe when installing the booster. If the U-type clip pin is damaged, replace it. Add new liquid of "901-4" to meet the requirements of "GB12.981-HZY4". May use other brand liquids which meet the requirements of GB12.981-HZY4, but two kinds of liquids are not allowed to mix up for usage.

  • Page 140: Vacuum Pipe

    Brake System Vacuum Pipe Note; Pay attention to the following points when installing the vacuum hose: Do not put any oil on the vacuum hose and check valve. Insert the vacuum pipe to the vacuum hose and make the hose touch the upper protruding ring of the formed pipe. Install the Nylon tube with single one-way valve assy., pay attention to the direction.

  • Page 141: Front Brake

    Brake System Front Brake Disassembly Caliper body Caliper bracket Insulation spacer Hose joint core Guide pin Spring leaf Dustproof Dustproof Left brake friction block with alarm inductor assy Oil drain screw plug Piston 17.Friction block assy Rest pin Sealing ring Insulation spacer Dustproof 13.Damping spacer...

  • Page 142: Rear Brake

    Brake System Rear Brake Disassembly 1.Rear left brake bottom plate assy 16.Brake shoe pressure spring 2.Dustproof 17.Spring seat 3.Oil drain screw 18.Rear brake drum 4.Joint core 19.Return spring 5.Wheel cylinder shield 20.Return spring 6.Piston 21.Fork 7.Rubber cup 22.Ratchet wheel 8.Rear brake wheel cylinder body 23.Fork 9.Wheel cylinder spring 24.Return spring...

  • Page 143: Parking Brake System

    Brake System Parking Brake System Rubber bush Parking brake control lever assy Elastic clip Rocker assy Parking brake wire rope assy Cotter pin Bracket with welding nut assy Pin shaft Monotube clamping piece Return spring Monotube clamping piece Parking brake wire rope assy Flexible shaft shim Connecting rack and welding nut assy Bracket assy...
  • Page 144 Cab & Frame Clip and Fastener ..................BF-1 Cab Front Panel ................... BF-2 Door ....................... BF-3 Instrument Panel ..................BF-4 Cab Interior Trims and Exterior Trims ..........BF-5 Seat ......................BF-12 Cab Safety Belt ..................BF-13 Rear Mirror Outside Cab ................

  • Page 145: Cab

    Precautions •When removing or installing various parts, place a cloth or padding onto the vehicle body to prevent scratches. •Disassemble or assemble the handle device, molding parts, instrument, inner trims and so on carefully, not to soil or damage them. •Apply seal glue on necessary place when assembling.

  • Page 146: Cab Front Panel

    Cab Front Panel Disassembly of the front bumper assy: 1.Remove the fixed bolt of front bumper. 2.Disassemble the connection device for right and left fog light. 3.Remove the bumper assy. 4.Disassemble the clip and bolt.. BF-2...

  • Page 147: Door

    Door Front Door Note: •When disassembling the front door, it is better to disassemble the cover at front side first. •After adjusting the door or door lock, check the door lock open and lock condit ion. BF-3...

  • Page 148: Instrument Panel

    Instrument Panel Note: •Before disassembling the instrument panel, switch off the power-supply. •e careful not to scratch pad and other parts. •These parts are made of plactic. Excessive force will damage them. Cab arrangement 1.Ignition lock 9.Fog light switch 2.Horn button 10.Heater switch 3.Combined light switch 11.Hazard warning light switch...

  • Page 149: Cab Interior Trims And Exterior Trims

    Cab Interior Trims and Exterior Trims Interiorl trims Side ard floor trims--Passenger area Note: •Wrap the tip of flat-bladed screwdriver with a cloth when removing metal clips from garnishes. Disassembly of the side inner trims: ① Disassemble the sun visor. ②...
  • Page 150 Door trims Disassembly of the door trims: ① Disassemble lock knob. ② Disassemble inside seal. ③ Disassemble inside handle escutcheon rear door). ④ Disassemble pull handle. ⑤ Pull out regulator handle. ⑥ Disassemble inner guard board of door (front door). BF-6...
  • Page 151 Roof trims Disassembly of the roof trims ① Remove part of headlining from corner and gradually peel headlining off. Cab Exterior Trims BF-7...
  • Page 152 ① Front upper cover ② Front lower cover and lower cover board ③ Side external cover board ④ Front and rear windows ⑤ Cab door seal strips ⑥ Door and window seal strips ⑦ Front pedal cover and pedal mat Cab Front Panel Grill BF-8...
  • Page 153 Front and rear window pane Cab door seal strip BF-9...
  • Page 154 Door outside molding BF-10...
  • Page 155 Pedal shield and pedal pad Welded left side panel assembly Clip assembly Plastic nut assembly Front bracket Outer cover assembly Buffering rubber nail Door lock dowel pin assembly 4.Pedal shield Door sealing strip assembly 5.Pedal pad BF-11...

  • Page 156: Seat

    Seat Note: •When assemble or disassemble the seat, it should be maintarined clean and well. Front seat BF-12...

  • Page 157: Cab Safety Belt

    Cab Safety Belt Notes: •If the vehicle in severely dashed in an accident, whatever the nature of the accident is, the belt assembly must be replaced. •If any part of the belt has quality problems, it must be replaced instead of repairing it. •If there is any cut, looseness or damage on the texture, etc., replace the assembly.

  • Page 158: Rear Mirror Outside Cab

    Rear Mirror Outside Cab 1.Handrail 5.Rear view mirror assembly 2.Handrail 6.Inside rear view mirror 3.Sun visor assembly 7.Dome glove box with roo lamp assembly 4.Outside rear view mirror bar assembly 8.Down view mirror assembly BF-14...

  • Page 159: Cab And Cargo Body

    Cab and Cargo Body •The following parts at least should be disassembled in the area of cab engine: 1)Main electric system and wire harness. •Sparate the engine part from steering transminsion device, brake system and clutch operation system. •The following parts at least should be disassembled in the area of cab: 1)Transmission system and steering control system.
  • Page 160 Cargo Body Installation Front board assy Main sill supporting base plate Left side board assy Left rear mudguard assy Right side board assy Buffer stopper Rear board assy Left locking device assy Locking bar assy Aixs pin Rubber gasket License fixing plate assy Rubber base plate 15.Left rear locking bar Left rear mudguard...

  • Page 161: Chassis Frame

    Chassis Frame Chassis Frame Chassis Frame Front bumper Engine rear mounting cross member assy Left side member 3rd cross member assy Front tow hook Cross member 1st cross member assy Shock absorber cross member assy Left gusset assy Cross member Right side member Cross member Right side member gusset plate assy...

  • Page 162: Heater

    Heater Heater Using of Heater Control panel 1.Change-over switch (no use) 2.Fan switch 3.Operating-mode chosen switch 4.Plug 5.Inside air circulation switch Fan switch There are five speeds provided, from 0 to 4. At 0 position, the fan stops, and the wind will become even stronger from 1 to 4 speed successively.

  • Page 163: Air Heater Parts Structure

    Heater Air Heater Parts Structure Left air pipe Air inlet duct assembly Air duct assembly Plastic nut assembly Middle air pipe Heater assembly Right air pipe assembly Blower assembly Defrosting pipe assembly, left door Heater control mechanismassembly Defrosting nozzle assembly Water inlet &...

  • Page 164: Special Service Tool

    Heater Special Service Tool As for the operating method please see the tool service manual for detail. BF-20...
  • Page 165 Electric System Harness Connector ..................EL-1 Standard Relay .................... EL-1 Fuse Wire and Fusible Link ..............EL-2 Battery ......................EL-2 Charging System ..................EL-4 Starting System ................... EL-5 Combined Switches ..................EL-6 Front Head Lights ..................EL-6 Combined Instrument Panel ..............

  • Page 166: Harness Connector

    Electric System Electric System Harness Connector All the terminals have been improved, which could prevent from loosening and disconnection. Terminals could be loosened by pressing and pulling lock parts. Note: Don't pull electric wire while disconnecting terminals. Example: Standard Relay Relay can be divided into three types:open, close and mixed.

  • Page 167: Fuse Wire And Fusible Link

    Electric System Fuse Wire and Fusible Link Fuse wire If the fuse wire is broken,the problem must be solved before replac- ing the fuse wire. Use proper fuse,do not use the fuse with much higher than rated value. Insert the fuse box correctly,do not slope it. Take off the fuse wire of the clock,if the vehicle is not used for long time.
  • Page 168 Electric System 3.Check the condition of battery charge Check the proportion of electrolyte periodically, carefully watch the charge state to prevent over-charging. Liquid level check Warning: Do not let the electrolyte touch with your skin,eyes,and painted surface.After touching the battery,you must clean your hands thoroughly.If acid liquid goes into your eyes, skin,and cloth,wash them right away with clean water for 15 minutes and seek some medical attention.

  • Page 169: Charging System

    Electric System Battery charging Charging per-fixed current 7.0A can be used for initial charging until average pressure of the single battery reaches to over 2.4V,then 3.0A can be changed for charging. If the pressure change of the battery is not over 0.05 V/h within 2 hours at the end of charging period,the proportion of the electrolyte does not change obviously,also taking temperature into consideration,then the battery can be regarded as fully charged.During the whole charging period, the temperature of electrolyte should be maintained around 20~40℃,taking the middle single battery measuring value as standard.

  • Page 170: Starting System

    Electric System Charging current too big: Adjusting pressure of adjuster too high. Battery internal short circuited. Charging current too small: Adjuster pressure value too low. Motor abnormal noise: Motor not well installed. Motor bearing worn and loose. Rotator and stator rub each other. Coils of rotate and stator cut circuited, diode cut and short circuited and electric appears.

  • Page 171: Combined Switches

    Electric System Combined Switches Replacement It is not necessary to dismount the combined switch base while replacing each switch. When dismount the combined switches, first dismount the connecting bolts. Front Head Lights Bulb replacement The front head light is half sealed, using a replaceable halogen osram lamp.The lamp can be replaced from the inner end without releasing off the whole head light assembly.

  • Page 172: Combined Instrument Panel

    Electric System Keep the vehicle and the tester at the same level. No load on the vehicle, except the driver (on place the same weight on the driver's seat). Low beam Switch on the low beam. Make beam-focus adjustment by adjusting screws. First tighten all the adjusting screws,and then loosen them to adjust.

  • Page 173: Windshield Washer And Wiper

    Electric System Windshield Washer and Wiper Disassembly of wiper Before disassembling, turn off the wiper switch. Disassembly Disassemble the wiper arm. Disassemble the lock nuts, washer and seal rubber shim. Disassemble the instrument assembly. Disassemble the left and right guide pipe and ventilating pipe. Prize the wiper connecting rod off the motor arm with a screw driver.
  • Page 174 Electric System Before reassembling the wiper arm,clean the core shaft as shown in the picture so that the arm will not be easily loose after assembling. Adjust the cleaner nozzle Adjust the cleaner nozzle with the tool as shown in the picture. Max adjusting range: 10°...

  • Page 175: Radio Cassette And Antenna

    Electric System Radio Cassette and Antenna Adjustmen of the antenna rod Adjust the antenna nutted rod under following condition: MW (AM) signal can't be received or very weak. After installing the new antenna, feeder cable, or radio, before the adjustment, check the connection of harness and antenna or feeder cable for correctness.

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