Jac Servicio HFC1020K-D134

WORKSHOP MANUAL
HFC1020K-D134
JAC International
2008.07
JAC Motors
WORKSHOP MANUAL Contents

Group
HFC1020K-D134 Code
Name Page
Foreword 01 General GE
02 Engine EN
This workshop manual was prepared as
reference to properly carry out servicing and 03 Clutch CL
maintenance on Jianghuai vehicles.
04 Transmission TR
The contents, pictures and technical parameters
this manual supplied are the latest data.
05 Transmission Shaft
Because of the continuously development and SHA
renewal of technique and products, there may
06 Rear Axle
be some difference between the explanation and RAX
the vehicles.
07 Front Axle
This shop manual was prepared for 4 x 2 Truck. FAX
Configurations as follows:
08 Steering STR
HFC1020K-D134 ， QC490Q engine ， LG5-20
transmission ， D120 rear axle(5.83). 09 Hydraulic brake SBR
Please inform Customer Service Department of
JAC International if there is any mistake, and 10 Suspension SU
you will be highly appreciated.
11 Electrical System ELE
12 Cabin CAB
General GE-1
Specifications
HFC1020K (D134) Specifications
高顶/半高顶型号 Model HFC1020K

High/Half Height Roof
驱动形式 Drive mode 4×2
Cab，tilt cab
结构区别号 Serious number D134
型号 Model QC490Q
排量(cc)Displacement 2545
发动机
Engine 最大输出功率（Kw/rpm）Max output
power 45.6/3200
最大扭矩（N.m/rpm) Max torque 152.4/2240
变速箱
Transmission LG5-20
驱动桥 Real axle 型号 Model
JAC D120-5.83 Axle
主参数外形尺寸（mm）Overall dimension 5090×1868×2100
Main parameter 轴距（mm）Wheelbase 2600
总质量（Kg）Mess weight 3330
车架断面尺寸
Frame section sizes(mm) 140×55×5
轮胎 Tire 6.50-15/6.50-16
General GE-2
HFC1030KR (D213) Specifications
高顶/半高顶型号 Model HFC1030KR

Cab，tilt cab
结构区别号 Serious number D213
型号 Model QC490Q
发动机
power 45.6/3200
变速箱
Transmission LG5-20
JAC D4-sg0-5.83 Axle
主参数轴距（mm）Wheelbase 2800
Main parameter
车架断面尺寸
轮胎 Tire 6.50-15/6.50-16
The above mentioned specifications are subject to change without prior notice.
General GE-3
HFC1020KL（DF4JC-seG）Specifications
高顶/半高顶型号 Model HFC1020KL

Cab，tilt cab
结构区别号 Serious number DF4JC-seG
型号 Model QC490Q
发动机
power 45.6/3200
变速箱
Transmission LG5-20
JAC D4-sg0-5.83 Axle
主参数轴距（mm）Wheelbase 2800
Main parameter
车架断面尺寸
轮胎 Tire 6.50-15
General GE-4
1.2 Vehicle Model：HFC4131KR1
Company Vehicle Type Main Code from

Product
Code Name Code Specifications company
Serial No.
Code
Company Code Name：HFC-----represents JAC motor

Vehicle Type Code：1---Cargo truck 2---Off-road vehicle 3---Dumper
4---Tractor 5---Special purpose vehicle 6---Passenger car
7---Sedan 9---Semitrailer
Main Specifications Code：25---represents the maximum gross weight is 25 tons.
Product serial No.： 1---Product development serial No.（1st change，2nd development）
Code from company：K---Diesel R1---King cabin
For example：HFC3251KR1 represents JAC vehicle with king cab, 25 tons maximum gross weight,
the first change.
General GE-5
1.3 VIN----Vehicle Identification Number

VIN comprises of 17 digits. They separately represent:
黑色
中国安徽江淮汽车股份有限公司制造
36.5
VⅠN L J 1 1 K D F A 4 4 0 0 0 2 5 2 1
2- O 3
品牌：江淮型号 R2
73
发动机型号额定功率 kW
总质量 kg 整备质量 kg
出厂编号出厂日期年月
119
125
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
L J 1 1 K D B C X 8 X X X X X X X
Sequence Number
Vehicle Description
Symbol
Assembly Plant
World Manufacturer Identification

Year
Check Code
General GE-6
1.4 The mechanic performance table of bolts in China

Quality Grade( mark) 6.8 8.8 9.8 10.9 12.9
Tensile strength limit σbmax(MPa) 600 800 900 1040 1220
Yield limit σsmax(MPa) 480 640 720 940 1100
Corresponding to Hyundai standards 4T 6T 7T 8T 10T

The number before the radix point represents one percent of the nominal tensile strength;
The number after the radix point represents ten times of the ratio of the nominal yield limit and
nominal tensile strength.
Clutch System CL-1
Clutch System
Overview
Precautions on clutch installation
General inspection and repair
Diagnosis and repair of common failures of clutch

Clutch System CL-2
Overview
The clutch is located at the rear end of the engine crankshaft, and its basic functions:
(1) Allow smooth connection of the engine with the transmission system, ensuring smooth
starting of a vehicle;
(2) Temporarily disconnect the engine from the transmission system, ensuring smooth gear shift
of the transmission;
(3) Use the sliding friction between driving and driven parts of the clutch to limit the max. torque,
preventing the transmission system from overload.
The clutch of the model is a dry single disc clutch, operated hydraulically with pneumatic booster.
Clutch assembly Driven disc assembly of clutch

Clutch System CL-3
Master cylinder
Slave cylinder
Clutch System CL-4
Major data and specification

Clutch type: Dry single disc diaphragm spring clutch
Outside diameter of driven disc (mm) Ф 254
Bore of general clutch cylinder X stroke (mm) Ф 19.05×35
Bore of working cylinder clutch X stroke (mm) Ф 26.99×19.05
Clutch pedal travel mm 160
Free travel clutch pedal mm 3— 5
Brake fluid DOT3 or DOT4

Clutch System CL-5
Precautions on clutch installation

1. Before assembly, confirm whether the clutch matches with vehicle model, one shaft can
be sleeved into driven disc; check whether there are grooves or objects on the fly wheel surface;
whether the release fork and guide shaft work normally; whether master cylinder, slave cylinder,
crankshaft and transmission leak oil or malfunction; whether release bearing seat can slide freely;
whether release bearing is lack of oil, stuck or damaged seriously, etc. Repair or replace it if the
situations above exist. At last, carefully remove foreign objects inside the fly wheel and the oil
stains on the fly wheel and clutch plate working surface.
2. When installing clutch, use special positioning spindle, etc.; note the size and direction of
positioning pin holes. When installing fixing screws, tighten them in a diagonal, alternative and
even way. When connecting the transmission to the fly wheel housing, check whether positioning
pins of the housing are in good condition; when inserting one shaft, pay attention to height, angle
and gear surface. Sticking is not allowed.
3. After installation, check and adjust the free travel of the clutch pedal, depending on
service manual of different models, so as to ensure that the clearance between release bearing
and release rod complies with provisions (adjustment not required for normally contact release
bearing mechanism).
4. It is prohibited to use a driven disc assembly with oil stains. Do not install a wetted driven
disc assembly.
Warning: Do not wash a release bearing pre-filled with lubricant in solvent, which may solve the
lubricant.
General inspection and repair

Driven disc rivet depth
Using a depth rule, measure the subsidence

from the rivet head to the friction surface,
including both sides. If the measurement is less
than the specified limit, replace the driven disc.
Subsidence of rivet head:
Limit: 0.2mm
Clutch System CL-6
Height and travel of clutch pedal

1. Loosen the locking nuts of the general clutch
pump pushrod.
2. Adjust the pedal by rotating the pushrod.
Clutch pedal height A: 160-180mm
Clutch pedal travel B: 160-170mm
3. Tightening torque of pushrod locking nut of
the master clutch pump 13 N·m
4. Re-install instrument
Adjust the free travel of the clutch pedal
1. Loosen clutch switch or pedal limit bolt.
2. Adjust clutch switch or pedal limit bolt until the
free travel of the clutch pedal is 3-5mm.
Air bleeding of clutch pipe

1. Apply parking brake.
2. Fill brake fluid to the oil storage pot to max. fluid
level. Take care whether there is brake fluid in the
oil storage pot during air bleeding.
3. Remove the rubber cap of the air bleeding
screw on the clutch slave cylinder, and connect a
plastic hose to the screw, with the other end of the
hose inserting into a transparent container
containing brake fluid.
4. Depress the clutch pedal several times
continuously and then keep it depressed.
5. With the pedal depressed, loosen the air
bleeding screw to discharge air, and then tighten
the screw.
6. Repeat the operations above until the air in the
pipe is completely discharged.
After completing air bleeding operation, fill the oil
storage pot with brake fluid to the “MAX”mark.
Clutch System CL-7
Diagnosis and repair of common failures of clutch

The following failures are common when a clutch is in service:
1. Clutch slipping
2. Poor disengagement
3. Clutch trembling
4. Unsmooth engagement
5. Abnormal sound
6. Oppressive clutch pedal
Here we will analyze these failure types item by item.
Clutch slipping
Failure description: low vehicle speed, slow acceleration, weak slope climbing, high fuel
consumption, etc. The main reason for these is that the clutch transfers smaller torque, or even
does not transfer torque.
Driving operation problem: the clutch pedal is not completely released, mostly semi-clutching,
overload running, climbing steep slope.
Slipping test method: Brake a vehicle with hand until it is braked completely. Depress the
clutch pedal, start the engine at gear shift 1, and then release the clutch pedal. If the engine can
stop, it indicates that the clutch works normally. Or there is slipping in the clutch. Disassemble it
and check it. There are several reasons as follows for clutch slipping:
(1) Driven disc assembly: Friction plate oiling, carbonization, burning, damage.
(2) Plate assembly: Diaphragm spring damaged, working surface of plate excessively
damaged, deformed, loose screws, over large runout of release rod end, improper diaphragm
spring force.
(3) Fly wheel: Working surface of fly wheel excessively worn, polished.
(4) Release mechanism: No clearance for release fork, no free travel for clutch pedal, and no
clearance for release bearing.
Repair method: Refer to the following orders for slipping repair according to the four reasons
mentioned above:
Step 1: Pay attention to driving method during driving process after confirming no clutch
Clutch System CL-8
slipping exists through slipping test method.
Step 2: After confirming clutch slipping exists through slipping test method, first check
whether the clutch pedal has free travel, and if so, whether the free travel meets requirements. If it
does not meet requirements, adjust it to the required range. If failure still exists, go to the next
step.
Step 3: Remove the transmission, and check whether the release sleeve and release fork
are stuck, and replace it if so. At the same time, check whether there is oil on the clutch. If so,
confirm oil source and repair it. Remove the clutch and check whether the clutch disc assembly is
too thick. Use a vernier caliper to measure its free thickness which shall comply with
manufacturer’
s requirements. Replace it if it is too thick. Check whether the friction plate is burned.
In case of slight burning, use coarse sand paper to grind it and use it again. In case of serious
burning, replace it.
Poor disengagement (hard to apply gear shift)

Failure description: poor disengagement of clutch causes hard application of gear shift, or in
worse condition, gear shift can only be applied by stopping engine.
Test method: in case of poor disengagement of clutch, confirm its release point and
engagement point through the following method:
1. Allow the engine to run at idle. (Transmission in neutral shift)
2. For the sake of safety, apply the hand brake and keep the foot brake depressed.
3. With the clutch pedal not depressed (clutch in engagement), slowly move the shift lever
toward reverse shift. When gear sound is heard, stop lever operation to keep the sound continue.
4. While keeping the sound continue, slowly depress the clutch pedal to locate the position
where the gear sound disappears. Such position is called “disengagement point”.
5. At this status, depress the clutch pedal until it is completely disengaged. With the shift
lever remaining unchanged, slowly release the clutch pedal and you will hear gear sound again.
Such position is called “engagement point”. If the release mechanism works normally, and
disengagement point and engagement point cannot be located, it can be judged that poor
disengagement of clutch exists.
Causes:
(1) Insufficient release travel of clutch pedal causes incomplete release of clutch.
Clutch System CL-9
(2) Driving disc of clutch cover assembly deforms, causing poor disengagement.
(3) Input shaft of the transmission rusts, which causes inflexible motion of the driven disc
assembly of the clutch on the input shaft and poor returnability.
(4) Transmission reasons: for example, over large self-locking force of gear shift causes hard
shift operation.
Repair method:
Step 1: Measure the free travel of the clutch pedal. If the release travel does not meet
requirement, adjust it and then confirm whether release works normally. If the failure still exists, go
to the next step.
Step 2: Remove the transmission and clutch, and check whether there are rusts on the
transmission input shaft and in the spline hole of clutch disc assembly. If so, remove the rusts and
apply an appropriate amount of lubricating grease (high-temperature resistant lubricating grease).
Check whether the guide bearing of the fly wheel rotates freely by rotating it with hand. If there is a
sense of sticking, replace it. Check whether there is deformation in the three groups of driving
discs in the clutch cover assembly. If there is, replace it. Before the transmission is installed, check
whether there is sticking or large operation force is needed by operating all gear shifts with hand. If
so, repair the transmission. In the above operations, if problems are found, repair it and then
re-confirm it after installation, until failure is eliminated.

Clutch System CL-10
Clutch trembling
Failure description: vehicle body vibration at a constant speed, at idle, at starting and at load.
Diagnosis method (operation order):
1. Allow the engine to run at idle, depress the clutch; place the shift lever to gear shift 2, and
release hand brake and foot brake.
2. Slowly release the clutch without depressing the acceleration pedal.
3. At this time, confirm whether the vehicle body vibrates.
4. Depress the clutch in the same way above, and place the shift lever to gear shift 3.
5. Slowly release the clutch without depressing the acceleration pedal.
6. At this time, confirm whether the vehicle body vibrates.
7. The methods above can be operated at cold status of engine and transmission, and at
hot status of engine and transmission after the vehicle runs for a period of time.
Note:
(1) Confirm whether the clutch trembles only at gear shift 2 and 3.
(2) Gear shift 1 is too light, and not suitable for diagnosis.
(3) Friction plate tends to burned at gear shift 4 and 5.
(4) If a vehicle starts at gear shift 3 without depressing the acceleration pedal, the engine
may stop sometimes. At this time, vehicle body vibration cannot indicate clutch trembling.
In case of clutch trembling, there is generally saw-shaped contact on the friction plate. Oil
on local friction plate surface may also cause trembling sometimes. Confirm the oil source and
repair it.
Clutch System CL-11
Unsmooth engagement
Failure description: when a vehicle starts, slowly release the clutch pedal, and gently depress
the acceleration pedal. The vehicle does not accelerate smoothly, but suddenly, shaking forward.
The basic reason is sudden engagement of pressure plate with friction disc.
Test method: with the clutch in full engagement, control throttle opening, accelerate and brake
the vehicle alternately at running status, and check for unsmooth engagement of clutch.
If trembling still exists, the clutch works normally, or otherwise the clutch trembles.
There are following reasons:
(1) Driven disc (steel plate) assembly: the friction plate contains oil stains and has other
substances, damping spring breaks or high friction coefficient of friction plate
(2) Cover (pressure plate) assembly: big diaphragm spring force enables instantaneous
engagement of the friction plate with the plate, which causes instantaneous slipping and trembling.
(3) Release mechanism: unsmooth operation of clutch pedal, unsmooth support of release
mechanism, and unsmooth release fork.
(4) Engine installation frame damaged, fly wheel installation loose, poor match of driving
system.
Clutch System CL-12
Abnormal sound
Failure description: there is an abnormal sound when operating the clutch at parking status.
The basic reason is: serious wear of parts due to long time of service causes sound produced from
abnormal friction or impact between metal parts. Therefore, such sound is generally clear.
Test method: allow the engine to run at idle, place the shift lever to neutral shift, apply hand
brake. If there is no abnormal sound when depressing the clutch pedal or releasing it after
depressing it to the full, the clutch works normally; or otherwise, the clutch produces abnormal
sound.
There are following reasons:
(1) Abnormal sound at disengagement of clutch: poor perpendicularity of fly wheel surface
and crankshaft; diaphragm spring worn, broken; support ring broken, falling; release bearing
containing oil lacking oil, burned or damaged; front shaft bearing of gearbox worn, burned or
damaged.
(2) Abnormal sound at engagement of clutch: spline hole or spline shaft over worn; damping
spring broken; driven disc hub rim damaged; loose rivet of driven disc assembly; hub loose in axial
direction.
(3) Random abnormal sound: damaged chips of clutch enters.

Clutch System CL-13
Oppressive clutch pedal

Failure description: oppressive foot clutch pedal, causing foot fatigue easily. There are
obvious differences in the clutch pedal compared with other vehicles.
Causes:
(1) Driven disc (steel plate) assembly: large wear (worn to the rivet of friction plate)
(2) The clutch rope, release fork and release sleeve have a sense of sticking, with inflexible
movement.
(3) Working surface of the fly wheel is worn seriously.
(4) The release bearing has a relatively big diameter and is excessively worn.
Figure 1 Figure 2
Repair method:
Step 1: Check whether there is sticking and inflexible movement in clutch pedal, rope,
release sleeve, and whether the clutch pedal returns normally.
Step 2: Verification of release bearing diameter: the diameter of clutch release bearing shall
comply with manufacturer’ s provisions. Measurement method: with the clutch being installed, use
a vernier caliper to measure symmetrically the contact wears on the release bearing and clutch
release rod, as shown in Figure1. If a release bearing that does not comply with specification is
used, replace it. On the other hand, confirm whether the release bearing is worn flat, as shown in
Figure2. If a release bearing is worn flat, and the wear surface at contact part of the release rod
end is enlarged, replace the release bearing.
Step 3: Check the clutch disc assembly, cover assembly and fly wheel for excessive wear.
Use a vernier caliper to measure disc assembly thickness. The wear of plate working end of the
cover assembly shall not be more than 0.2mm. Use a depth rule to measure fly wheel’ s installation
depth which shall comply with manufacturer’ s specified value. Replace those parts not complying
with size requirements, but take care to replace an individual part if it does not comply with
requirement, instead of replacing the whole set. (For example, if a clutch disc assembly is
excessively worn, replace the disc assembly only, not the cover assembly)
Transmission TR-1
Transmission (LG5-20)
Transmission TR-2
Transmission TR-3
Transmission TR-4
Transmission TR-5
Transmission TR-6
Transmission TR-7
Transmission TR-8
Transmission TR-9
Transmission TR-10
Transmission TR-11
Transmission TR-12
Transmission TR-13
Transmission TR-14
Transmission TR-15
Transmission TR-16
Transmission TR-17
Transmission TR-18
Transmission TR-19
Transmission TR-20
Transmission TR-21
Transmission TR-22
Transmission TR-23
Transmission TR-24
Transmission Shaft SHA-1
Transmission Shaft
Overview
Disassembly and assembly
Disassembly and reassembly of parts
Check and repair
Troubleshooting
Overview
The transmission shaft works to transfer the torque output by transmission to the driving axle. As
the transmission stays far from the driving axle, the transmission shaft is usually divided into 2 or 3
sections in order to avoid deformation or vibration caused during high speed rotation because the
shaft is too long.
The function of universal driving device is to transmit power between the 2 shafts with certain
angle and constant-changing relative position.
Intermediate Transmission Shaft Assembly
OD
Thinkness
Rear Transmission Assembly
Diameter
Cross Shaft
Diameter of Cross
Shaft Pin
Intermediate Support Assembly
Intermediate transmission shaft assembly

Outer diameter x wall thickness of the pipe Universal joint cross shaft
(mm) diameter (mm)
69×2.5 18.46

For the sake of safety, the transmission shaft should be lifted with a crane or other metal wires or
ropes before it is disassembled.
Disassembly sequence:
1. Bolts, nuts and spring washers, differential end
2. Bolts, nuts and spring washers
3. Rear transmission shaft assembly.
Note:
Since there is a dynamic balance requirement
for a transmission shaft, mark the connection
position before disassembly to facilitate
re-assembly.
1. Bolts, nuts and spring washers, differential

end
Torque (N·m): 46-62
3. Bolts, nuts and spring washers

Torque (N·m): 46-62
Disassembly of components
Disassembly sequence
1. Retainer ring of universal joint bearing
2. Needle bearing
3. Flange fork
4. Cross shaft
5.Sleeve spline pipe assembly
6. Rear axle transmission shaft tube assembly
7. Dust cap
8. Oil seal
9. Spline pipe
Check and repair
Apply grease
Universal joint of the transmission shaft and
sliding socket (GB492 calcium base lubricating
grease).
Needle bearing
Strike the flange top to take out the needle
bearing.
Cross shaft
Visual Check
Needle bearing
Check the parts below for wear, damage and
Buffer rubber
other abnormal conditions.
Spline pipe assembly
Flange fork
Bearing
Align and assemble the spline shaft and spline

fork as indicated by the arrow.
Proper installation of spline shaft

Correct
Incorrect
Put up a stake on the nut.
Cross shaft
Install a grease nozzle on the cross shaft in the
specified angle.
Needle bearing
Insert the cross shaft on the flange fork. Using a
wrench with soft surface, install the needle
bearing into the fork.
1) Always use new retainer rings of universal
joint bearing
2) After fitting a baffle ring, check it for proper
position.
Troubleshooting
Vibration of transmission shaft
1. Failure symptom
When the car runs at certain speed, serious vibration occurs to the car body, and there may
be serious vibration noises of the door and steering wheel.
2. Causes
(1) The transmission shaft is assembled improperly, where the universal joint forks on the
two sides are not in the same level.
(2) Transmission shaft is bended or deformed.
(3) Transmission shaft is depressed or the balancing patch is dropped.
(4) Intermediate support bearing, bracket rubber gasket or spacer is worn and loosened.
(5) Needle bearing of the cross shaft is worn and loosened or broken.
(6) The spline teeth and spline keyway of the extension sleeve is fitted loosely.
3. Failure diagnosis and elimination
(1) If during running, the car has periodic abnormal knocking and vibration which tend to
become more serious when the speed increases, assembly marks should be inspected for
alignment. If marks are not aligned, they should be reassembled.
(2) If the assembly marks are correct, balancing patch should be inspected to check whether
it’
s dropped or whether the transmission shaft tube is depressed. If the balancing patch is dropped
or shaft tube is dropped, they should be repaired.
(3) If the balancing patch is in good condition, then tension the parking brake, rotate the
transmission shaft tube from side to side by holding it with both hands. If any quiver is felt, each
connecting bolt should be inspected to check whether they are loosened. If yes, they should be
fixed. Inspect the transmission shaft spline fit to check whether it is loosened and repair or replace
it if so.
(4) If the result of the above check is good condition, the transmission shaft should be
disassembled and checked whether it’

s bended and deformed. It should be corrected if bending or
deformation exists.
(5) Check the cross shaft and needle bearing to see whether they are worn and loosened or
broken. Repair or replacement should be made at any failure with the requirements.
(6) If constant vibrant noise occurs during the running of the car, hold the intermediate
transmission shaft to swing it radial after shutting down the car, to check whether the tighten bolts
of the intermediate support bracket are loosened, bearing is worn and loosened, rubber gasket
and separating collar have excessive radial clearance. Repair or replacement should be made at
any failure with the requirements.
(7) If good condition can be concluded from the above checks, the intermediate transmission
shaft should be disassembled for check. It should be corrected if bending or deformation exists.
There is abnormal noise on transmission shaft.

1. Failure symptom
Knock sound occurs during the start or running of the car, and becomes more obvious when
the speed of the car changes.
2. Causes
(1) The transmission shaft is assembled improperly, where the universal joint forks on the
two sides are not in the same level.
(2) The cross shaft of the universal joint is assembled too tightly.
(3) Connections of the universal driving device are loosened.
(4) Intermediate support bearing, cross joint needle bearing is insufficiently lubricated, worn
or loosened.
(5) Spline teeth of the transmission shaft and flange spline keyway are worn and loosened,
or the transmission output spline teeth and flange spline keyway are worn and loosened.
(6) The fit of intermediate support bearing and intermediate transmission shaft journal is
loosened.
(7) Transmission shaft is bended, depressed or the balancing patch is dropped.
3. Failure diagnosis and elimination
(1) Inspect the universal joint fork on both sides of the transmission shaft to check whether
they are in the same level. If installed improperly, they should be reassembled.
(2) Inspect the bolts at the connections of universal driving device to check whether they are
loose, and if yes, fasten them.
(3) In case of sound connection, apply the parking brake, examine by rotating the
transmission shaft with both hands, and check the cross shaft fitting for over tightness or lack of oil
if significant resistance is felt and make adjustment or repair if necessary. Rotate the transmission
shaft, and if it feels loose, check the bearing for serious wear or damage, check the spline teeth
and spline keyway of extension sleeve for over wear, and make repair or replacement if necessary.
(4) Check the fitting of intermediate support bearing and intermediate transmission shaft
journal, and if loose, repair or replace the bearing.
(5) If abnormal noise remains after above checks, disassemble the transmission shaft to
check it for bending, depression or dropped balancing patch, and if yes, repair the transmission
shaft.
Rear Axle RAX-1
Rear axle
Summary
Rear Axle RAX-2
Summary
Main data and specifications of rear axle

Item
Half-shaft bearing type Full-float type

Drive and driven gear type Hyperboloid gear
Drive and driven gear clearance（mm） 0.18－0.25
Drive gear bearing preload
（without oil seal）（kg） 1.3－2.2
Differential bearing preload（kg） 1.5－2.6
Lubricating grease number of single wheelhub （g） 280
Dosage of lubricating oil（Litre） 3
Rear Axle RAX-3
Tightening torque
Rear wheel hub （kg．m）
33— 43
9.5— 11.6
Rear Axle RAX-4
Main retarder and differential （kg．m）
16---20 15---17
14.5---17.5
7---9
9--11
30---35
Rear Axle RAX-5
Disassembly
1. Wheel assembly 2. Half shaft 3. Exterior oil seal 4. Locking washer
5. Bearing nut 6. Wheel hub and brake drum assembly 7. Exterior bearing
8. Inner oil seal 9. Inner bearing 10. Wheel hub, brake drum
Rear Axle RAX-6
Important works
I. Dismantle rear axle half shaft
1. Dismantle bolts and nuts of half shaft
2. Knock half shaft flange end surface lightly

with copper hammer until half shaft has been
loosened.
3. Screw bolts to thread hole of flange plate

until flange plate has left its position, then
take out half shaft.
II. Dismantle wheel hub and brake drum

assembly
1. Dismantle locking washer
2. Dismantle locking nuts of wheel hub bearing
Note:
Dismantle adjusting nuts with wheel hub
bearing nut-adjusting wrench.
Rear Axle RAX-7
3. Dismantle wheel hub and brake drum

assembly.
Note:
Use wheel hub puller to dismantle
III. Dismantle and install the bolts and

nuts of wheel
Thread turning direction of tyre bolts and
nuts on right wheels is right.
Thread turning direction of tyre bolts and
nuts on left wheels is left.
Note: Distinguish the direction in
disassembly and re-assembly process
to avoid any mistake.
IV. Dismantle and install the nuts in bolts

of wheel hub and brake drum assembly
Tightening torque of the nuts in bolts of

wheel hub and brake drum assembly:
30--36 kg. m
Make three mark pegs on each nut after
re-assembly screw to avoid any loose.
Rear Axle RAX-8
Inspection and repair
If there is any abrasion, damage or any other abnormal situation in checking process, it is
necessary to repair or change parts by requirement.
Visual inspection
Wheel bearing、oil seal、wheel hub、 Check whether there is any abrasion, damage or any
brake drum、 other abnormal situation about parts on left side.
axle shell ventilation plug assembly
Concentric degree limit of half shaft 1．0mm

Rear Axle RAX-9
Reassembly
Reassembly sequence
1. Wheel hub, brake drum 2. Inner bearing 3. Inner oil seal 4. Exterior bearing
5. Wheel hub and brake drum assembly 6. Bearing nut 7. Locking washer
8. Exterior oil seal 9. Half shaft 10. Wheel assembly
Rear Axle RAX-10
Important works
1. Dosage of lubricating grease on each side wheel hub is
280 gram, after spreading inner and exterior bearing,
complete surplus lubricating grease should be spread on
middle part of wheel hub evenly.
2. Adjustment of wheel hub bearing preload

Screw bearing nut until wheel hub is immovable or heavy,
then unscrew bearing nut back for 1/6— 1/8 rings,
measured preload tangential pull on tyre bolts is 3— 5. 5
kg.
3. Fix locking washer

If convex pin of locking washer could not head
thread stop slot of positive half shaft sleeve, reverse
locking washer; if it could not head after reversal all the
time, it is necessary to turn bearing nut by requirement.
4．Wheel
Tightening torque of wheel nut 33— 43kg．m
shim
and
engine oil level
level Dosage of changed rear axle gear oil（reference）3 litres
Leakage plug
Rear Axle RAX-11
Main retarder
2
Disassembly sequence 1. Transmission shaft 2. Half shaft 3. Main retarder assembly
Assembly sequence 1. Main retarder assembly 2. Half shaft 3.Transmission shaft
Important works
Dismantle main retarder assembly
1. Dismantle the nuts on main retarder shell
2. Screw the bolts into thread hole of main

retarder shell, and turn the bolts to loosen main
retarder assembly.
Rear Axle RAX-12
3．Use transmission jack to move main retarder

assembly.
Assembly
Tightening torque of fixed nuts of main retarder
shell 6－8 kg．m
Tightening torque of transmission shaft

assembly 7--9kg．m
Rear Axle RAX-13
Main retarder
Disassembly
1. Main retarder shell assembly 2. Locking sheet 3. Bearing cap
4. Adjusting nut 5. Exterior loop of differential bearing
6. Differential assembly 7. Drive gear assembly
8. Adjusting washer of drive gear bearing saddle
9. Retainer plate of guiding bearing 10. Exterior ring of guiding bearing
Rear Axle RAX-14
Important works
1．Before disassembly, make assembly marks on

Adjusting bearing cap and main retarder shell to avoid any
mark mistake.
Adjusting mark
2．Before adjusting the nuts, make assembly

marks on adjusting nut and bearing cap
3 ． Before dismantling the adjusting nut, it is
necessary to unscrew fixed bolts of bearing cap
at first.
left
4．Left and right mark of bearing cap, adjusting

nut and inner and exterior bearing ring should be
placed independently to avoid mixed assembly.
5．Get through differential assembly with a proper

stick, and lift differential assembly with hand or
crane.
Rear Axle RAX-15
Disassembly of differential assembly
1. Differential right shell 2.Half shaft gear 3. Thrust washer of half shaft gear 4.Thrust
washer of planetary gear 5. Planetary gear 6.Cross shaft 7.Driven gear, half shaft gear
and differential left shell
Important works
To install left and right shell of differential on
original position in re-assembly process,
adjusting mark make adjusting marks on left and right shell
body before dismantling differential shell.
Rear Axle RAX-16
Disassembly of drive gear assembly
７
６
４
1. Flange nut 2. Flange plate 3. Drive gear bearing saddle 4. Bearing space cover and
adjusting washer 5. Drive gear, inner bearing and guiding bearing 6. Oil seal of main gear
7. Inner loop of exterior bearing
Important works
1. Flange nut
Fix drive gear assembly on table vice, and
dismantle flange nut with lengthened wrench.
Rear Axle RAX-17

If there is any abrasion, damage or any other
Gear, Bearing. oil seal, abnormal situation in checking process of those
parts on left side, it is necessary to repair or change
parts by requirement.
differential shell, drive small
Visual inspection Check whether there is any
gear shell abrasion, damage or any other abnormal situation
about those parts on left side
Change driven gear

1．Place drive gear together with driven gear all
the time.
2．Tightening torque16--20kg．m。 When

installing driven gear, add loose-proof glue on
the thread of bolts and the thread hole of driven
gear,
then screw the bolts to regulated torque.

Rear Axle RAX-18
Clearance between cross shaft and

planetary gear
Limit 0.2mm
Clearance between half shaft gear and

differential shell
Limit 0.2mm

half shaft spline
Limit0.5

planetary gear
Limit 0.2mm
Rear Axle RAX-19
Drive gear assembly
Reassembly
Reassembly sequence
1. Inner ring of exterior bearing 2. Oil seal of main gear 3 . Drive gear, inner bearing and
guiding bearing 4. Bearing space cover and adjusting washer 5.Drive gear shaft bearing
saddle 6. Flange 7. Flange nut
Rear Axle RAX-20
Important works
Clean inner part of dustproof cover, and
spread a sheet of lubricating grease.
Spread a sheet of engine oil on sliding

Lubricating surface of main gear oil seal.
grease oil
Adjustment of main gear bearing preload

1. Adjust main gear bearing preload by
increasing/decreasing adjusting washers.
2. Without installing main gear oil seal,

measured tangential force on bolt hole of
bearing saddle is 1, 3-2.2 kg.
After adjusting main gear bearing

preload, operate by following steps:
1.Dismantle flange and install oil seal.
folding space
sheet
2. Install flange, then after screwing flange

nut with 30— 35 kg. m torque, make two
mark pegs on the nut.
Rear Axle RAX-21
Differential assembly
Reassembly
Reassembly sequence:
1.Driven gear, half shaft gear and differential left shell 2.Cross shaft 3.Planetary gear
4.Thrust washer of planetary gear 5.Thrust washer of half shaft gear 6. Half shaft
gear 7.Differential right shell
Important works
1. Find adjusting marks on the equipment.
adjusting
mark 2. Abandon original fixed bolts and nuts, and
install new ones.
Make two mark pegs on each nut after
screwing.
Torque 14．5－17．5kg .m
Rear Axle RAX-22
Main retarder
Reassembly
Re-assembly sequence：
1. Exterior ring of guiding bearing 2. Retainer plate of guiding bearing
3. Differential assembly 4. Exterior ring of differential bearing
5. Adjusting nut 6. Bearing cap 7. Adjusting washer of drive gear bearing saddle 8.Drive
gear assembly 9. Locking sheet
Rear Axle RAX-23
Important works
1．Adjustment of differential bearing preload
Screw fixed bolts on bearing cap to torque

5kg．m，and adjust left and right adjusting nut
to adjust side bearing preload. Measured
tangential pull on fixed bolts is 1.5－2.6 kg.
2．Inspection of driven gear deflection

Deflection limit measured on negative surface
of driven gear is 0.2 mm.
3．Adjustment of clearance between drive and

driven gear side
Measure on four positions placing along

round ring of driven gear, and measuring
head of micrometer should be vertical with the
surface of measured point.
Clearance between drive and driven gear side

is 0.18— 0.25 mm.
Rear Axle RAX-24
4．Drive gear bearing saddle
Screwing moment of fixed bolts on drive gear

seat: 9－11kg．m
5．Adjustment of mesh mark of drive and driven

gear Correct mesh mark is that shown in left
figure, and the mark locates at small end of high
and middle part of driven gear occupying over
60% of gear surface. Correct mesh mark is
adjusted by increasing/decreasing adjusting
washers of drive gear bearing saddle and
adjusting washers of differential bearing, just
Correct gear liking that in following table.
contact To guarantee adjusted differential bearing
preload is unchangeable, screwed ring number
of one end adjusting nut should be equal with
that number on the other end adjusting nut.
Lastly, fix locking sheet.
6．Fix bearing saddle

After getting correct gear mesh mark, screw the
bolts of bearing cap, its tightening torque is
17— 20kg．m.
Rear Axle RAX-25
Contacting mark of
Reason Adjusting step
driven gear
1．Adjust driven gear close to
drive gear.
Drive gear is too

close to driven gear 2．Adjust drive gear apart from
driven gear
Driven gear root (increase adjusting washers)
1．Adjust driven gear apart

from drive gear.
Drive gear is too
apart from driven 2．Adjust drive gear close to
gear driven gear
(decrease adjusting washers)

Driven gear top
1．Adjust drive gear apart from

driven gear.
Driven gear is too
(increase adjusting washers)
close to drive gear
2．Adjust driven gear apart
from drive gear.
Driven gear small end
1．Adjust drive gear close to
driven gear
Driven gear is too
apart from drive (decrease adjusting washers).
gear
2．Adjust driven gear close to
Driven gear big drive gear.
end
Front Axle FAX-1
Front Axle
Overview
Technical parameters
Check items for front axle in use
Check and repair
Front wheel hub and brake hub
Front axle and steering knuckle
Troubleshooting
Front Axle FAX-2
Overview
The front axle supports and transfers front weight of a vehicle to the tyres, and is a part of the
steering system and brake system. To keep a vehicle stable during driving, the front axle shall
have a proper wheel alignment.
The front axle of the model is H-beam front axle that bears load as a whole.
Toe-in (B-A)
Kingpin Inclination & Wheel Camber Kingpin Caster
In front of vehicle
Kingpin Caster
Kingpin Inclination
Wheel Camber
Angle
Angle
In front of
vehicle
Ensure straight driving direction Reduce tyre sliding and

Convenient for steering and be convenient for steering wearing
Front Axle FAX-3
Vehicle model
Item
Wheelbase
Calibration of front wheel:
Toe-in (mm) 4~6 (bias tyre) 1~3 (radial tyre)
External inclination of front wheel (°) 1°±45'
Kingpin caster angle (°) 1°30'±1°
Kingpin inclination angle (°) 7°
Steering angle:
External steering angle (°) 35°
Internal steering angle (°) 42°
Amount of grease for front wheel hub bearing:
One side (g) 220±10
Pre-tightening of front wheel hub bearing:
New bearing (N) 17～31
Used bearing(N) 14～28
Front Axle FAX-4
Check items for front axle in use

A front axle (non-driving steering axle) consists of front shaft, steering knuckle, kingpin, bracket
and wheel hub, etc. The front shaft is an H-shaped forged part, and both of its ends are connected
to the steering knuckle via a kingpin, forming a hinge joint. There is a thrust bearing under the front
shaft ends respectively.
Steering knuckle Check

For a steering knuckle, mainly check its root and journal for crack and wear. If there is a crack, be
sure to replace it. Do not run a vehicle with a failure to avoid serious accident. The wear of steering
knuckle bearing journal shall not exceed 0.05mm.
Front axle Check

The front axle tends to deform due to bending stress and twisting moment when a vehicle runs.
Deformation occurs generally at the external side of steel spring seat. Replace it if deformation is
found.
Check of clearance between kingpin and lining

The tolerance clearance between the kingpin and lining exceeds 0.16mm, replace the kingpin and
lining. Large tolerance clearance between the kingpin and lining may cause the front wheel to swing
and unstable direction, and may also cause damage of such parts as steering knuckle. When the
kingpin wear reaches 0.1mm, replace the kingpin.
Check of thrust bearing

The thrust bearing of the front wheel will not be damaged generally if it is well maintained and
lubricated in service. Fill grease every time the vehicle runs across water. It is preferable to fill the
amount of a half grease gun. If the front wheel gives out noises when the steering wheel is turned
and the steering gear oscillates, normally the thrust bearing is damaged and it shall be replaced.
Front Axle FAX-5
Check and Repair
Adjustment of the wheel alignment

1. Measurement and adjustment of toe-in
(1) Lay the front wheel on a flat place.
(2) Use chalk to mark the centre position of tyre.
(3) Put the toe-in measuring instrument on the
centre position of the tyre.
(4) Measure the distance (A) between tyre centre

lines in front of the vehicle.
(5) Push the vehicle backward or forward, rotating
every wheel by 180°.
(6) Measure the distance (B) between back tyre
centre lines of the front wheel according to the
original mark.
The toe-in is equal to B minus A.
If size of the toe-in is incorrect.

(7) Loose the clamping bolt of connecting joint.
(8) Use pipe spanner to rotate the connecting rod
and adjust the toe-in.
Front Axle FAX-6
2. Turning radius
(1)． Put a piece of wood with the thickness
equal to the turning radius measuring instrument
under the rear wheel.
(2)． Put the front wheel on the measuring
instrument and ensure it is located at the center of
the instrument.
(3)． Rotate the front wheel clockwise and
anticlockwise respectively to the maximum.
Note: depress the brake pedal when rotating the
front wheel.
Turning Angle of inside wheel
Turning Angle of outside wheel
If the angle doesn’ t match, adjustment should be
made.
Adjustment steps:
(1)． Loosen the lock nut of the adjustable bolt
on the steering knuckle.
(2)． Adjust the height of the bolt until the turning
angle meets the requirements.
(3)． Tighten the lock nut.
external inclination of front wheel 3. Other front wheel alignment parameters
kingpin caster angle (1)． Disassemble the front wheel hub cover.
main pin
(2)． Install front wheel alignment parameter
inclination
F measuring instrument on the steering knuckle head.
angle
Calibrate the turning angle of the front wheel to 0.
(3)． Measure the front wheel alignment
parameters as shown in the figure.
4. If the obtained parameters don’ t match, Check

following relevant parts :
·Whether the front steel plate spring is soft.
·Whether the front H beam is deformed.
·Whether the kingpin, kingpin bushing, bearing is
over-worn.
Measurement of sideslip
The measurement of sideslip shall be done after the
Front Axle FAX-7
measurement of the toe-in and kingpin caster angle

and the process of adjustment.
(1) Keep the wheel rolling across the sideslip
measuring instrument as slowly as possible. Read
the readings on the sideslip measuring instrument.
(2) If the slipping value is over 5mm per meter, the
front wheel alignment shall be re-adjusted.
Front Axle FAX-8
Front Wheel Hub and Brake Hub

Disassembly
1. Wheel 2. Hub cover 3. Cotter pin, slotted nut 4. Gasket 5. Wheel hub and brake
drum assembly 6. Wheel hub oil seal seat 7. outer bearing 8. inner bearing oil seal 9.
inner bearing nut 10. inner bearing hub 11. outer bearing hub12. Brake drum 13. Hub
14. Tyre bolt 15. Inner bolt of the tyre
Main operation steps of disassembly

Apply the parking brake and jack up the front axle.
1. Disassemble the wheel.
2. Disassemble the wheel hub cover.
Note: DO NOT damage the contacting surface of the

wheel hub cover.
Front Axle FAX-9
3. Disassemble the cotter pin and the slotted nut.
4. Use a drawing tool to disassemble the wheel

hub and brake drum assemblies.
5. Disassemble the outer bearing cup.
1. Wheel hub. Check and repair

2. Wheel hub bearing, and oil seal. Visually check whether there are damaged or
3. Steering knuckle groove. defective components listed on the left side to check
if there is any damage or failure.
4. Brake drum.
5. Brake shoe, liner, etc.
Front Axle FAX-10
Main operation steps of installation
Apply grease with the quantity as shown in the

figure.
Inside the wheel hub 220g
Inside the wheel hub cover 40g
Grease
Adjust the preloading degree of wheel hub bearing
Firstly adjust the clearance between braking liners.

Use wheel hub nut to adjust the preloading of
bearing.
Measure the stress at the wheel bolt to make sure it
is within the range specified by the standard.
Reassembly
The installation is performed in the reverse order of
the disassembly.
Front Axle FAX-11
Front axle and steering knuckle

Disassembly
1. Tie rod assembly 2. Steering elbow arm 3. Steering knuckle arm 4. Kingpin upper cover
5. Locking bolt 6. Kingpin lower cover 7. Kingpin 8. Steering knuckle assy 9. Adjusting shim
10. Thrust bearing 11. H-beam
Main operation steps of disassembly:

Apply the parking brake and jack up the front axle.
Use push tool to disassemble the tie rod assy.
Front Axle FAX-12
During the disassembly of steering elbow arm, put a

brass bar under the steering elbow arm and knock
the arm with a heavy punch.
Disassemble the locking pin.
H-beam Steering knuckle

Check and repair
Steering knuckle arm Tie rod Kingpin
Visually check whether there are damaged or
Thrust bearing Adjust pad and liner
defective components listed on the left side to check
Tie rod ball head
if there is any damage or failure.
Check and repair the H-beam

Kingpin or measuring stick Insert kingpin or measuring stick into the H-beam
Thin thread hole.
Positioning bolt holes of Stretch a thin thread through the center of the stick.
leaf spring. Observe whether the H-beam thin thread is aligned to
the two positioning bolt holes of leaf spring.
Observe from one side to check whether the two

kingpins or measuring sticks are aligned.
Front Axle FAX-13
Observe whether the surface of kingpin hole is

deformed or worn.
Observe the wearing status of the steering knuckle

surface. Careful check is specified at the location
pointed out by arrow in the figure.
Use magnetic flaw-detecting machine to detect flaws.
The contact area

should be more than
3/4 of the total area. Use the method of color marking to inspect the
contact between steering knuckle arm, steering
elbow arm and ball head conical surface.
The contact area should be more than 3/4 of the total
area.
Otherwise, relevant parts should be replaced.
Measure the clearance between the kingpin and

kingpin bushing.
The clearance should be less than 0.15mm.
Otherwise the bushing should be replaced.
After the replacement, if new bushing is inserted too

tightly, a reamer can be used to carefully machine the
inner surface of the bushing.
Front Axle FAX-14
The concentricity of the connecting rod is 1mm.
Main operation steps of installation

Housing
Upper
Appropriate volume of grease should be applied to

the thrust bearing before its installation.
Lower side
Note: DO NOT install at the wrong direction.
Measure the clearance between the steering knuckle

and H-beam and select a washer of appropriate
thickness.
The standard clearance after the installation of
washer is 0 –0.1mm.
When installing kingpin, attention should be paid to

ensure the notch on the kingpin is aligned to the
locking bolt hole.
The steering knuckle should be able to work
smoothly after grease is applied.
Install the locking bolt and tighten it to specified

torque.
Front Axle FAX-15
Use an appropriate cylindrical stick to load kingpin

cover.
Install steering knuckle arm, steering elbow arm and

tighten them to specified torque.
Tighten tie rod ball head to specified torque.
Reassembly
The reassembly is performed in the reverse order of
installation.
Front Axle FAX-16
Troubleshooting
Phenomenon Causes Solutions
Replaced with kingpin
Kingpin wear
bushing
Clearance between kingpin and bushing is too
Replace
large
Wheel hub bearing is stuck, worn or does not
Adjust
rotate smoothly.
Replace the tie rod fitting
The wheel alignment is inaccurate
assy.
The ball joint pin of tie rod fitting is over-worn Adjust
Steering wheel
Tighten to the specified
vibration The filled air pressures of tyres are unequal
torque
The tightening slotted nut of steering knuckle Tighten to the specified
arm and tie rod arm are loose torque
The tightening nut of tie rod ball joint pin is Tighten to the specified
loose torque
The tightening nut of the front suspension Use the thrust gasket for
frame U bolt is loose adjustment
The vertical clearance between steering
Be replaced as kingpin assy.
knuckle and front axle is too large
Clearance between kingpin and bushing is too
large Replaced with kingpin
The thrust bearing is stuck, worn or hard to be bushing
The steering wheel is turned
hard to be turned The filled air pressures of tyres are
Fill tyres with air
inadequate
The wheel is not aligned Adjust
The kingpin lacks lubrication grease Fill grease
Steering wheel cannot The front axle component is over tightened Adjust
return The wheel alignment is inaccurate Adjust
The steering wheel The adjustment of turning angle is wrong Adjust the turning angle
cannot turn The tie rod is bended. Replace
The dimensions of left and right tyres are not Use the tyres with the same
the same dimension
The outer diameters of left and right tyres are Use the tyres with the same
different outer diameter
Running deviation
The air pressures of tyres are not the same. Adjust
The front axle is bended. Replace
One side of the front wheel spring has
Replace
decreased elasticity or gets broken.
Front Axle FAX-17
Adjust or replace the front

The wheel alignment is inaccurate
axle
Uneven abrasion or The dimensions and types of left and right Use the tyres with the same
early abrasion of the tyres are different dimension or type
front wheel tyres Uneven pressure on tyres Adjust
Interchange the tyre
Improper treatment on tyres
positions
Power Steering PS-1
Power Steering
Technical Data
Tightening Torque
Disassembly and Assembly of Steering Wheel, Shaft and Column
Oil Change
Free Rotating of Steering Wheel
Air Bleeding
Installation of Steering Gear
Drag Link
Failure Diagnosis
Power Steering PS-2
Technical Data
Diameter of steering wheel mm 410

Clearance mm 10～60
Steering shaft type Dual cross shaft
Vertical (°) 40
Adjustable range
Front & Rear (°) 60
steering gear type
Steering ratio 18.85:1
Maximum working pressure 10.3MPa
Oil pump flow (8-11) L/min
Working temperature (-40～+120)℃
Output torque 1580N·m
Output swing angle ±46°
Total turns of steering wheel ≥4.8
Load of front axle 1.5T-2.5T
Power steering fluid Automatic Transmission Fluid (ATF)
Lubricant for steering gear Apply power steering fluid
Power Steering PS-3
Tightening Torque
Steering gear, pitman arm and drag link
Code Tightening torque (Nm)

1 90-110
2 250-280
3
4
5
6

1
2 90±15
Power Steering PS-4
Disassembly and Assembly of Steering Wheel, Shaft and Column
Disassembly steps: Assembly procedures:

1. Steering shaft cover 7. Steering column
2. Horn button 6. Steering shaft assembly
3. Steering wheel 5. Tilt adjuster
4. Start switch assembly 4. Start switch assembly
5. Tilt adjuster 3. Steering wheel
6. Steering shaft assembly 2. Horn button
7. Steering column 1. Steering shaft cover
Power Steering PS-5
Disassembly
Disassembly of horn button:

Pull out the horn button by hand.
Disassembly of steering wheel:

Alignment Marks
When drawing marks, hold the steering wheel
and the steering shaft crosswise to ensure all
parts can stay in the original positions during
assembly.
Disassembly of start switch assembly:

1. Loose the fastening screw
Power Steering PS-6
2. Remove the clamp spring by caliper
3. Dismantle the wire harness
Removal of the tilt adjuster:

1. Remove the tilt adjuster, and the tightening
bolt on the bracket of steering column
2. Tilt the steering column, and dismantle the

tilt spring
Disassembly of steering shaft:

Draw an alignment mark on the yoke and worm
Alignment Marks
shaft, remove the bolt, and then pull out the
flange yoke from worm shaft
Power Steering PS-7
Disassembly of parts between steering shaft

and steering column:
Pull out the steering shaft from steering column
Disassembly of parts between spline shaft and

spline tube:
Before disassembly, draw an alignment mark
across the spline shaft and spline tube, so as to
ensure these parts can be reassembled at
original position
Check
Check and repair:

Clean the disassembled parts, and check each
part carefully
Check steering shaft:

1. Check the steering shaft for bent
2. Check the yoke for cracking, distorting, and
check the associated parts of the yoke for
abnormal noise
3. Check for abnormal noise of the spline
when rotating the steering shaft
Note: this yoke can not be repaired
Check steering column:

1. Check the steering column for serious
distortion
2. Check the shaft sleeve for wearing or aging
Power Steering PS-8
Oil Change
Change of power steering oil:

1. Jack up the front wheel of the vehicle to
make it off the ground
2. Disconnect the steering gear, oil storage
pot, and oil pipe of the oil storage pot
3. Rotate the steering wheel for several turns
in two directions, and then discharge oil of
the hydraulic system
Change of hose:
Change hose every twice when the oil has been
changed
Power Steering PS-9
Free Rotating of Steering Wheel

Check free rotating of steering wheel:
1. Front wheels are straight ahead, and the
steering wheel should be turned from left to
right till the front wheel starts to rotate; then,
the measured value can be used as free
rotating movement
Free rotating movement of steering wheel:
10~30mm
Regulate free rotating of steering wheel:

1. Make the front wheel straight ahead
2. Loose lock nuts, and adjust the adjust
screw
3. Turning the adjust screw clockwise, the
clearance will decrease; turning it
counterclockwise, the clearance will
increase
4. When free rotating movement is reached,
tighten the lock nut to required torque
Note: before regulating free rotating movement
of steering wheel, clearance of steering
shaft and yoke, etc. shall be checked. If
these parts are in normal conditions, utilize
adjusting screws on the device to adjust
the backlash.
Power Steering PS-10
Air Bleeding
Bleeding of power steering pipes:
1. Fill oil into the oil storage pot, jack up the
front wheel of the vehicle to make it off the
ground, rotate the steering wheel slowly to
make it lock against two direction for
several times.
2. Start the engine idling for 2-3 minutes.
3. Rotate the steering wheel to make it lock
against two direction for several times.
4. Rotate the steering wheel counterclockwise
to lock it, and then loose the oil connector to
release air. Repeat this operation until the
air bubbles totally disappear.
5. Turn the steering wheel clockwise to lock it,
and continue air bleeding operations.
6. Lower the front wheels, and rotate the
steering wheel in the two directions on
condition that the engine runs at a medium
speed. If no abnormal noise is heard in the
process of steering operation, it can be
considered that air is exhausted completely.
7. If abnormal noises are heard, keep on
turning the steering wheel until the
temperature reaches 60 - 80℃ and keep
the engine running for approximately 10
minutes and then repeat the air bleeding
procedures.
8. After air bleeding, inspect whether there is
any leakage of the steering device and
pipes.
Note: during the air bleeding operations, always
check the oil level inside the storage pot and
add engine oil as necessary to maintain the
normal oil level.
Check the oil level of power steering gear:

Turn down the cover of storage pot from the
power steering gear and check the fluid position
of engine oil on the level gage.
Installation of Steering Gear

1. Locate the steering shaft in the center of the steering gear and joint it with intermediate
transmission shaft, then install the steering gear mounted with arm onto the longitudinal frame
beam, check whether the rubber gasket is intact, install rubber gasket and tightening screw,
tighten the tightening screw to place the steering gear at the center.
2. Connect the steering elbow arm with the ball joint of the drag link.
3. Connect the fuel pipe to the steering gear and tighten all oil pipe joints.
4. Put power steering fluid into the storage pot of the pump, and exhaust the air inside the
system.
Note:
① During the installation of steering gear, avoid causing the deformation of other parts,
especially the column. The column, transmission shaft, elbow arm, drag link should not be
interfered and can rotate freely.
② Attention should be paid when connecting the oil tube, and there are “ ”and “ ”marks at oil
inlet and outlet of the steering gear; otherwise, the steering gear will be damaged.
Additionally:
1. Because of the complicated structure, compact parts, high inner cleanliness requirements of
the steering gear, the installation processes of all parts should be performed with strict training and
operations, inaccessible for common users, thus users are not allowed to decompose it by
themselves.
2. Because the steering gear is applicable to certain load, excessive load is forbidden; otherwise
it will cause insufficient assisting force.
3. As collision may cause damages to the steering gear, the steering gear should be timely
inspected to check whether there is crack or whether it feels well, and should be checked in
required maintenance and repair station if necessary, otherwise steering accident will occur.
Drag Link
Disassembly steps: Assembly procedures:

1. Cotter 5. Straight drag link
2. Nut 4. Nut
3. Cotter 3. Cotter
4. Nut 2. Nut
5. Straight drag link 1. Cotter
Disassembly
Removal of straight drag link:
Use special tool to remove straight drag link
Check and repair:

Ball joint dust cover, thread,
cone surface Correct or replace by new parts if there are
worn, damage or other abnormal situations
found during checking.
Assembly of pitman arm:

Align with the alignment marks during assembly
Alignment Mark
(cut groove)
Assembly of universal joint:

Align the marks made before removal and
disassembly.
Failure Diagnosis
1. Diagnosis of the main failures of power steering gear
No. Phenomenon Possible causes Repair method
(1) Low fuel level, gas entering (1) Add power steering fluid as per
1 The steering force into the oil circuit. requirements.
increases (2) The belt of the oil pump (2) Stretch or replace the belt.
instantaneously when slips. (3) Replace the steering oil pump.
turning the steering (3) Leak of the oil pump is (4) Replace the steering gear.
wheel left or right serious.
quickly. (4) Leak in the steering gear is
serious.
(1) Add oil as per requirement.
When the engine is (1) The oil level is low. (2) Adjust tension according to the
2 working, steering, (2) The belt of the oil pump is provisions.
especially steering in loose. (3) Calibrate clearance.
the original place, will (3) The steering linkage hits the (4) Inspect the pump pressure (A
cause the steering bottom shell of the engine at pressure test is necessary). If
wheel to quiver or the extreme position. the relief valve is damaged,
vibrate. (4) The pressure in the oil replace it.
pump is insufficient. (5) Check whether the flow control
(5) The flow control valve of oil valve of the oil pump is stuck,
pump is blocked. and replace oil pump if
necessary.
No. Phenomenon Possible causes Repair method

(1) Fuel the tank and then conduct
(1) There is air in steering gear. steering operation to remove
3 The steering wheel (2) The steering bar system is air. Check hose joint for its
is over-returned or loose due to over wear. tightening torque and adjust it if
loose (3) Engagement clearance of the necessary.
sector gear is too big. (2) Replace the loose joints.
(4) Steering gear is loose. (3) Take off the steering gear from
the vehicle for adjustment.
(4) Tighten the bolts to the
specified tightening torques.
Judgment of (1) Oil pipe joint is loose or (1) Tighten or replace oil pipe joint.
4 steering gear leak damaged (2) Replace the seal of steering
(2) External leak of steering gear. gear.
Power steering fluid Air mixed in the oil. Remove air.
5
produces milk foam
2 Oppressive steering
2.1 Failure and analysis
Failure is that the driver feels oppressive in steering the vehicle to the left or to the right during
driving and feels no sense of returning. When the vehicle runs at low speed and turns, it is very
oppressive to turn the steering wheel, or even it cannot be turned. Reasons for the failures
include:
① Steering shaft bent and deformed or too deep dent in pipe column which causes impact.
② The pre-tightening force of bearing of the steering worm in the steering gear is too big.
③ The engagements between threaded rod and nut, and between sector gear shaft and rack, are
too tight.
④ Lack of oil in the steering gear
2.2 Diagnosis and elimination
1) Support the front axle. If steering operation is free, failure occurs to the front axle, tyre or other
parts.
2) Support the front axle. If steering operation is oppressive, failure occurs to the steering gear
or transmission mechanism.
① Remove the steering arm. If steering operation is free, failure occurs to the transmission
mechanism (check all joint pins and adjust them if necessary. Whether thrust bearing is
damaged or lack of oil. Check whether drag link is bent and damaged. Check whether the hub
bearing is too tight.) Replace or adjust it.
② Remove the steering arm. If steering operation is still oppressive, failure occurs to the steering
gear itself (check whether there is lack of oil, impact sound produced when steering, whether
the steering gear bearing is over pre-tightened, and the engagement clearances between
threaded rod and nut, and between sector gear shaft and rack, are too small).
③ Disassemble the steering gear and check whether the elbow arm and the sliding clearance
are too tight, and whether there is damaged part, etc.
3 Steering wheel clearance is too big

3.1 Failure description: vehicle steering or road sense is not sensitive, steering wheel clearance
exceeds the specified value; though the steering wheel turns much, wheels do not deflect, or the
steering wheel does not turn, but wheels deflects automatically, which produces “snake
movement”.
3.2 Check and elimination
⑴: Steering check: cooperation of two persons is required. One person turns the steering wheel
on the vehicle while the other observes the elbow arm. If the elbow arm does not swing when the
steering wheel turns much, it indicates that failure occurs to the steering gear.
① Gently swing the steering wheel and feel there is a sense of loosening. It means the steering
wheel and shaft are loose. Adjust the clearance.
② Hold the steering wheel and push and pull it in the axial direction. If there is a sense of
loosening, it means the threaded rod and bearing of the steering gear are loose. Adjust it.
③ If there is obvious impact sound when turning the steering wheel to the left or to the right, it
means the engagement clearances between threaded rod and nub of the steering gear, and
between sector gear shaft and rack, are too big (in case of a transmission mechanism with a
universal joint cross shaft, check whether the spline of the shaft and universal joint bearing are
loose).
⑵ Transmission mechanism check: cooperation of two persons is required. One person turns
the steering wheel on the vehicle while the other observes the elbow arm and the wheels. If the
wheels do not deflect when the elbow arm turns much, it indicates that failure occurs to the
transmission mechanism.
4 Hard returning of the steering wheel

Failure analysis and elimination: check the steering gear and the steering transmission device are
not properly assembled and adjusted, each part is tightly fit or in poor lubrication condition, which
increases friction forces between moving parts. Eliminate the failure by adjusting the clearances of
parts or applying lubricant.
5 Oil leak
If oil leak is found during use,
⑴ Check whether oil seals at the sector gear shaft and upper cover are damaged. Replace them
if they are damaged;
⑵ Check whether oil leaks from side cover. If so, remove the side cover of the steering gear,
apply anaerobic adhesive between the side cover and the housing, and then assemble them
together.
⑶ Check whether oil leaks between the upper cover and the housing. If so, remove the upper
cover of the steering gear, apply anaerobic adhesive between the upper cover and the housing,
and then assemble them together.
6 Malfunction of steering or with abnormal noise

If steering malfunction or abnormal noise is found during use, check whether there is damaged
guide pipe, steel ball runs out of the pipe, and steel ball is broken. Replace the steering threaded
rod and nut assembly.

Service Braking SBR-1
Service Braking
Overview
Tightening torque
Main braking cylinder
Vacuum booster
Troubleshooting
Overview
The service braking system of this model is 2-circuit hydraulic system, the brakes of which are all
drum brakes.
Front brake assembly Rear brake assembly

(two leading shoe) (dual two leading shoe)
Vacuum booster
Sketch of braking system tube line (with exhaust braking)
Connectors of steel pipe

Connectors of hose
Vacuum hose
Flexible hose
Vacuum steel pipe
Brake tube
Rubber hose
A. Brake fluid pot;B. Assembly of vacuum booster with tandem main braking cylinder
C. Five-way joint; D. Wheel cylinder of the front brake; E. Three way fuel pipe; F. Wheel
cylinder of the rear brake; G. Vacuum pump; H. Three way vacuum tube I. Exhaust brake;
J. Exhaust braking solenoid valve; K. Vacuum cylinder; L. Connecting board of vacuum tube.
Technical parameter
Brake
Position of brake Front Rear
Style Two leading shoe Dual two leading shoe
Brake drum ID (mm) 280 280
Length (mm) 307 307
Friction plate size
Width (mm) 64 64
Free length (mm) 208.0 208.0
Brake shoe
Design length (mm) 224.0 224.0
Return spring
Design load (N) 225～275 225～275
Less than 0.05 at the rivet, less than 0.2 on the
Clearance between friction plate and brake shoe
side,
(mm)
and less than 0.3 at the end
Main braking cylinder
ID (mm) 31.75
Piston stroke (front cavity + rear cavity) (mm) 18+15.5
Vacuum booster
Assistance force ratio
Brake pedal
Stroke (mm) 35
Free stroke (mm) 5-8
Wheel cylinder of the brake
Front Rear
ID (mm) 30.16 30.16
Tightening torques
Tightening torques of the connection of braking pipeline:

Tube type Tightening torque(Nm)
 tube 4.76 16-20
 tube 6 23-27
 8 27-33
 10 45-53
 12 59-67
 15 63-67
 Nylon tube 12 46-62
Front brake (two leading shoe)

1
2
3
4
Rear brake (dual two leading shoe)

1
2
3
4
Inspection and Repair

Adjustment of wheel brake
1. Insert a screwdriver into the adjusting hole; turn
at the direction shown by the arrow to adjust the
screw until the wheels start braking.
2． Turn backward the adjust screw; use a plug
gauge to check the braking clearance at the
inspection hole, and 0.25 –0.4mm will work (turning
backward for approximately 5 –9 teeth).
Adjustment of brake pedal
Use adjustable bolt to adjust the height of brake

pedal. Then adjust the free stroke of the pedal to 5 –
8mm by rotating the vacuum booster push rod.
Return spring must not be removed during the
adjustment.
Air bleed of braking line

The level of brake fluid inside the brake fluid pot
Air discharge vent
should be kept at a certain value during the air
bleed.
Air bleed procedures
1． Make the brake pedal move up and down for
several times until certain resistance is felt, then
step on the pedal. Loosen the bleeder screw for air
bleed, and then tighten the bleeder screw.
2． Repeat the above operations until the air in the
pipeline is completely vented.
3． Add the brake fluids to the oil storage pot to the
mark of “MAX”.
Remove old friction liners

Rivet new friction liners
Brake drum (mm)

Note: If the ID of the brake drum increases caused
by wearing or grinding, the friction liner with bigger
size should be used.
Standards Limit
ID 280 281.5
Dis-alignment ≤0.1
Apply lubricating grease on the adjusting screw

before reassembly.
Check friction plate for abnormal wearing.

Depth limit of rivet holes limit 0.5mm
Main Braking Cylinder
1. Clip 2. Oil intake 3. Captive screws 4. Washer 5. Rear piston 6. Front piston
7. Pump body
Clean all parts before reassembly.

Also, pay attention to clear out the compensate
opening.
Apply brake fluid on the surface of the piston

before loading piston assembly into the pump
body.
Vacuum booster
The performance of vacuum booster directly influences the brake effect, thus the sealing property
and boosting effect of vacuum booster should be examined.
(1) Examination and repair of vacuum booster

1) After the engine is shut down, depress the brake pedal with force for several times to
eliminate the negative pressure remaining in the booster.
2) Step on the brake pedal to keep it at the brake position and start the engine to make negative
pressure regenerated in the inlet pipe. If the brake pedal tends to lower, it indicates the booster is
in good performance and effective, otherwise it indicates the vacuum booster is in poor
performance or failure.
3) For failed booster, its assembly should be replaced. During the replacement, the negative
pressure inside the intake manifold of the engine should be completely released.
(2) Sealing inspection

After the engine gets started, increase its speed to 1,500r/min and immediately release the
accelerator pedal, then shut it down for approximately 90s. Quickly depress the brake pedal, after
which intake noise should be heard around the pedal and will be heard again after a quick
repeated depressing, indicating good sealing property. Otherwise, the performance of negative
pressure pipe and check valve should be inspected, and repaired timely if there is any abnormal
condition.
Troubleshooting
The brake cannot work effectively.
Abnormal Check the brake Normal
Check brake fluid Check the performance
Abnormal Normal Normal Abnormal
Check the hose on the

Replace brake Check brake drum and booster
fluid friction plate
Normal Abnormal
Abnormal Normal
Check brake wheel Repair and replace Replace damaged

Replace parts, cylinder booster parts
adjust brake
Abnormal Normal
Replace necessary Adjust

Braking drag
Check free stroke and

pedal reserve of the
brake pedal
Abnormal Normal
Check clearance of service

Make necessary
braking friction plate and
brake pedal stroke
Normal Abnormal
Make necessary
All wheels dragged One wheel dragged
Check the main Check clearance of service

brake cylinder for braking friction plate and back
blocked return hole stroke movement of shoes
Abnormal
Check brake wheel Adjust clearance or

cylinder for jammed replace return spring,
piston etc.
Noises of brake
Clean parts
Check installation status and friction surface of friction plates

The brake doesn’

t work.
Check the free stroke of brake pedal

Abnormal Normal
Check braking
Check brake fluid
Abnormal Normal
Abnormal Normal Check main Clean or

cylinder for jam replace
Add brake fluid and Check brake braking
exhaust air from the fluid for pipeline
pipeline leakage
Replace parts
Abnormal Normal
Replace necessary Check brake drum and

parts friction plates
Abnormal
Replace necessary parts Adjust brake

Braking deviation
Check the wear on the

tyre side
Abnormal Normal
Check wheel
Replace parts
positioning
Abnormal Normal
Adjust and repair Check braking pipeline for

leakage
Abnormal Normal
Replace necessary parts Check the

performance of brake
wheel cylinders
Abnormal
Normal
Check friction plates of

brake drum
Abnormal
Normal
Check return spring of brake
Abnormal
Replace or repair parts

Parking Brake PBR-1
Parking Brake
Overview
Check and repair of parking brake
Parking brake system
Parking brake
Relevant adjustments of parking brake

Parking Brake PBR-2
Overview
The parking brake works to keep reliable parking of the car, prevent car from sliding, make it easy
to start uphill, and perform emergency braking in association with service braking device or
perform secondary braking in case the service braking device fails.
The parking brake of this model is a machine-controlled internal tension drum brake, installed on
the back part of the transmission casing. The control pull wire of parking brake is in the cab,
connected to the control handle of parking brake.
Technical parameter
Parking brake
ID (mm) 178
Brake drum
Wear limit diameter （mm）
Length (mm) 193
Friction wafer size Width (mm) 35
Thickness (mm) 5.0
Clearance between brake drum and friction liner （mm） 0.5
Spring No. First Second
Brake shoe Free length (mm) 62 49
return spring Designed length (mm) 70 57
Design load (N) 108～132 90～110
Parking Brake PBR-3
Check and repair of parking brake

1. Check the parking brake for potential damage, and replace it if there is.
2. Knock and visually check the brake drum and replace it with new one if crack occurs.
Replacement should be made if the wear exceeds the use limit;
3. Check the brake shoe for crack, and replace it with new one if crack exists. Replace loose rivet
of liner with new one and re-rivet. If liner surface is checked to be closer than 0.5mm to rivet head,
the liner should be replaced with the same processes as drum wheel brake.
4. Brake shoe should be replaced with new one if the its return spring tension is obviously
weakened or crack, damaged oil seal occurs, resulting in defective sealing or serious wear of pawl
mechanism making it unable to lock reliably.
Insufficient braking force of the central drum brake
No. Causes Measures

1 Dirty liner or exposed rivet, etc. Replace
2 Excessive clearance between liner and brake drum Adjust
3 Rough surface of brake disc Trimming
4 Inappropriate adjustment of the length of brake pull wire Adjust

Parking Brake PBR-4
Parking brake system

Disassembly
1. Control handle of parking brake 2. Control wire of parking brake 3. Parking brake drum
4. Flange 5. Parking brake
Note during disassembly:
Loosen the adjusting nut ① to remove the

control pull wire from the handle.
Loosen the nut ② to remove the handle.
Parking Brake PBR-5
Parking brake
Disassembly
1. Pull rod spring
2. Return spring
3. Regulating unit
4. Adjusting spring
5. Second brake shoe and lever assembly
6. First brake shoe assembly
7. Compressive bar
8. Control wire assembly
Thickness of friction liner
Measure the thickness of brake liner with a

caliper.
If the thickness is less than 1mm, the brake
shoe assembly should be replaced.
Measure the inner diameter of brake

drum with a caliper.
If the inner diameter exceeds the
limit, the brake drum should be
replaced.
Parking Brake PBR-6
Relevant adjustments of parking brake
Adjust the clearance of brake friction liner
Use a screwdriver to turn the adjusting device

upward until the brake drum is locked out, then turn
the adjusting device back about 25 teeth. Now the
clearance between brake drum and friction liner is
approximately 0.5mm.
Opening direction
调整螺栓
Adjust bolt of制动蹄张开方向
the brake shoe
Brake
制动鼓shoe
Brake
制动蹄 drum
Adjust
调整工具 tool
Clearanc
间隙
Adjust the parking brake control handle
Completely pick up and push down the parking

brake control handle several times.
Loosen the lock nut of pull wire.
Adjust the lock nut to meet following requirements:
Pick up the handle with approximately 15kgf, with the
handle moving 5 –8 teeth.
Suspension SU-1
Suspension
Front suspension
Overview
Technical parameter
Disassembly
Reassembly
Front shock absorber assembly
Failure diagnosis of front suspension
Rear suspension
Overview
Technical parameter
Disassembly
Reassembly
Rear shock absorber assembly
Failure diagnosis of rear suspension

Suspension SU-2
Front suspension
Overview
Suspension SU-3
Technical parameter
Front suspension
Spring type Semi elliptic leaf spring
Length mm 1140
Width mm 60
Rubber bushing with flange pin
Front Mount
Pin type
Pin diameter mm 22
Metal-rubber bushing with flange pin
Rear Mount bushing type
Pin type
Pin diameter mm 22
Shock absorber type Double acting hydraulic cylindrical shock absorber
U bolts tightening torque N·
m
Suspension SU-4
Disassembly
1 Front shock absorber 2 U bolts3 Lug pins 4. Fixed pin 5 Leaf spring
Preparatory Work
Brace the rear wheel, raise the car and then jack up
the front axle.
Suspension SU-5
1. Front shock absorber

Disassemble the shock absorber assembly, nuts, washers
and bearing pads according to diagrams, and be careful not
to damage them.
2. U bolts
(1) Loosen (not remove) U bolts and nuts
(2) Raise the vehicle and support it on the chassis
bracket
(3) Remove U bolts and nuts.
3. Shackle pin.
Attention shall be paid to avoid damaging the thread and

spur surface of leaf spring pin
Suspension SU-6
4. Fixing pin.
Attention shall be paid to avoid damaging the thread and

spur surface of leaf spring pin
Leaf spring assembly Buffer Inspection and repair

Leaf spring clampShock absorber If over-wear or damage is found during the check, repair
Central bolt Rubber liner service shall be made or the components shall be replaced
U type bolts as necessary.
Fixing pin
Lifting lug pin Visual Inspection
Make a visual inspection for parts at left side; change the

damaged parts in case any damage or failure occurs.
shock absorber
1. Check the shock absorber for leakage, and slight
leakage is allowed.
2. After the vehicle traveled for a certain period, check if
the temperature of shock absorber was increased; if the
temperature does not increase, it is indicated that the shock
absorber is out of order and should be replaced.
3. Draw the shock absorber; if there is a litter resistance,
the shock absorber is out of order, and should be replaced.
4. Check liners at two sides of the shock absorber for
wearing conditions, replace with new ones if they are badly
worn.
Change of leaf spring
Identification
Code
1. Before disassembling the leaf spring, make marks on
the transverse plane of the leaf spring for installation.
2. Smear the grease over two sides of leaf spring.
3. Use the bench lathe during disassembly and
reassembly.
4. Do not use the disassembled the central bolt, and
replace it with a new one.
When changing the leaf spring, use the leaf spring with “A，
B,C”marks indicating same arc height.
Suspension SU-7
Central bolt
Tightening torque for the central bolt: 34-44N·

m
Measure the clearance between liner and pin of leaf spring.

If the clearance is more than 1mm,
The liner or pin of leaf spring should be changed.
Change the liner of the leaf spring

Rotate by hands to pull out and insert the liner of leaf spring.
Suspension SU-8
Reassembly
1 Leaf spring 2. Fixed pin 3 Lug pins 4 U bolts 5 Front shock absorber
Assembly
Front side Rear side
Leaf spring assembly

The installation directions of leaf spring should be
same as that of original state.
Suspension SU-9
Nut
U bolts
(1) Park the vehicle on the level ground, and install U
bolts at corresponding positions of the leaf spring.
(2) Raise the vehicle.
(3) Align the front axle holes and U bolts.
(4) Apply oil to nuts before tightening so as to

prevent their threads from damaging.
(5) Tighten nuts.

torque.

Nuts, gasket and rubber bearing pad
Disassemble the shock absorber assembly, nuts,
washers and bearing pads according to diagrams.
Suspension SU-10
Style Double acting hydraulic cylindrical shock

absorber
Maximum outside diameter of liquid ￠45
receivers (mm)
Compressed length (mm) 335
Stretched length (mm) 555
Suspension SU-11
Failure diagnosis of front suspension
Car body bouncing
Road test car
Noise produced with specified intervals Noise produced without specified
Change tyre
Check the tyre for balance
Normal Abnormal
Adjust
Normal Abnormal
Adjust or change
Check the liner of suspension
Normal Damage
Change
Check the nut and screw of the suspension
Normal Loosen or damaged
Tight or change
Suspension SU-12
Harsh noises of the tyre
Check tyre for alignment
Norm Abnormal
Adjust
Check steering joint shaft and steering

transmission rod
Normal Deformation
Change
Check the fixing bolt of the suspension
Norm Loose
Tighten
Check pressure of the tyre
Norm Abnormal
Adjust
Suspension SU-13
Tyres are over-worn or partly worn
Check tyre pressure
Normal Abnormal
Adjust
Check wheel for alignment
Normal Abnormal
Adjust
Check the bearing of wheel
Normal Failures
Change
Check the brake regulator
Normal Abnormal
Adjust
Check rotating conditions of the tyre
Normal Dead
Rotate the tyre with recommended intervals
Methods for checking the driving
Normal Unstable or incorrect
Driving with more stable driving force

Suspension SU-14
Breakage of springs
Loads
Check lug and guide pin
Normal If the nut is loose Worn or damaged
Normal Change
Check the U bolt
Normal Check bolt and nut Damaged
Normal Change
Check shock absorber
Normal Oil leakage Liner Bracket Worn
Change Worn Breakag Change
Change Change
Check the liner of spring
Normal Worn or broken
Change
Check the central bolt
Normal Loose Damage
Normal Change
Suspension SU-15
Car body inclination
Check spring
Normal Rust Weakening or breaking of spring
Clean Change
Check lug pin and liner
Normal Inadequate lubricating Worn or broken
Apply grease
Check steel plate gasket and U bolt
Normal Bolt loosen Breakage
Tighten
Wearing or breaking of liner
Normal Change Check fixed bracket
Normal Damage
Change
Suspension SU-16
II. Rear suspension
Overview
Suspension SU-17
Technical parameter
Rear lifting
Spring type Semi elliptic leaf spring
Length mm 1,250
Width mm 70
Front Mount bushing type Rubber bushing with flange pin
Pin type
Pin diameter mm 25
Rear Mount bushing type Metal-rubber bushing with flange pin
Pin type
Pin diameter mm 16
Shock absorber type Double acting hydraulic cylindrical shock absorber
Suspension SU-18
Disassembly
2
4
5
1
1 Rear shock absorber 2 U bolts3 Lug 4.Leaf spring pins5 Leaf spring
Preparatory Work
Brace the front wheel, raise the car and then jack up
the rear axle.
Rear shock absorber

Loosen the shock absorber, install nuts and then
remove the shock absorber.
Suspension SU-19
2. U bolts
Loosen the U bolts, lift up the vehicle; use chassis to
support the vehicle and remove U bolts, then remove
rear axle assembly.
3.Lug
Loosen lug pin nuts, disassemble lug plate and lug
pins.
4. Leaf spring pins

Use a jack to lift the leaf spring assembly, remove
the nuts and move the bolts out.
Attention shall be paid to avoid damaging the thread

and spur surface of leaf spring pin
Inspection and repair:

Visual inspection: If any wear, damage or any other
abnormal conditions are found during inspection,
repair it or replace parts according to the actual
condition.
Leaf spring assembly Shock absorber Visual Inspection

Leaf spring clampBuffer Visually check left side part s for wear, damage or
other abnormal conditions.
Central bolt Rubber liner
U type bolts auxiliary rubber spring
gasket
Leaf spring pin
Shackle pin
Suspension SU-20
Other inspection and repair steps are in the same

manner with front suspension frame.
Change of leaf spring
1. Before disassembling the leaf spring, make
Setting mark marks on the transverse plane of the leaf spring for
installation.
2. Smear the grease over two sides of leaf spring.
3. Use the bench lathe during disassembly and
reassembly.
4. Do not use the disassembled the central bolt,
and replace it with a new one.
When changing the leaf spring, use the leaf spring
with “A, B, C”marks indicating same arc height.
Measure the clearance between liner and pin of leaf

spring.
If the clearance is more than 0.4mm,
The liner or pin of leaf spring should be changed.
Change the liner of the leaf spring

Use special device to disassemble and install leaf
spring bushing.
Suspension SU-21
Reassembly
5
1
Reassembly sequence
1 Leaf spring Leaf spring pins 3 Lug 4. U bolts and nuts 5 Front shock absorber
Assembly
The installation directions of leaf spring should be

same as that of original state.
U bolts
(1) Park the vehicle on the level ground, and install U
bolts at corresponding positions of the leaf spring.
(2) Raise the vehicle.
(3) Align the front axle holes and U bolts.
(4) Apply oil to nuts before tightening so as to
prevent their threads from damaging.
(5) Tighten nuts.
Suspension SU-22

torque.
Torque （N· m） 157-196
Apply lubricating grease after the installation.

Nuts, gasket and rubber bearing pad
Disassemble the shock absorber assembly, nuts,
washers and bearing pads according to diagrams,
and be careful not to damage them.
Tighten nuts till matching surfaces of the washer and

the bearing end contact with each other
Type Double acting hydraulic cylindrical shock

absorber
Max OD of the liquid resorvior (mm) ￠45
Compressed length (mm) 336
Stretched length (mm) 556
Suspension SU-23
Failure diagnosis of rear suspension
Car body inclination
Check spring
Normal Rust Weakening or breaking of spring
Clean Change
Check lug pin and liner
Normal Inadequate Worn or broken
Apply grease
Check steel plate gasket and U bolt
Norm Bolt loosen Breakage
Screw tight
Wearing or breaking of liner
Normal Change Check fixed bracket
Normal Damag
Change
Suspension SU-24
Shortened clearance with the earth
Check loading condition
Leaf spring
Check leaf spring
Normal Breakage
Change
Check the Clip
Normal Loose Worn or damaged
Screw tight Change
Check the liner
Normal Deterioration or breakage
Change
Lubricating conditions
Normal Inadequate lubricating Over lubricating
Add grease Remove redundant grease
Check if the nut is loose
Normal Loosen Damaged or broken
Screw tight Change

Suspension SU-25
Car body bouncing
Road test car
Noise produced with specified intervals Noise produced without specified intervals
Change tyre
Normal Abnormal
Adjust
Normal Abnormal
Adjust or change
Check the liner of suspension
Normal Damage
Change
Check the nut and screw of the suspension
Normal Loosen or damaged
Tight or change
Electrical System ELE-1
Electrical System
General
I . Operation table
II. Electric diagram identification
1. Wire code identification:
2 . Electrical component identification:
III .Electrical designations and usages of the complete vehicle
1. Battery
2. Starter
3. Generator
4. Speed sensor
5. Electric preheating
6. Fuel cutoff solenoid valve
7. Wiper
8 .Washer
9. Headlamp
10 .Front small lamp
11. License lamp
12. Direction signal lamp and hazard warning lamp
13. Rear combination lamp
14 .Reversing lamp and switch
15. Interior lamp and switch 150
16. Brake lamp and switch
17. Parking brake lamp and switch
18 Fog lamp and switch
19. Electric horn
20. Vacuum alarm
21 .Various relays
22 .Combined switches
23. Combined instrument
24 .CD player
25. Idle speed boost device
26. Exhaust brake controller
27. Electrical device
General
I . Operation table
12 V
4DA1-1 4DA1
Battery 6-QA-100D B B
Speedometer B B
Thermometer B B
Instrument Fuel meter B B
Two abnormal shape crystal
B B
Headlamp headlamps
Fog lamp B B
Speedometer B B
Thermometer B B
Fuel meter B B
Illuminator Meter board B B
Direction indicator and hazard
B B
lamp
Far beam indicator B B
Parking brake indicator B B
Brake liquid level indicator B B
Heating plug indicator B B
Oil pressure indicator B B
Indicator and caution Exhaust brake indicator B B
lamp Water separator indicator B B
Brake lamp and reversing lamp B B
Interior lamp Three level lamp changes B B
Intermittent wiper B B
Cigarette lighter B B
Horn B B
CD player and stereo
B O
radio cassette player
Buzzer Vacuum warning buzzer B B
Warm air and air conditioner B O
Manually-operated door and window B B
Motor-driven door and window O O
Note: B: Standard equipment O: Optional
II. Electric diagram identification

1. Wire code identification:
Specifications and colors of wires on the wiring diagram are distinguished by different
codes. As different countries use different color codes for the wires, JAC product
users and maintenance personnel should identify the wires according to Wire Color
Code in Electric Maintenance Manual of JAC automobile.
E.g.: 1.5GR
1.5----------Section of wire conductor is 1.5 mm2
G-----------Color of insulating layer is green
R-----------Color strip is red
Wire conductor section -Insulating layer ground color Color strip
1.5 G R
Color strip
Ground color
Cross-section area
Color codes of cables
Vinylon insulated wire

Application circuit
Black - white Black- yellow Black- red
Black (B)
Starter motor (BW) (BY) (BR)
White- red White- black White- blue White-
White (W)
Charging circuit (WR) (WB) (WL) Green (WG)
Red- white Red- black Red- yellow Red- green Red- blue
Red (R)
Lamp circuit (RW) (RB) (RY) (RG) (RL)
Green-
Green- white Green- red Green- Green-
Green (G) orange
(GW) (GR) yellow (GY) black (GB)
Signal circuit (GO)
Yellow- red Yellow- black Yellow- Blue -
Yellow (Y)
Metering circuit (YR) (YB) black (YB) yellow (LY)
Blue- white Blue- black Blue-
Blue (L) Blue- red (LR)
Wiper circuit (LW) (LB) orange (LO)
Lamp green Lamp green - Lamp green -
(Lg) black (LgB) red (LgR)
Brown- white Brown- red Brown-
Brown (Br)
Miscellaneous (BrW) (BrR) yellow (BrY)
2 . Electrical component identification:

Electrical components in the JAC automobile electrical diagrams are indicated in
common general signs. Refer to Common Automobile Electrical Signs for details.
Battery unit Fuse Relay Flasher Button

switch
Solenoid Electric Illuminator, Speaker Fuel gauge

valve horn indicator
tº
Combination Buzzer General Radio Thermometer

lamp hand cassette
switch sign player
M
U A
Motor Voltage Semiconductor Twin-filament Amperemeter

regulator diode lamp
Fig. 2 Common automobile electrical signs
III .Electrical designations and usages of the complete vehicle

1. Battery
(1) Battery is a kind of reversible low voltage direct current power supply that can
convert chemical energy into electric energy and vice versa. Lead acid battery is
supplied by JAC, which is dry-charged battery.
(2) Electrolyte in the battery is prepared by pure sulfuric acid and pure distilled water
in a certain proportion. Electrolyte purity is an important factor affecting the electrical
performance and service life of the battery. As the industrial sulphuric acid and
ordinary water contains foreign materials as copper and iron that accelerate the self
discharge, it cannot be used in battery. The sulfuric acid and distilled water used must
meet specialized standard.
(3) The battery is composed of six separate single cells that are connected in series
with led rod. The voltage of a single cell is 2V, so the nominal voltage of one battery of
six cells of series connection is 12V.
(4) The battery has charging hole that is sealed by plug screw. Charging hole plug
screw has vent hole to release hydrogen and oxygen generated from chemical
reaction. The vent hole must be kept clear in service. The shell may crack or explode
if it is clogged.
(5) Battery inspection: a If the electrolyte level is too low, please add distilled water to
the max. liquid level; b If the measured specific weight is under 1.23 (at 20℃), add or
replace the electrolyte.; c Keep the terminals reliably connect, remove any corrosive
marks and keep the battery terminal, power line and earth wire connection clean.
Battery inspection:
1. Check the terminal post for
looseness and corrosion
Keep the connection reliable. Remove
Max. level Max. level any corrosive mark and keep the
connection clean.
2. Check the electrolyte level of the
battery
If the electrolyte level is too low ，
Min. level please add distilled water to the max.
liquid level
2. Starter
The function of starter is to convert the electric energy of battery into mechanical
energy to drive the engine.
The starter used in this vehicle is 12V DC series excitation motor. It is composed of
three parts: (1) DC series excitation motor: to convert the electric energy of battery
into mechanical energy to generate torque; (2) Drive mechanism, also called
engaging mechanism: To engage the driving gear of the starter into the engine
flywheel toothed ring when the engine is started, so that the torque of starter is
transmitted to the engine crankshaft, and to disengage the driving gear of starter and
the engine flywheel toothed ring after the engine is started; (3) Control device: To
connect and disconnect the starter and battery.
Starter structure:
Adjusting shim
Moving core Reset spring Electromagnetic switch
Screw
Shift yoke
Conducting strip
Clutch
Brush
Driving gear Middle support Armature Reverser Magnetic

plate pole
Starter operating circuit:

Main power switch coil Combined switch (key) Earth
Power supply Main power switch contact Ampere meter Combined switch (start) Starting relay coil Earth
Fuse Starting relay contact Electromagnetic switch Starter

Earth
The maintenance personnel should carry out inspection and repair for the lines
indicated by the starter operating circuit diagram.
3. Generator
AC generator is the main power for the automobile. It is actually a self-exciting
three-phase synchronous generator. There are three windings at an interval of 120º
on the stator core of the generator. The ends of the three windings are connected,
which are usually called star connection. The rotor has field winding on it. Magnetic
field is generated when direct current passes the rotor winding. When the rotor is
turned by the engine, relative cutting movement is generated between magnetic line
of the rotor and three-phase winding of the fixed stator. Three phase alternating
electromotive force, i.e., AC power, is generated in the three-phase winding. DC
power is used in automobile circuit. So the AC power generated by the AC generator
must be rectified before using. The rectifying is made mainly by the silicon rectifier in
the generator. The three phase bridge full wave circuit composed of several silicon
diodes commutates alternating current into direct current.
Silicon rectifying shunt excitation AC generator is adopted in this vehicle, which is
composed of three phase AC motor and silicon diode rectifier. Minus earth is adopted.
Do not connect otherwise, or the generator may be damaged.
A
winding
Rotor
Winding
用电设备
蓄电池
Rotor
D D
consumers
Electricity
Battery
D
C
Stator D D D
AC generator Rectifier
Fig. 1 AC generator wiring diagram
4. Speed sensor
Speed sensor is fit on the generator end. The signal is taken from generator speed
signal terminal P. The number of pole pairs is 6. The generator and engine
transmitting ratio is 82: 145. The sensor output waveform is regular square wave.
5. Electric preheating
Electric preheating for the engine is adopted in cold season for this vehicle. The
heating wires should not be electrified for more than 30 sec., or they may be
damaged.
If the preheating effect is not good, check if the circuit is switched on first. If the circuit
is OK, use universal meter to check the heating wire and replace the burned-out
electric heater.
6. Fuel cutoff solenoid valve

There is one electronic component on the rear end of the engine injection pump. Its
function and wiring is as follows:
The electrical component is fuel cutoff solenoid valve. Its function is the same with that
of electric engine shut down device. The fuel cutoff solenoid valve is powered on
when the engine is started. The electric magnet lifts up the seal iron, so the injection
pump of the engine starts to supply oil and the engine starts normal operation. When
the engine needs to be shut down, turn the key to shutdown position, so the fuel cutoff
solenoid valve is power off and the seal iron cut the fuel path by the spring operation.
Power supply  Fuse Ignition lock LOCK (shutdown)
7. Wiper
The electric wiper of this vehicle is automatic reset type. For installation, the motor
should be in reset state. Then connect the link rod and wiper blade (wiper blade
position should be in reset state).
The variable speed switch controls the motor circuit to implement variable speed
wiping. The variable speed control circuit is as shown in the figure. The control
process is as follows:
a) Low speed wiping。 When the power switch is ON and the variable speed switch is
in I position, the current flow is as follows: battery positive pole→ power switch→ fusing
element→ brush B3→ armature→ brush B1→ variable speed switch I position
earth→ battery negative terminal. As the brush B2 has an offset angle, the wiper blade
swings fast when the motor is running at high speed.
b) When the power switch is ON and the variable speed switch is in II position, the
current flow is as follows: battery positive pole→ power switch→ fusing
element→ brush B3→ armature→ brush B2→ variable speed switch II position
earth→ battery negative terminal. As the brush B2 has an offset angle, the wiper blade
swings fast when the motor is running at high speed.
c) Shutdown and reset. The automatic reset mechanism of motor wiper is as shown in
Fig. 1－21 (b). The nylon impeller is embedded with copper ring 7 and 9. The copper
ring has two parts. The larger copper ring 9 is connected to the casing to earth.
Contact piece 3 and 5 is made of phosphorus copper or other elastic material.
Wiper variable speed control wiring diagram
1-Power switch; 2-Fusing element; 3、5-Auto reset contactor; 4, 6-Contact;

7, 9-Auto reset slide ring (copper ring); 8-Worm wheel; 10-Armature; 11 - Permanent
magnet
Contact 4 and 6 is riveted on one end. As contact 3 and 5 is elastic, when impeller 8
turns, contact 4 and 6 maintains contact with the end surface of impeller 8 (including
copper ring 7 and 9).
When wiper variable speed switch is in "0" position, if the rubber brush does not stop
at bottom edge of the windshield glass, the impeller turning will make contact 6 and
copper ring 9 connect, so the current keeps flowing into the armature. Here the
current forms a circuit from battery positive pole→ power switch→ fusing
element→ brush B1→ variable speed switch→ contact piece 5→ contact 6→ copper ring
9→ earth→ battery negative terminal. The motor runs at low speed until the impeller
turns to the position shown in Fig. 1－21 (a) and contact 4 and 6 connects with copper
ring 7.
When contact 4 and 6 is connected with copper ring 7, the motor cannot stop
immediately owing to the inertia force of armature turning. Instead, electricity is
generated with engine operation. As the direction of electromotive force generated by
armature winding is opposite to that of external supply voltage, the current flows in the
circuit of brush B3→ contact piece 3→ contact 4→ copper ring 7→ contact 6→ contact
piece 5→ variable speed switch→ brush B1. Torque is also generated (called brake
torque) to make the motor stop immediately. Here the rubber brush is just reset to the
bottom edge of the windshield.
The maintenance personnel can look for the fault of wiper circuit according to the
wiper working principle and variable speed control wiring diagram.
a. Main components
Designation Quantity Mounting position
Connecting rod assembly 1 Bottom edge of front windshield
Wipe rod and brush assembly (left) 1 Front windshield
Wipe rod and brush assembly (right) 1 Front windshield
Rain wiper motor assembly 1 Inside the cab
Washer jug assembly 1 Inside the cab
Water pipe assembly 1 Inside the cab
Nozzle assembly 2 Cab front panel
Control switch (combined switch) 1 On steering column
Wiper relay 2 Inside the cab fuse box
b. Functional requirements
I. Three operation modes of high speed, low speed and intermittent
II. Automatic reset function of wiper rod
III. Interval of intermittent operation can be adjusted
IV. Linked control of washer and wiper
c. Circuit design
Slow speed relay

High speed relay
High
speed Slow Wiper motor
speed
Motor
Washer
motor
Diode
Combined
switch
Earth
8 .Washer
Dust or dirt may get onto the windshield glass during the driving. To ensure good sight
of the driver, most vehicles have windshield glass washer.
When the washing engine armature is powered on, it turns in the permanent magnetic
field. When the armature shaft turns, it drives the pump shaft via coupling, so the
pump rotor also rotates. The pump rotor pumps the washing liquid from the pot to the
wind shield via the outlet hose and the nozzle. In the meantime, the wiper blade
swings to remove the dirt on the wind shield glass.
To use the washer, switch on the washing pump before the wiper. The continuous
work time of washing pump should not exceed 5s, interval not be less than 10s. When
there is no washing liquid in the pot, do not switch on the washing pump. Otherwise,
the motor may be damaged.
9. Headlamp
The headlamp of this vehicle is anti-glare combination lamp. The bulb is twin filament
type (long-distance beam/short-distance beam). When long-distance beam is
switched on, the long-distance beam indicator on the dashboard illuminates at the
same time. Lamp switch and change is operated from the group switch.
If the lamp is not ON, please check in the following sequence.
Step Inspection content Method
Check if the fuse is If the fuse is blown, replace it after the cause is
1
blown found. If not, check the next item.
Turn on the lamp switch to see if the headlamp relay
Check if the lamp relay
2 operates. Or use a universal meter to check if the
operates normally
relay terminal is OK.
If the result of the above checks is acceptable,
Check the headlamp
3 please check if the bulb is damaged. If not, check
bulb
the next step.
Check if the wiring Check if all the terminals are reliably connected
4
connectors are reliable according to the wiring diagram.
Check the combined Check if the lamp switch on the group switch can be
5
switch (lamp switch) normally turned on
Main power supply
Headlamp
circuit
Short-distance Long-distance
beam relay beam relay
Left Headlamp Right

Short-
distance Long-
headlamp long-dista Short-
distance Long- headlamp
beam distance beam distance
beam nce beam beam
indicator
Small Short- Combined

lamp distance
Headl
amp Lamplight
Flicker
beam Lamplight
switch
switch
switch
10 .Front small lamp

The front small lamp of this vehicle (width lamp) is combined lamp, i.e., front small
lamp on the lower part and direction lamp on the upper part. Check for fault according
to the small lamp operating circuit:
Power supply Fuse  Relay coilCombined switchEarth
Relay contact Front small lampEarth
The trouble shooting method is the same with that of front lamp. The difference is that
you need to check the small lamp relay when you check the relay.
11. License lamp

The license lamp is on the plate support on the rear of the vehicle. The license lamp is
ON when the lamplight switch is in any position.
The trouble shooting method is the same with that of small lamp.
License lamp
To replace the bulb, remove
one screw fixing the lens.
Check for fault according to the license lamp operating circuit:

Power supply Fuse  Relay coilCombined switchEarth
Relay contactLicense lampEarth
12. Direction signal lamp and hazard warning lamp

The direction lamp and front small lamp is combined. It is on the top of the combined
lamp. The light color is yellow. The operating circuit of the direction lamp is shown
below:
Power supply  Fuse  Flasher ---Combined switch ----Left and right direction lampEarth
---Left and right direction lampEarth
---Warning switch
The direction lamp circuit should be checked according to the circuit diagram. When
the vehicle is at fault or there is other danger, turn on the warning switch. The bulbs of
the direction lamp flicker at the same time to give a warning. The trouble shooting
method is the same as above.
13. Rear combination lamp
Rear lamp is a combined lamp with brake lamp, reversing lamp and direction lamp at
the bottom of the rear of the vehicle on both left and right. The color is red. The rear
lamp control switch is on the lamp switch of the combined switch. Its circuit is:
Power supply  Fuse  Relay coilCombined switchEarth
 Relay contactRear lampEarth
Note: The rear lamp use the same relay with front small lamp. It also share the same
fuse with front small lamp, license lamp, fog lamp and instrument lamp. The
maintenance personnel should pay attention to this in maintenance. The trouble
shooting method of rear lamp is the same with that of front small lamp.
Rear combination lamp

To replace the bulb,
unscrew the four bolts
fixing the lens.
14 .Reversing lamp and switch

Reversing lamp position is the same with that of rear lamp. The reversing lamp light is
white in color. The reversing lamp works together with the reverse gear switch
mounted on the gearbox. Its operating circuit is:
Power supplyFuseReverse gear switchReversing lampEarth
Note: the reversing lamp shares the same fuse with brake lamp and roof lamp. Please
pay attention to this in maintenance and repair.
15. Interior lamp and switch 150

The interior lamp is at the middle of the upper edge of the front windshield of the cab.
It has two switches, one is the roof lamp composite switch and the other is the door
post switch installed on the left door post of the cab. Its operating circuit is:
Power supply  Fuse  Interior lamp  Interior lamp switch  Earth

 Door post switch  Earth
Interior lamp switch

circuit diagram
OFF ON
Interior lamp
Door switch
Interior lamp switch position
ON OFF Door
16. Brake lamp and switch

Brake lamp position is the same with that of rear lamp. The brake lamp light is red and
the brightness is higher than that of rear lamp. The brake lamp works together with the
brake lamp switch mounted on the brake pedal. Its operating circuit is:
Power supply FuseBrake switchBrake lampEarth
Note: the brake lamp shares the same fuse with reversing lamp and roof lamp. Please
pay attention to this in maintenance and repair.
17. Parking brake lamp and switch

Parking brake switch is integrated with parking brake control lever. When the manual
control lever is lifted, the parking brake switch is ON. Here the parking brake indicator
on the dashboard turns ON. Let down the manual control lever, and the parking brake
switch is OFF and the parking brake indicator is OFF. Its operating circuit is:
Power supplyFuse Parking brake indicatorParking brake switch Earth
Parking brake indicator sign on the dashboard:
P
18 Fog lamp and switch

The fog lamp is combined with the headlamp and its light color is yellow. The working
principle of fog lamp is: when you drive on a foggy day, first switch on any lamp on the
combined switch and then press the fog lamp switch to turn it on. Turn off the lamp
switch on the combined switch or the fog lamp switch to turn off the fog lamp.
Fog lamp operating circuit:
Power supply  Fuse  Relay coil Combined switchEarth
 Relay contact Fog lamp switch Fog lamp Earth
Note: The fog lamp shares the same fuse with the front small lamp, rear lamp, license
lamp and instrument lamp. The maintenance personnel should pay attention to it in
repair.
19. Electric horn

The electric horn of this vehicle is dual tone (high and low tone) electric horn. It is
fitted on No. 1 girder on the chassis in the middle of the front bumper. Its operating
circuit is:
Power supply  Fuse  Horn relay coil Horn buttonEarth
 Relay contact Horn Earth
Note: The contact of horn button is an elastic joint on the combined switch that keeps
effective connection with the button contact iron ring on the steering wheel. Pay
attention to the connection state of the contact in maintenance.
Electric horn:
Relay：Horn Wiring diagram
Switch
：Horn
Horn
Horn specifications:
Structural Diaphragm Sound level Base frequency Volume range
shape diameter mm dB (A) range Hz fitting (dual tone)
Disc type >115 105~125 250~650 4: 5
If the horn does not sound or sounds
abnormally when you press the horn
button, check the line and battery voltage
before the following items:
1. Check if the fuse is blown. At the same
time, check if the wire connection is tight.
2. If both the fuse and connector can
operate in normal sequence, remove the
horn from the steering wheel and
short-circuit the horn switch guide line
terminal and the steering shaft thread.
a. No sound --- Poor contact between horn
contact of the combined switch and the
steering wheel bottom.
b. Sound --- The horn switch is at fault.
3. If the horn sounds without stop, the
source of trouble may be the horn switch
or bad reset contact ring.
20. Vacuum alarm

When the vacuum pressure in the vacuum cylinder exceeds certain value, the
pressure contact on the vacuum horn closes to complete the circuit. The vacuum
alarm buzzer and alarm lamp on the dashboard is switched on to warn the driver to
find out the cause.

The vacuum abstraction is carried out by the vacuum pump on the generator. The
maintenance personnel should pay attention to this in repair.
Alarm lamp identification:
！
21 .Various relays
The relays for this vehicle include lamp relay, horn relay, warm air relay, starting relay
and preheating relay. As the lamp, horn and warm air does not consume high current,
relay of the same specification is used for these current consumers. The solenoid
switch of the starter and heating plug consumes high current, so they use special
purpose relays that are installed in the chassis electric box. From left to right, starting,
preheating, horn, air conditioner and braking relay.
22 .Combined switches
The combined switch is a switch integrating power, start, lamp, wiper, washer and
direction lamp. There are many lines together, so faults are likely to occur here. It will
help the maintenance personnel a lot to know about the structure of the combined
switch in electric trouble shooting.
Combined switch structural diagram

1. Ignition switch working position conduction diagram
Contact code
ACC ON R ST P1 P2 R1 Remark
and power B B1 R2
220W 240W 60W 220W 40W 40W 60W s
Working gear
Wire color B L BY BR BW LY LW L R Y
Specification mm² 5.0 3.0 3.0 3.0 3.0 1.0 1.0 1.0 0.75 0.75
LOCK 〇〇
ACC 〇〇〇〇
ON 〇〇〇〇〇
START 〇〇〇〇〇〇 Automa
tic reset
Power Key in 〇〇
switch
Key out 〇
2 Lamp switch beam selection and overtaking signal conduction diagram

Contact code BT E J B BH HU
Rated power 80W 120W 10W 150W 150W
OFF
〇〇〇 Overtaking
〇〇
Small lamp
〇〇〇 Overtaking
Gear
Short-distance 〇〇〇〇
Headlamp
beam 〇〇〇〇〇〇 Overtaking
Long-distance 〇〇
〇〇
beam
3 Direction switch, warning switch, exhaust brake switch and horn conduction
diagram
Contact code TL TB TR B1 F B2 EX ER HO
Rated power 72W 144W 72W 120W 120W 120W
Warning Direction
switch switch
L 〇〇〇〇
OFF OFF 〇〇
R 〇〇〇〇
ON OFF 〇〇〇〇〇
Exhaust OFF
brake
ON 〇
switch
Horn 〇
4 Wiper switch and water spraying switch
Water
Wiping 11 E1 12 AS L H E2 W E3
spraying
OFF 〇〇
INT 〇〇〇〇
OFF
LO 〇〇
HI 〇〇
OFF INT 〇〇
ON
LO HI
EZ
23. Combined instrument
Instrument
Disassembling and reassembling
Disassembling sequence:
1. Transparent top cover 6.Pointer component
2. Instrument decorative ring A 7.Gauge plate
3. Instrument decorative ring B 8.Middle cover
4. Black frame 9.Circuit board parts
5. Reset rod 10.Bottom cover
Disassembling sequence:
Follow the reverse order of disassembling to reassemble.
1 Instrument indicator:
No. Designation Function Color
1 Engine oil pressure alarm ON when the engine oil pressure is too Red
lamp low
2 Charging indicator ON when the battery discharges Red
3 Parking brake alarm lamp ON when the parking brake is switched Red
on
4 Preheat indicator ON during the preheating Yellow
5 Exhaust brake indicator ON when the exhaust brake is switched Yellow
on
6 Left/right direction indicator ON when the direction lamp is switched Green
on
7 Beam indicator lamp ON when the headlamp is switched on Blue
8 Fog lamp indicator ON when the fog lamp is switched on Yellow
9 Hazard alarm lamp indicator ON when the hazard alarm is switched Red
on
10 Fuel oil level alarm lamp ON when the fuel oil level is low Yellow
11 Small lamp indicator ON when the small lamp is switched on Yellow
12 Door open alarm lamp ON when the door is open Red
13 ABS alarm lamp ON when the ABS system is at fault Yellow
14 Brake fault alarm lamp ON when the brake is at fault or the Red
brake fluid is low
1) Main component installation
Main component Model Mounting position
Combined Stepping motor type Under dashboard
instrument
Speed Middle of combined instrument
meter/odometer Electronic
Odometer sensor On gearbox output shaft
Engine oil pressure Varistor type On engine oil pipe
sensor
Water temperature Thermister On engine water inlet pipe
sensor
Fuel oil sensor Varistor type Inside oil tank
2) Indicator and warning switch:

Engine oil pressure indicator switch
Wiring diagram
Indicator switch position
Switch specification
Working pressure: 0.3- 0.5 KSC.
When the oil pressure is as low as the
switch action pressure, the indicator
is ON.
Vacuum alarm switch

Alarm buzzer Wiring diagram
Its position is the inner side of the left
pedal in the cab.
Switch：Vacuum
Switch specification
Stamping sign: 350
Negative pressure (mm hg): 320- 380
Note: The switch has working negative

pressure mark. Make sure that you
replace it with switch of the same
negative pressure when necessary.
ON Parking brake switch

Wiring diagram
OFF
Switch
2 Technical requirements:
Technical requirements of combined instrument
3801910D800 Combined instrument assembly
The basic deviation requirements are as follows:
Basic deviation
Indicated speed 20 40 60 80 100 120 140 160
Km/h
Speedometer
Allowable +5 +5 +5 +5 +6 +7
(stepping motor ±3
deviation Km/h 0 0 0 0 0 0
type)
Transmitting 1:637 Interface mode Sensor type
ratio
Indicated mark E 1/2 F
Basic resistance 97 32.5 6
Fuel gauge (Ω)
(stepping motor Allowable ±16 ±6.5 ±3
type) deviation (Ω)
Sensor Designation Fuel oil Model RG1164B1
sensor
Indicated mark C (50) 100 H (115)
(℃)
Water Basic resistance 230 40.4 26.4
temperature (Ω)
gauge Allowable ±30 ±5 ±1.5
(stepping motor deviation (Ω)
type) Sensor Designation Water Model WG1371
temperature
sensor
All alarm indication systems of 3801910D800 instruments conform to GB4094 - 1999

Signs of automobile controls, indicators and signal devices.
DJY7121-1.6-20;DJY7141-1.6-20;DJY7121A-1.6-20 combined socket is adopted for
the instruments.
24 .CD player
A single disk dual track CD player is mounted on this vehicle. The L channel speaker
is mounted in the left door and the R channel speaker is mounted in the right door.
If you find that some functions do not work, please read carefully the operation
instructions in the manual first before you send it for repair. You can check the player
according to the following table. It will help you fix the trouble.
Please send the player to the maintenance service station if the fault cannot be fixed.
Do not disassemble the player to repair it by yourself.
General situation
The player does not work and there is no display.
·Check the fuse connection of the player and vehicle
·Check the voltage.
The player works but there is no sound or the sound is very low
·Raise the volume.
·Check the front and rear, left and right balance setting of the horn.
·Check the antenna and connection.
Horn volume lowers by itself
·The internal safety circuit can prevent the internal temperature from exceeding
certain value.
·Raise the volume after the temperature is lowered.
Reception
Cannot get the channel:
·Check if the antenna is fully drawn and if the connection is right.
·Check if the negative terminal (brown line) is grounded (chassis).
·Please use manual tuning if the signal is too weak.
Poor reception:
·Some vehicle (such as Volkswagon and SEAT) needs a 12 V antenna on the top.
Please consult your dealer if there is 12 V power supply to this antenna.
CD
CD ERROR is displayed:
·Check if the CD is correctly inserted, and make sure that the CD is not broken or dirty.
Distortion of sound
·CD cannot be read, damaged or dirty.
CD player out of operation:
·Moisture may condensate on the laser magnetic head when it is very cold. Turn it to
radio reception for about 5 minutes to let the moisture evaporate.
NO CD or NO DISC is displayed.
·Check if there is CD in the CD player.
25. Idle speed boost device

A solenoid valve called idle speed boost device is fitted on the rear end (left side of the
chassis) of the vacuum pump on the engine. When the engine is at idle speed and the
air conditioner is switched on, it boosts the idle speed of 700r/min to 850±50r /min, so
that the power generation meets the requirements of the air-conditioner. Its functional
diagram is as follows:
Connecting rubber tube2 Vacuum membrane box Engine throttle lever
Wire1
Drawbar
Wire2
Connecting rubber tube1

Vacuum
pump pipe
Solenoid valve DF156(Suction voltage<9V, Release voltage>1V)
When the air conditioner is switched on, the solenoid valve of the idle speed boost
device operates so that rubber tube 1 and rubber tube 2 is connected. With the
vacuum membrane, the fuel up lever is pushed by the push rod to the fuel up direction,
so that the engine idle is raised to 850±50r /min. The wiring diagram is as follows:
Compressor
Fuse Air conditioner switch electromagnetic clutch
Idle speed boost valve

26. Exhaust brake controller

Exhaust brake switch
1. Wiring diagram
Acceleration Clutch
switch switch
Alarm
buzzer
Magnetic
valve
Vacuum
switch
2. Switching diagram
ON OFF
3. Accelerator and clutch switch:

Maximum stroke: 4mm;
Working stroke: 2.0-2.8mm.
OFF
Max. travel
4.Position of exhaust brake solenoid valve

(left arrow)
27. Electrical device

Disassembly of line bundle connector:
Please always both hands to cut the
connector. Drawing the connector with
single hand will result in rupture of the
wire terminal.
Note: press the lock plates on both sides
before drawing out the connector to cut.
Connection of line bundle connector:

Wrong
Clench both sides (male and female) of the
connector and make sure that the connector
terminal pins match and align with the
holes. Press both sides of the connector
carefully until you hear a clear click.
Correct
Wrong Inspection of line bundle connector:

Use circuit tester to check the connector
Probe continuity. Insert test probe from side of
the connector wire
Do not insert the test probe in connector

open end
Correct
Probe
Inspection of fuse line:

Fuse line
The fuse line is fitted on battery positive
Starter
switch
terminal and starter switch B terminal
If there is over current, the fuse is blown to
protect the main power supply from being
overloaded. Please use universal meter to
check the continuity of the circuit.
Starter motor
Pin Disassembly of wire terminal

Barb 1. Insert a pin into the open end of the
Wire
connector shell
2. Press the barb (facing the connector wire
side) and pull the wire on the connector
wire side.
Terminal
Open end
Insertion of wire terminal:

Barb Wire
1. Check if the barb is completely open.
2. Insert the terminal from connector wire
side and press it until the barb fixes it
firmly.
3. Pull the wire gently to reset the terminal.
Terminal
Wrong Precautions of line bundle arrangement:

Use jacket or sleeve to protect the line
bundle and avoid direct contact with sharp
edge or surface.
Correct
Wrong There should be sufficient clearance between

the line bundle and bracket. Use ethylene
sleeve and clip to protect the line bundle and
avoid direct contact.
Correct
Sleeve
Clamp
The line bundle between the engine and chassis

should be long enough to avoid abrasion or
damage owing to vibration.
Wrong
Correct
Normal Damaged Fuse:

Fuse is the most used circuit protection of
vehicle circuit. When there is over current in
the circuit，the fuse is blown to prevent the high
current from damaging other parts in the circuit.
Find out the cause of overload current and solve
the problem before you replace the fuse.
Use new fuse of the same ampere to replace the
original one. Otherwise, there will be line
burning or other serious damage to the circuit.
Circuit breaker:
Breaker is a protective device to open the
circuit when the load current exceeds the rated
breaker capacity.
If there is short circuit or other form of
overload, the over current will open the circuit
on both sides of the breaker. When the circuit
is open, the breaker button pops up.
Push
Chassis electrical device diagram:

Front side:
Generator
Engine earth
To cab line bundle wire
To compressor
To water
temperature To heater plug
line
Electric horn
Engine oil
pressure alarm Engine line
bundle
Starter
To fluid tank Idle speed boost device
Chassis electrical
devices box
31
Middle and rear side:
Oil water separator
Clamp
Reverse gear switch Exhaust brake solenoid valve

To rear lamp
license lamp
To condenser fan
Band
Battery negative
Battery positive terminal line
Battery
terminal line assembly
32
Air heating & air conditioning equipment
Generator
Disassembling and reassembling
Troubleshooting
General
1. Air conditioner refrigeration cycle

1.1 main parts of refrigeration system
Refrigeration cycle system of integrated air conditioner (warming and cooling) of JAC
vehicle mainly consists of compressor, compressor exhaust hose, condenser
assembly, reservoir, HP hose, F type expansion valve, evaporator assembly, and LP
hose. The reservoir assembly includes internal drier and filter etc., as well as HP/LP
pressure switches, sight mirror and fusible plug installed on casing.
1.2 Refrigerating principle
The compressor sucks in and compresses low temperature, low pressure refrigerant
gas to generate high temperature, high pressure refrigerant gas, which will be sent to
condenser via HP hose for condensing, releasing heat to air passing condenser and
being condensed to high pressure medium temperature liquid. This liquid flows to the
reservoir where impurities in refrigerant are filtered and water content is removed, and
then flows to expansion valve via HP hose, where it is changed to low pressure, low
temperature liquid-gas mixture by throttling and depressurizing effect of the valve, and
then enters the evaporator. This mixed refrigerant will evaporate in the evaporator and
absorb heat from air inside vehicle and flowing pass the evaporator to become
superheated gas, which will enter compressor for next refrigeration cycle. Air inside
vehicle passing the evaporator will discharge heat to the evaporator and become cold
air. In addition, since temperature of evaporator surface is lower than air dew point,
water vapor in air will condense to become dew that will be drained outside the vehicle,
hence reducing temperature and humidity of air inside vehicle. Fig.1 shows air
conditioning refrigeration schematic diagram.
Expansion Reservoir
valve
Evaporator Condenser
Compressor
Fig.1 Air conditioning refrigeration schematic diagram

2. Air conditioning warming cycle

2.1 Main parts of warming system
Warming cycle system of integrated air conditioner (warming and cooling) of JAC
vehicle mainly consists of warm air blower, engine, water pump, water valve, water
tank and pipelines etc.
2.2 Warming principle
By means of a water pump, hot coolant of engine is pumped into warm air blower core,
where heat exchange occurs to release heat to air inside vehicle. Later, this coolant
returns to the water tank and enters next warming cycle.
Water pump Warm air

(water tank) blower core
Engine Water valve
Fig.2 Air conditioning warming schematic diagram
3. Electric control
3.1 Main parts of electric control
The electric control mainly consists of power supply switch, electromagnetic clutch,
controller, defrosting thermistor, defrosting temperature controller, HP/LP pressure
switches, electric control box, governing resistor, and connection harness etc.
3.2 Electric control principle
The controller is the control center of air conditioning (refrigerating and warming parts).
Electronic elements in the electric control box are used to control On/Off of
refrigerating and warming, and adjustment of AC fan rotation speed and temperature.
The power supply switch is used to control driving power of the air conditioning. This
switch is a mina part of the controller and functions to turn AC on or off (also referred
to as A/C switch). At gears 1, 2, 3 and 4, refrigeration will be executed.
3.2.1 Temperature control
The defrosting thermistor is a control element that senses temperature of discharged
air from evaporator. It directly converts temperature to electric signal and transmits
this signal to the defrosting temperature controller inside electric control box. The
defrosting temperature controller receives electric signal from defrosting thermistor
and control On/Off of compressor EM clutch according to set parameters (i.e. On/Off
of air conditioning refrigeration cycle), so as to control temperature inside the vehicle.
The electric control box is the execution center of air conditioning control. It receives
commands from controller and feedback electric information from defrosting
thermistor, and uses internal relays to control On/Off of compressor clutch.
3.2.2 Pressure protection control
The HP/LP pressure switch is a safety part used to ensure safe operation of
refrigeration system. When the high pressure is ≥3.14MPa or low pressure is
≤0.2MPa, this switch will be turned off, disengaging compressor clutch and stopping
the refrigeration system. When system high pressure falls to 2.5MPa or system low
pressure rises to 0.23MPa, this switch will be turned on, engaging compressor clutch
and starting the refrigeration system.
1. Technical parameters
S/N General item Sub-item Parameter
Code R134a
1 Cooling medium
Amount of filling 0.85kg
Code PAG56
2 Refrigerating oil
Amount of filling 150g
Model 5H14
3 Compressor Voltage 12V
Displacement 138cm3/r
Condenser heat sinking
9000W
capacity
Condenser with
4 Voltage 12V
reservoir assembly
Maximum current 15A
Air flow 1800m3/h
Refrigerating capacity 3900W
Heating capacity 4000W
Front evaporator/
5 Voltage 12V
heater assembly
Maximum current 18A
Air flow 350m3/h
Disconnected at
High pressure protection
2-state pressure ≥3.14Mpa
7 characteristics
switch Connected at ≤2.5Mpa
Low pressure protection Disconnected at
characteristics ≤0.2Mpa
Connected at ≥0.23Mpa
2. Structure of main parts of air conditioning
2.1 Heating equipment, blower equipment and evaporator
1
7
3
5
1. Lower cover; 2. Fuse and relay box; 3. Ventilating air duct; 4. Evaporator; 5. Blower;
6. Heating equipment; 7. Instrument stand
For removal of heating equipment, blower and evaporator from instrument stand,
follow this sequence: 1. lower cover 2. fuse and relay box 3. ventilating air duct 4.
evaporator 5. blower  6. heating equipment.
Sequence of assembling is the reverse of this sequence. For tightening torques, refer
to the table below:
Tightening torque (N·m)

Diameter of thread (mm) Pitch (mm) Standard
Maximum Minimum
value
6 1 9 12 6
8 1.25 23 26 16
8 1 25 28 17
10 1.5 59 75 37
10 1.25 63 79 45
10 1 64 80 46
12 1.75 95 111 73
12 1.5 97 113 75
12 1.25 99 115 78
Important operation-assembling
● To assembly blower, prevent water leakage.
Sealant Butyl rubber (none-dry type)
Air conditioning panel

● Turn mode handle to left most (FACE direction);
● Turn temperature lever to left most (COLD
direction);
● Turn inner/outer air control lever to left most
Control cable “A”
(INSIDE direction)
Control cable “B”
● Hang control cable “C” on blower clip, press

butterfly nut to bottom and fix cable on clip;
Air heater ● Hang control cable “B” on heater clip, press
butterfly nut to bottom and fix cable on clip.
Control cable “C”

Hang control cable “C”on blower clip, press
butterfly nut to bottom and fix cable on clip
Blower
2.2 Structure of condenser assembly
1. Condenser damping pad sleeve; 2. Hex flanged face nut;

3. Pad; 4. Condenser core;
5. Condenser damping pad; 6. Condensing fan assembly;
7. Bolt combination
Important operations
1. When removing pipe from each device, avoid damaging connecting nut or the pipe.
2. Cover pipe port with plastic cloth to avoid ingress of dust in pipe.
2.3 Disassembling and assembling of compressor
Disassembling sequence: Assembling sequence:

1. Pipe 4. Compressor
2. Belt 3. Idler
3. Idler 2. Belt
4. Compressor 1. Pipe
Important operations
1. To remove pipe from each device, avoid damaging connecting nut or the pipe.
2. Cover pipe port with plastic cloth to avoid ingress of dust in pipe.
Operation prompts
1.1 To avoid accidents and ensure safety of relevant personnel, non-discipline
personnel must not perform disassembling or repair.
1.2 Use of open flame or smoking is prohibited.
1.3 Always wear working clothes during working. Ensure intact protective devices.
1.4 Perform operation in a weld ventilated environment.
1.5 Before starting the engine, confirm that there is no tool, measuring instrument or
other part on moving and rotating parts, and parts through which electric current flows.
1.6 Before start of engine, blow horns to warn operating workers and confirm safety.
1.7 To check electric lines, take care not to touch terminals or other parts through
which electric current flows; otherwise short circuit may occur due to human body or
other part.
1.8 Use fuses of rated capacity. Avoid burning of electric devices such as relay and
fire.
1.9 When using hose and hard pipeline, take care to avoid leakage of gas.
1.10 Thoroughly clean dust at hose or hard pipeline connecting part and inside
pipelines; prevent gas leakage and abnormal operation.
1.11 Avoid water or oil etc. on fan, fan motor or V belt, so as to prevent damage and
fire.
1.12 Before shutdown of air conditioner is confirmed, do not touch belt or fan to avoid
injury.
1.13 Do not place refrigerant cans on engine or radiator, so as to prevent serious
accident.
1.14 Do not subject refrigerant cans to direct sunshine, moisture, or temperatures
exceeding 40℃, so as to prevent serious accident. Store these cans at a cool and dry
place.
1.15 Store refrigerant cans where no fierce collision with other hard matter or iron
ware etc. will occur, so as to avoid serious accident.
1.16 When handling refrigerant gas, wear protective goggles to avoid injury of eyes. In
case such gas enters the eye, timely wash with large amount of clear water to prevent
frostbite; if serious, go to hospital at once.
Items that must be inspected before AC system maintenance or diagnosis
2.1 Visually check hoses for damage and friction.
2.2 Ensure that condenser fins are not blocked by insects, impurities and dirt etc.,
2.3 And that fins have no apparent falling.
2.4 Correct operating direction of condenser fan.
2.5 No overheating of engine water tank.
2.6 Check tension of driving belt and for damage.
2.7 Operation of compressor.
2.8 Check for clogging of evaporator drain hose.
2.9 Check free action of switch at each air outlet.
2.10 Check if blower and evaporator fan can operate at specified fan speed.
2.11 Check that there is no apparent refrigerant leakage or oily dirt on device or
pipeline connector.
Troubleshooting
Blower motor rotates but no

hot air comes out from
outlet
Check water
hose
YES Hose sharp

twisting, bending or
clogging
Replace
No air comes out from defroster

outlet
Check connecting pipe

between defroster &
heater
YES Wear
Replace
Check defroster door & control
cable
YES Replace &

adjust
Blower speed cannot be

adjusted
Check electric connector
YES Disconnect
Replace
Check control switch
YES Faulty
Replace
Blower motor not rotating
Check fuse
YES Faulty
Replace
Check circuit & connector
YES Open or
disassemble
Replace
Check switch circuit
YES Incorrect
Replace
Check engine motor
YES Faulty
Replace
High blower motor noise
Check blower motor bearing
YES Broken
Replace
Cold air blown out intermittently
Check magnetic clutch
YES Slipping or not operating
Replace
Check expansion valve
YES Faulty
Replace
Check wiring
YES Faulty
Repair
Insufficient cooling
Check condenser
Check driving belt Clean or

replace
YES Slipping
Check compressor Replace
YES Faulty
Replace
Check expansion
valve
YES Faulty
Replace
Check thermostat
YES Faulty
Replace
Check coolant
YES Insufficient or
excessive
Adjust
Cabin CAB-1
Cabin
Front wall
Front windshield glass
Rear windshield glass
Instrument desk
Ceiling inner trim
Ceiling ventilation
Door
Seat
Seat safety belt
Disassembling and assembling of tilting mechanism
Disassembling and assembling of lock mechanism

Cabin CAB-2
Front wall parts
Disassembling and assembling
Disassembling sequence Assembling sequence
1. Front bumper assembly ▲ 5. Front wall side board assembly
2. Veil 6. Front wall trim board
3. Clip on veil 4. External rear view mirror assembly
4. External rear view mirror assembly 3. Clip on veil
5. Front wall side board assembly 1. Bumper assembly
6. Front wall trim board 2. Veil

Cabin CAB-3
Front wall side board

Upper rubber Important operation--assembling
Front wall side 5. Front side board
● Use 507 glue to stick upper/lower
Front wall rubber pads on front wall side
side board board
Crossed recessed ● Use 507 glue to stick front wall
pan head tapping side board rubber strip on front
Front wall side
wall side board side
board expansion
● Install front wall side board clip on
door column.
5. Install front wall side board assembly

Front wall side on door column.
Install front wall side board sleeve on

front wall side board clip (use cross
recessed pan head screw for fixing)
Cross recessed
pan head tapping screw
Cabin CAB-4
Front windshield glass
▲ 3. Front windshield glass 1. Front windshield inner rubber strip
2. Front windshield front rubber strip 2. Front windshield front rubber strip
1. Front windshield inner rubber strip ▲ 3. Front windshield glass

Cabin CAB-5
Important operation---disassembling
1. Front windshield glass
 Tear out sealing strips from upper
flange and each corner of vehicle body
flange, and then slowly push out and
remove the glass. Do not touch glass
surface.
 Use gasoline to wash sealant on
vehicle body.
Important operation---assembling
3. Front windshield glass
Range of application of sealant  As shown in left figure, apply enough
sealant on flange (about 10mm dia.). If not
enough, water leakage may occur.
Sealant Single component

polyurethane glass glue
3. Windshield assembly
 Stick windshield glass on cab
proper front windshield flange.
 Lightly tap glass with rubber

Rubber hammer Windshield hammer so that vehicle body
flange is in full contact with
Sealing strip sealing strips.
Vehicle body
flange
Cabin CAB-6
Rear windshield glass
▲ 3. Rear windshield assembly 1. Rear windshield glass
2. Rear windshield rubber strip ▲ 2. Rear windshield rubber strip
1. Rear windshield glass ▲ 3. Rear windshield assembly

Cabin CAB-7
Important operation --disassembling

1. Rear windshield assembly
 Remove sealing strips from upper
flange and each corner of flange,
then slowly push out and remove
the glass. Do not touch coated
surface or glass.
Important operation ---assembling

Seal strip
2. Sealing strip
 Place glass brand position at left
lower corner. Adjust glass center to
Center align with seal strip lower
connector.
Left Right
Connection
Seal strip
 Thread Ф 5-6mm rope in the flange.
Wind rope for one round for
coinciding at lower center of glass.
Rope
1. Rear windshield assembly

Push
 Adjust glass so that it is at center of
windshield. Press glass from outside, then
pull rope toward glass center from inside.
Stick rear windshield rubber strip on vehicle
body flange.
Pull
Avoid twisting of strip and mismatching with
rear windshield; otherwise water leakage
may occur.
Rubber Windshield glass

hammer  Lightly tap glass with rubber hammer so
that vehicle body flange is in full contact with
Sealing strip sealing strips.
Vehicle body
flange
Cabin CAB-8
Instrument desk
Disassembling Reassembling

1. Instrument desk front cover plate 16. Fuse box and relay box
2. Instrument desk side end cover 15. Cigarette lighter
3. Brake oil pot cover 14. Instrument desk frame
4. Glove box 13. Air conditioning panel
5. Central control panel 12. Radio cassette (or CD) player
6. Instrument hood 11. Left ash tray
7. Relay box cover 10. Combination instrument
8. Idling button 9. Instrument desk cover
9. Instrument desk cover 8. Idling button
10. Combination instrument 7. Relay box cover
11. Left ash tray 6. Instrument hood
12. Radio cassette (or CD) player 5. Central control panel
13. Air conditioning panel 4. Glove box
14. Instrument desk frame 3. Brake oil pot cover
15. Cigarette lighter 2. Instrument desk side end cover
16. Fuse box and relay box 1. Instrument desk front cover plate
Cabin CAB-9
Important operation-- disassembling

AC panel Radio cassette player
5. Central control panel
 Remove central control panel (do not
touch the panel)
 Remove connector between cigarette
lighter and vehicle body harness.
Central control
Steel clamp Cigarette lighter panel
12 & 13. AC panel and radio cassette (or CD)

player
 Disconnect each connector of radio
cassette (or CD) player and AC control
wire
Screw  Remove radio cassette (or CD) player
and AC panel
AC panel
Radio cassette
14. Instrument desk frame

Brake oil pot and hose
 Remove brake oil pot mountings from
instrument desk frame. You must first
loosen hose and drain oil in the pot;
otherwise brake oil may leak.
 Disconnect all plugs connected to

vehicle body harness
 Remove bolts; do not touch and damage
surfaces of other parts
Cabin CAB-10
16. Fuse and relay box

Fuse and relay box
 After removal of instrument desk frame,
remove the fuse and relay box installed
on this frame, then the vehicle body
harness.

Fuse and relay box 16. Fuse and relay box
 Fit vehicle body harness on instrument
desk frame, fix fuse and relay box at its
position, and use wire clip to fix harness.
Check harness or wire clip, and then
connect vehicle body harness with
chassis harness.
14. Instrument desk frame

 Fit and tighten bolts in holes 1-4 (as
shown)
 Fit frame on steering column support, fit
and tighten bolts
Torque: N·m 8－10

Cabin CAB-11
Brake oil pot and hose  Fit brake oil pot on instrument desk
frame
 Tighten nuts at A and B
 Connect the pot to hose and tighten
Torque: N·m 5－11
13. Air conditioning panel

 Thread control wire into instrument
panel, and then firmly fit AC panel.
 Turn mode switchover knob to left most
position (toward FACE direction)
 Turn temperature control knob to left
most position (toward COLD direction)
 Turn inner/outer circulation lever to left
Control cable “A”
Control cable “B”  Hang control cable “A”on blower pawl

hook, push butterfly valve to the end, fix
electric cable on clip.
 Hang control cable “B” on air heater
pawl hook, move butterfly valve to
Air heater lowest position, fix electric cable on clip.
Control cable “C”

Control cable “C”;
 Hang control cable “C”on blower pawl
hook, push butterfly valve to the end,
and then fix electric cable on clip.
Blower
Cabin CAB-12
12. Radio cassette (or CD) player

 Fit this player inside instrument panel,
and then connected harness connector
and antenna to rear of the radio
Make sure to fit firmly to prevent
vibration
Scre
Air conditioning Radio

panel
Connect harness at each point

below:
A. Antenna cable
B. Radio
C. Blower switch
D. Cigarette lighter
E. Instrument
F. Clutch switch, brake switch, throttle switch
G. Fog light switch, warning switch, warming
up switch
H. Combination switch
I. Washer pot
Cabin CAB-13
Ceiling inner trim
2. Ceiling inner trim buckle 1. Ceiling inner trim
1. Ceiling inner trim 2. Ceiling inner trim buckle

Cabin CAB-14
Ceiling ventilation
1. Inner cover assembly ▲ 3. Outer cover & control assembly
▲ 2. Hex nut ▲ 2. Hex nut
▲ 3. Outer cover & control assembly 1. Inner cover assembly

Cabin CAB-15
Important operation --disassembling

2. Nut
● After removal of nut, place outer
cover and control assembly at air
inlet
Turn by 90° 3. Outer cover & control assembly

● Move outer cover assembly upward
and turn it by 90°, then pull the control
assembly out.

Turn by 90° 3. Outer cover & control assembly
● Place this assembly at air inlet
position
● Move outer cover assembly upward
and turn it by 90°; install control
assembly
2. Hex nut
● At fully open position, tighten the hex
nut
Cabin CAB-16
1. Inner cover assembly
Top cover
Control Clip
Inner cover
Cabin CAB-17
Door Disassembling
Right door assembly
16. Door outer upper decorating strip 10. Door hand catch bracket
17. Door lower embedded strip, lower rubber strip 3, 4. Door window lift assembly, front
bracket assembly
2. Door rubber pad 5. Door window assembly
15. Door glass inner/outer water seal 15. Door glass seal strip
13. Door large arm rest 6. Door lock core assembly
12. Door hand catch 1. Door harness assembly
14. Lifting handle Additional note:
18. Door seal strip (15. Door glass seal strip, water seal)
11. Door inner trim board
7. Door seal cover plate assembly
9. Door seal membrane
8. Door inner handle
Cabin CAB-18
Reassembling
Right door assembly
▲ 1. Door harness assembly ▲ 14. Lifting handle

2. Door rubber pad 15. Door glass water seal
▲ 3. Door window lift assembly 16. Door outer upper decorating strip
4. Door glass front bracket 17. Door lower embedded strip/rubber strip
▲ 5. Door glass assembly 18. Door seal strip
15. Door glass seal strip Additional note:
▲ 6. Door lock core assembly (15. Door glass seal strip, door glass water seal)
7. Door hand catch bracket
▲ 8. Door inner handle assembly
▲ 9. Door seal membrane
10. Door cover plate assembly
▲ 11. Door inner trim board assembly
12. Door hand catch
13. Door large arm reset
Cabin CAB-19

1. Door harness assembly
● Thread harness assembly
through the hole on door inner
panel and fit a suitable rubber
washer according to shape of the
hole.
● Fit door harness clip on support
bracket and door inner panel
reinforcing part.
3. Door window lift assembly

● First fit the window lift assembly on
the door, then fit glass on lift front
bracket and glass front/rear bracket
● Next, install door window groove
and adjust the glass so that lifting is
smooth.
5. Door window glass assembly

● Fit window lift front bracket and
front/rear glass brackets on door
glass.
● Use a plastic or wood hammer to
tap the groove lightly; when
doing so, cover the glass with
cloth or similar
Cabin CAB-20
6. Door lock core assembly

● When door lock outer handle is
connected to the connector, rotate
this connector so that handle end
gap is about 5mm.
Torque: N·m 4－8
8. Inner handle assembly

● Firmly insert inner handle
Door lock assembly “a”in door lock “b”position
and rotate the sheath tight.
● Allow certain free gap of inner
handle assembly at door inner trim
board
Right door assembly 9. Door sealing membrane

● Stick butyl rubber tape (Ф 5mm) along
door inside protecting plate
Positioning ● Adjust door sealing membrane
positioning holes to corresponding
positions on door inside protecting
plate, and stick well. Avoid crimple of
tape; otherwise water leakage may
occur.
Cabin CAB-21
Door inside Door assembly 11. Door inner trim board assembly
protecting plate  Insert 7 inner trim board clips into
Clip
holes on door inside protecting plate.
backin When firmly inserted, a sound of
Clip section
“kata” will be heard; if not, water
Door assembly leakage may occur.
14. Lifting handle

 Adjust this handle to the position
shown in left figure and at 45°with
horizontal line Lift all door window
glasses.
Cabin CAB-22
Seat

3. Cross recessed pan head tapping screw 1. Floor batten expansion buckle
2. Map batten 2. Map batten
1. Floor batten expansion buckle 3. Cross recessed pan head tapping screw
4. Integral carpet 4. Integral carpet
12. Seat for 2 persons 5. 3-point safety belt
11. Driver seat 6. Hex head bolt, flat washer, spring washer
10. Passenger safety belt buckle assembly 7. Driver safety belt buckle assembly
9. Middle (additional) seat safety belt assembly 8. Middle (additional) seat safety belt buckle ASSY
8. Middle (additional) seat safety belt buckle ASSY 9. Middle (additional) seat safety belt assembly
7. Driver safety belt buckle assembly 10. Passenger safety belt buckle assembly
6. Hex head bolt 11. Driver seat
5. 3-point safety belt assembly 12. Seat for 2 persons
Cabin CAB-23
Seat safety belt
Seats
Disassembling sequence
6. Passenger safety belt buckle assembly
5. Middle (additional) seat safety belt assembly
4. Middle (additional) seat safety belt buckle assembly
3. Driver safety belt buckle assembly
2. Hex head bolt, flat washer, spring washer
1. 3-point safety belt assembly
Assembling sequence
▲ 1. 3-point safety belt assembly
2. Hex head bolt, flat washer, spring washer
3. Driver safety belt buckles assembly
4. Middle (additional) seat safety belt buckles ASSY
5. Middle (additional) seat safety belt assembly
6. Passenger safety belt with buckle assembly

Cabin CAB-24
Important operation--- assembling

1. 3-point safety belt assembly
Install seat safety belt mountings on floor.
Note installation direction of seat safety belt
mountings.
Seat safety
belt
Torque: N·m 30－50
Part Part
Rolled edge
Forward
Part
Seat safety
Rolled belt
Forward
Part Part
Cabin CAB-25
Cab tilting and locking mechanism
Tilting mechanism
Disassembling and assembling sequences

1. Cab rear support and bracket assembly 4. Can rear bracket
2. Can 3. Can front support tilting mechanism
3. Can front support tilting mechanism 2. Cab
4. Can rear bracket 1. Cab rear support and bracket assembly
4. Cab left rear bracket

(Right rear support is symmetric to left rear
support except absence of structure A)
Torque (N·m): 78
Cabin CAB-26
3. Cab front support tilting mechanism
For installation, align marking I on axle tube

assembly to marking I on torsion bar.
Torque (N·m): 116— — 153
Torque (N·m): (1) 105— — 133
(2) 76— — 92
Cabin CAB-27
2. Cab
Fit guide pin into support arm guide hole and

then fit cab.
Torque (N·m): 76— — 92
Tilt cab and tighten bolts so that bolts lean

against groove rear end.
Torque (N·m): 105— — 133
1. Cab middle rear support and bracket

assembly
Torque (N·m): 29— — 41

Cabin CAB-28
Disassembling and assembling of cab locking mechanism
Disassembling sequence
1. Short slide rod assembly
2. Long slide rod assembly
3. Lock mechanism right assembly
4. Lock mechanism left assembly
5. Tilting lock mechanism assembly
Assembling sequence
4. Lock mechanism left assembly
3. Lock mechanism right assembly
1. Short slide rod assembly
Cabin CAB-29
Important operation--- assembling
Fit tilting lock mechanism assembly on cab rear bracket.

Torque: (N·m): 14— — 24
Tilting lock
mechanism
assembly
4. Locking mechanism left assembly
Torque (N·m): 14— — 24
Tilting lock
mechanism
Locking
mechanism left
3. Locking mechanism right assembly
Torque (N·m): 14— — 24
Locking
mechanism right

1. Long slide rod
Short Long slide rod Apply grease at position A on rod contact face, and then fit
slide
rod long slide rod assembly.
Apply grease at position B on rod contact face, and then fit
short slide rod assembly.
Fit the part with stamp at handle side.
Move handle of cab lock mechanism from position a to

position b (locked position).
Adjust pins e and f of left and right locking mechanism

assemblies, use lock nuts to fit them on bracket, and then fix
them with clips
Bracket
LIQUID HEATER
Liquid Heater HT-1
Table of Contents
I. Specially Notice of Using this Product... ... ... ... ... ... ... ... ... ... Page 3.
II. Operating Procedure of Controlling Switches... ... ... ... .. ... ...Page 4.
III. Main Technical Parameter And Principle of Work... ... ... ... Page 5.
IV. Inspection Proceeding Before Use... ... ... ... ... ... . ... ... ... ... Page 7.
V. Maintenance... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Page 8.
VI. Fault Analysis and Solution... ... ... ... ... ... ... ... ... ... . ... ... Page 9.
VII. The Precautions and Installation of the Heater… … … … Page 12.
Appendix 1. The Electric Circuit Wiring Diagram of the Heaters
Appendix 2. The Dimensional Drawing of the Heaters
Appendix 3. The Schematic Drawing of the Heater Installation

Liquid Heater HT-2
I. Specially Notice of Using this Product
1. When selecting the medium of the heating circulation, our company suggests you
to select the corresponding anti-icing fluid according to the lowest ambient temperature
which the vehicles work in.
2. This machine only can use the diesel oil or the coal oil as the fuel. It is prohibited
to use gasoline. The user should use suitable class light diesel oil according to the exter-
nal ambient temperature.
3. Before using the heater the pipeline valve must be open and the anti-icing fluid
must be fully filled in the circulation pipeline, otherwise the water pump will be grinding
at the high temperature, it will cause the hydraulic packing part damaged.
4. The combustion-supporting blast pipe, the exhaust pipe and the after drip tubing
should be stretched outside the cabin, and unobstructed, to avoid the spate splashing and
blocking.
5. The heater should be prevented to be drenched and mud splashed into, to guard
against causing the electrical failure. When arranging the group of lines of the heater, the
user should guarantee it to be far away from the heat source of vehicles and the heater
(for example, exhausting pipe); At the same time, to guarantee the plug-in unit seal to be
free from smut splash by using the sealant or other ways. When the group of lines passes
through the partition board of compartment baggage compartment, it must be protected
by the rubber or plastic rings and fixed to prevent the vibration, the attrition.
6. The main engine of the heater should have the independent cabin space, please
guarantee it is clean, it is strictly prohibited to lay aside flammable sundry goods around.
7. You are suggested to take the oil from the passenger train main tank, avoid install-
ing the fuel tank for the heater in the heater cabin. If you attach the fuel tank for the heater,
you should pay attention: The fuel tank, the tubing should be far away from the engine
exhaust pipe and the heater exhaust pipe as far as possible, to reduce heating give-off to
the fuel tank, the tubing to avoid any danger. (The fixed bed or support of the main en-
gine of the heater is strictly prohibited to be made of combustible material).
8. It is prohibited to replace the parts or the plug-in units on the heater with
non-Nanfeng products. (Otherwise any damage does not belong to maintenance scope)
9. When stopping the heater, the vehicle main power switch may not be shut down
before the controlling switch burning indicating lamp is extinguished (namely to strictly
prohibit using it to shut down the heater), to prevent the main engine too hot to be dam-
aged.
The using environment of this machine:
1. Operating temperature: -40℃ to +85℃
2. Preserve temperature: -55℃ to +,125℃
3. Altitude: <= 3000M
4. Rated voltage: DC12V, DC24V
5. Fuel: Diesel oil or petroleum (pay attention to the temperature class)
6. This machine is suitable for any surface condition of roads.
Liquid Heater HT-3
II． Controlling Switches

1. wiring diagram of controlling switches
2. Operating Procedure of Controlling Switch

1) Turn the heater switch K1, the water pump starts to work, this operation
may realize using the engine afterheat to preheat the compartment and defrost
the windshield in front of the driver. Turn the heater switch
K2(green),auto-controlling procedure of heater starts working, the oil
starts to be supplied for 4 seconds, then preheat for 60 seconds. the heater
starts to burn, about 1 minute later the burning indicator is on, the heater
enters the burning condition, green light is on. When the heater is working,
the control circuit and the heater water temperature sensor can keep the
temperature of the recycling liquid inside the heater constantly between 65℃
- 81℃ (namely the heater starts to heat when the water temperature is 65℃,
and auto-stop at 81℃).
2) Stop heating up. Turn off the heater switch K2, water pump stops
working , after about 2 - 3 minutes later, the burning indicator is off.
Liquid Heater HT-4
3) Stop circling of water pump. Shut down water pump switch K1(red) ,water
pump stops working.
When shutting down the heater, it is prohibited to turn off automobile
main power before the burning indicator of the controlling switch is off,
(namely strictly prohibit using vehicle main power switch to shut down the
heater), to prevent the damage for over-heat inside the main engine.
III. Main Technical Parameter and Operational Principle

1. The data sheet of main specification and model, technical parameter and applicable
scope: (Heat flux 1KW = calorific capacity 859Kcal)
Item Heat Oil Motor Circulation of Dimension Suitable for Independent heat-
parameter flux consume Voltage power medium Weight (L╳W╳H ing and defrosting and low
Model (KW) (Kg/h) (V) (W) (Kg) ) temperature preheating start
(mm)
Pump forcible 647╳328╳3 in 12-meter large passenger bus

YJ-Q35TR 35 3.6 DC24V 140 24
circulation 14 and military vehicles
DC12V Pump forcible 647╳328╳3 in 11-meter large passenger bus

YJ-Q30TR 30 3.1 140 24
DC24V circulation 14 and military vehicles

YJ-Q27.9TR 27.9 3.0 140 23

YJ-Q23.3TR 23.3 2.5 140 23
in 8-9-meter large & medium

DC12V Pump forcible 575╳328╳3
YJ-Q19.8TR 19.8 2.16 140 22 passenger bus and military ve-
DC24V circulation 14
hicles
in 8-9-meter large & medium
DC12V Pump forcible 539╳247╳2
YJ-Q19.8D 19.8 2.16 80 19 passenger bus and military ve-
DC24V circulation 86
hicles
DC12V Pump forcible 538╳304╳2 in 7-8-meter medium passenger

YJ-Q16.3R 16.3 1.78 140 22
DC24V circulation 67 bus and military vehicles
DC12V Pump forcible 500╳292╳2 in 6-7-meter medium passen-

YJ-Q11.6R 11.6 1.22 140 20
DC24V circulation 73 ger bus and military vehicles
DC12V Pump forcible 500╳292╳2 In business car and mobile ma-

YJ-Q8.1R 8.1 0.85 140 27.8
DC24V circulation 73 chinery shop
Liquid Heater HT-5
2.The principle of work:
1 2 3
4 5 6 7 8 9 11 12
10
13
14
16 15
1 Air Intake Cover 2 Burner assembly 3 Electricthermal Plug connect 4 Electricthermal Plug 5 burning box
6 water pump 7 Heat exchanger 8 setdown resistance 9 Extra-temperature safety 10 Thermal coupling
11 Air outlet valve 16 after drip pipe 12 water temperature sensor （thermal coupling）
13 Control box of thermal coupling 14 Electric Magnet Oil filter 15 water outlet Plug
The heater is composed of the combustion system, the water jacket, the circulating water
pump and the control system. The combustion system is composed of the burner, the
combustion chamber, the spark plug and so on. The burner is composed of the direct cur-
rent motor, combustion-supporting wind wheel, the atomizer, the oil pump and so on. The
oil pump is driven by the electrical motor; the inhaled fuel oil is delivered through the pe-
troleum pipe to the atomizer, dispersed by the centrifugal force at high speed, the oil mix
Liquid Heater HT-6
with the air inhaled by the combustion-supporting ventilator in the combustion chamber
and form into fog shape, that is ignited by the spark plug. After it is fully combusted in
the combustion chamber, the fuel gas is turned back at 180°by the flame baffle plate be-
hind the heat interchanger, flows through the heat conduction piece of the heat inter-
changer wall, transmits the majority of heats through the heat conduction piece to the wa-
ter (anti-icing fluid) in the water jacket. The liquid is forced to discharge by the circulat-
ing pump in the pipeline, enter the natural radiator or forcible radiator tank in the vehicle,
then exchange with the air in the vehicle, the warm up is realized by the heater. The ex-
haust gas is discharged by the exhaust pipe.
IV． Inspection Items and System Debugging Before Use

1. Before using the heater, you must carefully check whether the electric circuit con-
nection of the system main engine is correct or not, fuel tank is sufficient or not, the stor-
age battery voltage is normal or not, the liquid medium in the circulatory system is fully
filled, the joints of the circulation and oil duct are well sealed.
(Note: the ground wire of this machine must be connected to the ground)
2. The heater is laid levelly and fixed firmly. The electric component unit should face
the outside of the heater cabin, in order to be convenient for the user to maintain the
heater. At the same time, the combustion-supporting air of the heater should be guaran-
teed to let in sufficiently, to avoid the heater to be bespattered by turbid water, and pre-
vent to suck in exhaust gas.
3. The heater after-drip tubing, exhaust fume pipe should stretch out the ledger wall
of the heater to guarantee the oil residue which is not burned completely and exhaust gas
to let out from the heater cabin body. The exhaust gas must be directly dispatched outside
the vehicle. It is not allowed to use the heat of exhaust gas directly to heat other spots.
4. The fuel pipe takes the oil from the main oil tank, cannot mix to connect with the
oil pipes of other equipment in the vehicle. The fuel pipes are made of the copper pipes of
Ф 5×1 or Ф 6×1, the joints are made of the standard cone-shape joints of M12×1.25, the
fuel tube connection is reliable, no leak air, the difference of the height between the liquid
levels of the fuel oil in the tank and heater center is in ±300mm.
5. The distance of the let-in joint of the oil filter solenoid valve and the fuel tank
should be in 7 meters (namely the oil pipe length). When the heater is first to use, the fuel
oil of the fuel tank cannot be sucked complete by the oil pump, the oil pump would take
the time longer a little bit than the normal start. Probably in 3 or 4 minutes, the oil pump
would come into normal condition to pump oil. If you find the oil pipe does not normally
take oil, you may stop the heater, and restart it. When it starts the second time, it will
work normally. Then the heater completes the process of ignition and combustion.
6. The fuel pipe must be fixed and protected section by section separately to prevent
from in vibrating, attrition and occurrence of unusual oil-taking during driving.
Liquid Heater HT-7
7. All the various pipes that connect to heater main engine must be guaranteed to be
unobstructed. The water intake of the water tank should be located at the most high posi-
tion; the heater main engine (and water pump) should be located underneath the entire
circulatory system for good circulation of the system. The warm water pipe should not be
curved in dog leg. The pipe system is combined by copper pipes, rubber pipes and other
fittings. The pipeline pressure resistance certainly is bigger than 6kg/Cm2.
8. The pipeline valves must be turned on before use, to prevent the heater organism to
be too hot.
Notice: When your first use the heater system or replace and replenish
anti-icing fluid, you must open the heater air escape valve first (on the heater water
inlet pipe) and other air escape valves. After starting the engine (to step on accel-
erator) and no gas coming out from the air escape valve, stop the air escape valve,
turn on the water pump switch and continue the replenishment, repeat the above
operations for 1 to 2 times, until there is no gas in the pipeline system to stop up, and
fill the anti-icing fluid up to be full.
V. Maintenance
After the warm-up season of the heater, the main engine of the heater should be un-
installed to be cleaned, maintained and overhauled. Usually it is not necessary to be
overhauled in the warm-up season. If you find that thermal efficiency obviously decreases,
the spark plug is not easy to ignite or other breaks down occurs it is supposed promptly to
search the reason and remove the problem.
1. After the heater works for a period of time (according to user service condition),
the spark plug should be removed to clean up carbon deposit, if the spark plug burns out,
it should be dismantled and replaced by a new spark plug.
2. If the carbon deposit is too heavy, that causes the thermal efficiency reduces, you
should clean up the radiator fin in the water jacket and the carbon deposit in the combus-
tion chamber.
3. If you discover the air feeder of the heater main engine, exhaust pipe and the af-
ter-drip tubing are stopped up by the soil, please clean up and dredge them promptly.
4. Keep clean the fuel tank, the oil tubing and the lubricate cup of the oil filter and
solenoid valve to prevent the contamination stop up the oil duct.
5. In the heater circulatory system the anti-icing fluid should be used as the circula-
tion heat-up medium which is seasoned with the external environment temperature.
6. The water pump of the heater should be periodically inspected according to the
user service condition, if it is discovered that the hydraulic packing part leaks water, or
the water pump starts and works difficult, an overhaul should be promptly carried out.
7. The automatic control box on the heater main engine, the oil filter solenoid valve
and other electric components should be maintained according to the maintenance method
of general low pressure electric appliance. The various performance parameters of the
automatic control box have been passed through the factory earnest regulation in the plant,
the user should not modify it arbitrarily.
Liquid Heater HT-8
8. In the normal condition, the main motor of the heater is free from service for 5,000
hours, if it does not work normally for the long period of revolution excessively or other
reasons, it should be overhauled to inspect the carbon brush wears or the bearing lubrica-
tion situation. If it is necessary you should add lubricant oil or replace the carbon brush.
9. In the warm season that the heater is not used, please regularly start it for 4-5 time,
and operate it approximately 5 minutes each time moves, that will guarantee the heater to
work normally in the next time.
10. Before changing a new brand diesel oil, the old one in the oil pipe should be
burned out.
VI. Fault Analysis and Solution
If the heater has malfunction during work, please analysis and inspect as below:
Malfunction Causes Resolvent
The power circuit does not connect or Check the wire or replace
the fuse is broken. the fuse.
The plugs of the circuit become flexi- Tighten or replace the
Power indicator does ble or bad contact plugs
not light，Motor does The circuit is misconnected or the
not work ground wire loose contacted Check the circuit，
（note：The ground wire must be Remove the fault.
earthed）
The control switch is damaged Replace the switch
After starting the pre- Thermocouple circuit is open Check the circuit
heating indicator lights, Charge or replace the
The voltage of the batteries is too low
the burning sound can batteries
be heard, but it does Check the cause，Remove
The oilway leaks or oil supply is lack
not work normally, fi- the fault.
nally the breakdown
Wrong fuel causes to ice in the oilway
indicator lights and Change the right oil
or wax
stop work.
The heater can not The oilway is jammed or the main oil Dredge the oilway and
ignite tank is lack of oil oil charge.
The oil adaptor is not pressurized and
Tighten the adaptor
leaks.
Liquid Heater HT-9
The oil filter magnet valve is open and Check the cause，Remove
does not supply oil. the fault.
Regulate the air intake
The combustion-supporting air is in-
and increase the intake
sufficient
air
Charge or replace the
The voltage of the battery is too low.
batteries.
The carbon deposit of preheating ig- Clean the carbon deposit
niter plug is heavy or heater strip is or replace the heater
turnoff. strip.
Replace or regulate the
The atomizing is not good.
atomizer.
Clean the stem in the air
The combustion-supporting air is in-
intake or regulate the air
sufficient.
intake
It is normal. The black
The heater starts nor-
The first oil supply is too much. smoke will disappear in a
mal but black smoke
few minutes.
comes from the smoke
Please give special order
pipe The altitude is high, the combus-
to the manufacturer in
tion-supporting air is lack of oxygen
advance.
The fouling in the water jacket is too
Clean the carbon deposit.
heavy.
The anti-ice liquid in the circulation
Increase anti-ice liquid
system is little.
Air block is in the heater main engine Discharge the air from
The body of the heater and tubes. the airout valve.
is too hot The valves in the circulation system of
Open the valves.
the heater are not open.
The rotate speed of the water pump is Check the cause，Remove
low. the fault.
Water pump has water Change the hydraulic
The hydraulic packing wore out
leakage packing
Liquid Heater HT-10
Abrasion without liquid inside the

Change the packing rub-
pump, the rubber parts of the water
ber parts.
pump packing wore and tore.
Fill anti-ice liquid after
No circulation of anti-ice liquid in the
deflating by air bleed
water jacket of the heater for air lock.
valve.
The heater does not The sensor of the water temperature is
Repair or replace it.
stop when the tem- out of order.
perature of water is The control box of water warmup has Change it to restore
higher than 80℃. malfunction. work.
The circuit is misconnected or the
ground wire loose contacted Check the circuit and
Turn on the switch of
（note：The ground wire must be remove the malfunction.
the heater at the water
earthed）
temperature of 65℃,
The control box of water warmup has Change it to restore
but the heater can not
malfunction. work.
work normally.
The sensor of the water temperature is
Change the sensor
out of order.(trouble light is bright)
The worm wheel of the oil pump is
Check the worm wheel.
not running free.
Check the cause and re-
The main motor is short-circuiting.
place.
The wind wheel is locked by foreign Check the cause and re-
bodies in air intake. move.
The heater is fused or Check the cause and re-
The pump motor is circuiting.
the wire burns out. place.
The pipe line of the heater does not
circulate; air lock or blade wheel is
place.
distorted.
The hole in the clapboard of the lug-
gage cabin is not protected by rubber
place.
ring, that cause short-circuiting.
Liquid Heater HT-11
VII. The Precautions and Installation of the Heater

The installation of the heater is especially important after the type is chosen, because the installa-
tion effect the use of heating system. While installing the heater do as below:
1. Place the heater level and fix it firmly. The heater should be easily installed and removed,
the control box should face outside (as per Fig.7), easy to be checked and maintained and have
space for maintenance. The heaters should be disposed in the luggage cabin, the environment tem-
perature can be high. Notice: the heater must be fixed on metal structure instead of wood floor or
bamboo floor.
the control box is forth the control box is entad
Door Door
Correct Incorrect
(Fig.7)
2. The heater must have enough air intake, open a window shutter of more than 100cm²(Fig.8) on
the side wall of the heater and prevent sucking exhaust gas in air intake pipe. The vent pipe exhausts
free out of the cabin of the heater. It is not allowed to introduce the exhaust gas into other parts to be
heated or lengthen the vent pipe to let.

Liquid Heater HT-12
The air intake area of the

heater is more htan 100C
8 )
3. The oil pipe of the heater had best connected to the main oil tank. The oil pipe is made of copper
pipe of Φ5×1, The joint is M12 x 1.25 standard taper tie-in, the connection is firm without leak. The
difference of the liquid level of oil tank and the center height of the heater is within ±300mm. The dis-
tance between the magnet valve of the heater and the oil tank should be within 7m ( as per Fig.9). The
oil pipe must be independent from other oil pipes.
(Fig.9)
4. The electric connection refers to the circuit diagram. It is absolutely forbidden to replace the
Liquid Heater HT-13
groupware of the heater and the plugs of the control box. The motor power should be enough. The
work should be done during power off. Note: the ground wire should be earthed.
5. The disposal of the pipes of the heater must be in reason. The position of the heater is as lower
as better. The heating pipe must be without dog leg. The compression resistance of the pipes is more
than 6kg/cm2 (as per Fig.10).
The pipeline is with dog leg, The pipeline is good,

circulation is not good circulation is well
Incorrect Correct
(Fig.10)
6. The radiation fin should be in full length, preventing the leak of quick disconnecting coupling
due to normative operation and break of joints due to vibration. That is easy to be installed.
7. The both ends of the radiation fin had better to connect the pipeline under the floor with rub-
ber elbows, it will avoid the break of joints during bodywork vibration. (as per Fig.11)
Liquid Heater HT-14
Nylon Tee coupling
Copper pipes
Floor
Rubber elbow
(Fig.11)（Preventing sympathetic vibration）

8. When the circulating agency in the pipeline is antifreeze, valves should be installed at the
water in and out pipes of the engine and the heater in order to prevent let out the antifreeze in the sys-
tem during examine and repair (for the antifreeze is expensive).
9. Especial notice to the water system of the heater: the water circulating direction must be same
when the heater joint the engine, the water in-take of the heater should be connected with the outlet of
the water jacket of the engine, after the outlet of the heater connected with the radiating defrost device
the backwater returns to the return pipe of the radiator of the engine. The intake and outlet of the en-
gine have to be fitted with valves to prevent leak of heating and effect the engine operation, and the
valves should be as near to the engine as possible. The pipe between the engine and valve must be
metal as per Fig.1 (rubber pipes are easy to be damaged for the high pressure and high temperature).
The joint between the intake of the engine and outlet of the radiation water tank may be special back-
water Tee coupling, cut off 30 or 40mm of the rubber return pipe in the middle and connect the Tee
coupling to them, or weld a valve 4/5”or 3/4”to the metal return pipe and joint the radiating and de-
frosting backwater pipes.

Liquid Heater HT-15
Radiation
ENGINE water
tank
Cut off 30cm or 40 ,connect the back

water pipe of the heater or weld a valve
or 3/4" on metal pipe of the
backwater pipe.
(Fig.13)
10. The water jacket of the engine has many shapes of water outlet. The imported engine has a
joint for water pipe of out dia. φ38, that can be connected with the heating pipe; some engines have a
pipe plug 3/4”or 1”at the side of the jacket or the calorstat, that can be replaced with a joint, or a
valve to be screwd on the engine. If it is necessary a rubber adaptor (φ25－φ38）can be connected to
the heater.
11. The choice of the pipes:
Copper tubes are better to be used as the water pipes. The outside of the tubes should be wrapped
with thermal insulation blankets to reduce heating loss (as per Fig.14). The copper tube has no such
problems as aging and dog leg, the effect of use is good. The joint of metal pipe can be connected with
a rubber elbow or nylon joint.
thermal insulation blanket Fixup board
Copper tube
(Fig.14)
Liquid Heater HT-16
Appendix 1, System Wiring Diagram of the Heaters
THE WIRE HARNESS:
The wire harness between the heater and switch board must be fire proofing and can not be mixed
with other wire harness, and keep distance from tinder, to prevent short circuit after longtime aging.
Notice: when wiring the heater through the luggage cabin or metal board, protect the wire harness by
rubber jackets, otherwise longtime rub of wire harness and bodywork will cause short circuit and bring
fire. At same time the plugs of the heater should be airproofed by glass glue or other method (Fig.16)
to prevent short circuit for drenching or wetting. The heater has a fuse of 30A.
Liquid Heater HT-17
Appendix 2, the Dimensional Drawing of the Heaters

Liquid Heater HT-18
Liquid Heater HT-19
Water intake
Water outlet
Technical Parameter
After drip hole Type：YJ-Q19.8D Heat Flux:19.8KW
Voltage: DC12V/24V Oil Rate:2.16Kg/h
Motor Power: 80W Weight:19Kg
Dimension: 539×247×286(L×W×H)mm
Air Vent Mounting hole
Water outlet
Water intake
Mounting hole
After drip hole Technical Parameter

Type：YJ-Q19.8TR Heat Flux:19.8KW
Dimension: 575×328×314 (L×W×H)mm
Air Vent
Liquid Heater HT-20
Water outlet
Water outlet
Water intake
Control
box
Technical Parameter
Type：YJ-Q16.3R Heat Flux:16.3KW
Air Intake Motor Power: 120W Weight:22Kg
Dimension: 538×304×267 (L×W×H)mm
Air Vent
Mounting hole
Water intake Water outlet
Control
box
After drip hole Technical Parameter

Type：YJ-Q11.6R Heat Flux:11.6KW
Air Intake Voltage: DC12V/24V Oil Rate:1.22Kg/h
Dimension: 500×292×273(L×W×H)mm
Air Vent
Mounting hole
Liquid Heater HT-21
Appendix 3, the Schematic Drawing of the Heater Installation
Air Bleed Valve

Automatic vent-pipe
connected to expansion tank
Connect to the backwater

Defroster
pipe of engine
Note:This pipe
must be metal
Connect to the
water oulet of
Figure 1. Schematic Drawing of assemblied engine
coercive radiator fins and natural radiator fins
Heater
Air Bleed Valve

Automatic vent-pipe
connected to expansion tank
Connect to the backwater

Defroster
pipe of engine
Note:This pipe
must be metal
Connect to the
water oulet of
Figure 2. Schematic Drawing of physical engine
radiator pipelines
Heater
Liquid Heater HT-22
Coercive Coercive
Radiator Radiator
Connect to the backwater pipe

of engine
Defroster
Post
Note:this pipe position
must be metal Engine
Connect to the
water outlet of
Coercive Coercive
engine
Radiator Radiator
Figure 3. Coercive and parallel connection
Coercive Coercive
radiator radiator
Connect to backwater
pipe of engine
Defroster
Note: this pipe must be

metal
Coercive Coercive
radiator radiator
Connect to water
outlet of engine
Figure 4. Coercive and Series-wound Type Heater

(the pipeline in the compartment)
Liquid Heater HT-23
Coercive Coercive
radiator radiator
Connect to backwater
pipe of engine
Defroster
Note: this pipe

must be metal
Connect to water
outlet of engine
Coercive Coercive
radiator radiator
Heater
Fig.5. Coercive and parallel connection

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WORKSHOP MANUAL

WORKSHOP MANUAL Contents

HFC1020K (D134) Specifications

高顶/半高顶 型号 Model HFC1020K

HFC1030KR (D213) Specifications

高顶/半高顶 型号 Model HFC1030KR

高顶/半高顶 型号 Model HFC1020KL

1.2 Vehicle Model：HFC4131KR1

Company Vehicle Type Main Code from

Company Code Name：HFC-----represents JAC motor

1.3 VIN----Vehicle Identification Number

World Manufacturer Identification

1.4 The mechanic performance table of bolts in China

Tensile strength limit σbmax(MPa) 600 800 900 1040 1220

Yield limit σsmax(MPa) 480 640 720 940 1100

Corresponding to Hyundai standards 4T 6T 7T 8T 10T

Precautions on clutch installation

General inspection and repair

Diagnosis and repair of common failures of clutch

preventing the transmission system from overload.

Clutch assembly Driven disc assembly of clutch

Major data and specification

Outside diameter of driven disc (mm) Ф 254

Bore of general clutch cylinder X stroke (mm) Ф 19.05×35

Bore of working cylinder clutch X stroke (mm) Ф 26.99×19.05

Clutch pedal travel mm 160

Free travel clutch pedal mm 3— 5

Brake fluid DOT3 or DOT4

Precautions on clutch installation

stains on the fly wheel and clutch plate working surface.

and gear surface. Sticking is not allowed.

General inspection and repair

Using a depth rule, measure the subsidence

Height and travel of clutch pedal

Air bleeding of clutch pipe

Diagnosis and repair of common failures of clutch

6. Oppressive clutch pedal

Here we will analyze these failure types item by item.

does not transfer torque.

overload running, climbing steep slope.

clearance for release bearing.

slipping exists through slipping test method.

burning, replace it.

Poor disengagement (hard to apply gear shift)

worse condition, gear shift can only be applied by stopping engine.

engagement point through the following method:

1. Allow the engine to run at idle. (Transmission in neutral shift)

disengagement of clutch exists.

assembly of the clutch on the input shaft and poor returnability.

to the next step.

apply an appropriate amount of lubricating grease (high-temperature resistant lubricating grease).

re-confirm it after installation, until failure is eliminated.

Diagnosis method (operation order):

release hand brake and foot brake.

2. Slowly release the clutch without depressing the acceleration pedal.

3. At this time, confirm whether the vehicle body vibrates.

5. Slowly release the clutch without depressing the acceleration pedal.

6. At this time, confirm whether the vehicle body vibrates.

(3) Friction plate tends to burned at gear shift 4 and 5.

There are following reasons:

substances, damping spring breaks or high friction coefficient of friction plate

mechanism, and unsmooth release fork.

高顶/半高顶型号 Model HFC1020K

高顶/半高顶型号 Model HFC1030KR

高顶/半高顶型号 Model HFC1020KL