Rear Suspension

Important operation-Assembling
The assembling direction of leaf spring must be the
same as that of the original state.
U- bolt
(1) Park the vehicle on a level surface, install the
U-bolt in the corresponding position of the leaf
spring.
(2) Lift up the vehicle.
(3) Align the front axle holes and the U-bolt.
(4) Apply machine oil on nuts before tightening them
so as to avoid damaging the thread.
(5) Tighten the nuts.
Install the leaf spring pin; tighten it to the specified
torque.
Torque (N.m) 157-196
Fill in grease after assembling.
Rear shock absorber assembly
Nut, washer and rubber bearing bush
Disassemble the shock absorber assembly, nut,
washer and bearing bush by following the sequence
indicated in the diagram.
Tighten the nut until the washer contacts the end
fitting surface.
Rear Suspension
Rear shock absorber assembly
Main data and specification
Types
Max. outer diameter of liquid storage cylinder (mm)
Max. outer diameter of boot (mm)
Main stroke (mm)
Compression length (mm)
Extension length (mm)
Two-wayhydraulic cylindrical shock
absorber
45
53
220
336
556
Rear Suspension
Trouble shooting of front suspension
Strident tyre noise
Check wheel
YES
Check steering knuckle spindle
and steering linkage
YES Deformed
Check suspension fixing bolt
YES Loosened
Tighten
Replace
Check tyre pressure
YES NO
Adjust
NO
Adjust
Rear Suspension
Body bounding
Road test vehicle
Noise is regular Noise is not regular
Replace tyre
Check tyre for balance
YES NO
YES NO
Check suspension system
YES Damage
Replace
Check tyre for balance
Adjust
Adjust or replace
Check bolts and nuts of suspension system
YES Loosened or
Tighten or replace
Rear Suspension
Excessive wearing of tyre or local wearing
Check tyre pressure
YES NO
Adjust
Check wheel alignment
YES NO
YES Fault
Check brake adjustment
YES NO
Adjust
Check wheel bearing
Adjust
Replace
Check wheel rotating condition
YES Not rotate
Rotate wheel withrecommended
Check drive method
YES Unstable or incorrect
Drive more evenly
Rear Suspension
Spring broken
Load condition
YES Wornor damaged
Replace
Check U-bolt
YES Check bolts and nuts Damaged
YES
Check shock absorber
YES Damaged
Check spring bushing
YES Wornout or
Check lifting lug pin and pilot
Whether bolt, nut loosened
Replace
Replace
Check center bolt
YES
YES Loosened Damage
Replace
YES
Oil
Replace
Bushing
Wornout
Bracket
Broken
Replace Replace
Replace
Rear Suspension
Body inclined
Check spring
YES Rusted Springiness of spring weakened or
Clean Replace
Check liftinglug pinand bushing
YES
Insufficie
Wornout or broken
Apply grease
Check steel plate bracket and U-bolt
YES Bolt loosened Broken
Tighten
Check
Bushing worn out or broken
YES Replace Check fixing support
YES Damaged
Replace
Rear Suspension
Trouble shooting of rear suspension
Body inclined
Check spring
YES Rusted Springiness of spring weakened or
Clean Springine
Check liftinglug pinand bushing
YES
Insufficie
Wornout or broken
Apply grease
Check steel plate bracket and U-bolt
YES Bolt loosened Broken
Tighten
Check
Bushing worn out or broken
YES Springine Check fixing support
YES Damaged
Replace
Rear Suspension
Space to ground reduced
Check load condition
YES Broken
Replace
Check clip strip
YES Loosened Wornout or broken
Tighten
Check bushing
YES Deteriorated or
Lubrication
Fill grease
YES
Insufficient
Over lubricated
Leaf spring
Check leaf spring
Replace
Replace
Remove surplus grease
Check parts for loosening
Tighten
YES Loosened Brokenor damaged
Replace
Rear Suspension
Spring broken
Load condition
YES Wornout or
Replace
Check U-bolt
YES Check bolts and nuts Damaged
YES
Check shock absorber
YES Damaged
Check spring bushing
YES Wornout or
Check lifting lug pin and pilot
Check whether bolt, nut
Replace
Replace
Check center bolt
YES
YES Loosened Damaged
Replace
YES
Oil
Replace
Bushing
Wornout
Bracket
Broken
Replace Replace
Replace
Rear Suspension
Body bounding
Road test vehicle
Noise is regular Noise is not regular
Replace tyre
Check wheel for balance
YES NO
YES NO
Check suspension system
YES Damaged
Replace
Check tyre for balance
Adjust
Adjust or replace
Check bolts and nuts of suspension system
YES Loosened or
Tighten or replace
Front axle assembly
General
Technical parameter
Tightening torque of main bolts and nuts on front axle
Inspection and repair
General
The front axle of this model is integrallysupported byI beam.
single tyre
Main data and specifications of front axle
Transmission systemform 4X2
Tread (mm) 1440
Front wheel alignment
Diagonal tyre 37 mm
Front wheel toe-in
Radialplytyre 13 mm
Front wheel camber 1 degree
Positive caster 240 (degree)
Kingpin inclination 7.5 (degree)
Inner turn 37 degree
Steering angle
Outer turn 30 degree
Amount of grease used for bearing on
the side of wheel hub
320 g
Tighteningtorque of mainbolts andnuts of the front axle
Unit Nm
113 14.7
441 49
49 9.8
186 19.6
32.4 4.9
186 19.6
50 75
441 49
Inspection and repair
Adjustment of front wheel alignment
1. Measurement and adjustment of toe-in
1 Place front wheel on a flat place.
2 Mark the centre of tyre wheel track with
chalk.
3 Place toe-in measuring device on the
central position of wheel.
(4) Measure the distance (A) between tyre
centrelines in front of vehicle.
(5) Push the vehicle back and forth to turn
everywheel of 180 .
(6) Measure the distance (B) of tyre centreline
on the backside of front wheel according to the
original mark.
Toe-in equals to B less A
In case of misalignment of the toe-in
(7) Unscrewthe clamping screw on the end of
connection rod.
(8) Turn the connection rod with a pipe wrench
to adjust toe-in.
2. Turning radius
1 Put a wood block beneath back wheel,
the thickness of which is the same as that of
measuring device.
2 Put front wheel onthe device and ensure
it is located at the centre of the device
3 Turn front wheel to maximumposition in
clockwise and counter clock-wise direction
respectively.
Note: steponbrake pedal whenturningthe front
wheel.
Inner turning angle
Outer turning angle
If turning angle is incorrect, make adjustment.
Adjustment steps:
1 Unscrewthe lock nut of adjusting bolt on
steeringknuckle
2 Adjust the height of bolt until steering
angle meets requirement.
3 Tighten the lock nut.
3. Other parameters of front wheel alignment.
1 Remove front wheel hub cover.
2 Mount a measuring device of front
wheel alignment parameter on the end of
steering knuckle. Calibrate front wheel
turning angle to zero.
3 Measure the front wheel alignment
parameters in the fig.
4. In case of incorrectness of parameter
measurement
Repair relevant parts in the left column.
Measurement of side slip
Measurement of side slip should be done after measurement
and adjustment of toe-in and positive caster.
(1) Slowthe rolling wheel as possible to pass over the side slip
measuring instrument. Read the side slip measuring
instrument.
(2) If side slip value exceeds 5 mm/m readjust front wheel
alignment.
If the front steel spring is fatigue
If the front I beamis deformed
If main pin, main pin bushing and
bearing are worn excessively
Front wheel camber
Kingpin inclination
Positive caster
Front
Front wheel hub and brake drum
Disassembling
Disassembling sequence:
1.wheel 2. wheel hub cover 3. split pin slotted nut 4. washer 5.wheel hub and brake drum
assembly 6. wheel hub oil seal seat 7. wheel hub outer bearing 8. wheel hub inner bearing oil
seal 9. wheel hub inner bearing nut 10.wheel hub inner bearing outer race 11. wheel hub outer
bearing outer race 12. brake drum 13. wheel hub 14. tyre bolt 15. inner nut
Installation sequence is just opposite to the disassembling sequence.
Main operating steps for disassembling
Pull the parking brake and jack up front axle.
1. Remove wheel.
2. Remove wheel hub cover.
Take care not to damage the contacting
surface of wheel hub cover.
3. Remover split pin slotted nut.
4. Remove wheel hub and brake drum
assemblywith an extractor.
5. Remove bearing bushing outer race.
Inspection and repair
Visual inspection of the parts listed in the left
for damage or failure.
1 Wheel hub
2 Wheel hub bearing, oil seal
3 Knuckle groove
4 Brake drum
5 Brake shoe, gasket, etc.
Main operating steps of installation.
Add grease according to the fig.
Inside wheel hub 280 g
Inside wheel hub cover 40g
Adjustment of preload of wheel hub
bearing.
Adjust the clearance of brake gasket in the first
place.
Adjust bearing preload with wheel hub nut.
It proves to be ok if the pulling force at the wheel
bolt is measured as follows:
11.726.4N
Grease
Front axis and steering knuckle
Disassembling
Disassembling sequence
1. String rod assembly 2. Steering bend arm 3. Steering straight arm 4. Main pin upper
cover 5. Lock bolt 6. Main pin lower cover 7. Main pin
8. Steering knuckle assembly 9. Adjusting washer 10. Thrust bearing 11. I beam
Main operating steps of disassembling
Pull parking brake and jack up front axle.
Remove string rod assemblywith an expeller.
Put a brass stick on the steering straight arm
and punch with a hammer when removing
the steering straight arm.
Remove lock bolt.
Inspection and repair
Visual inspection of the parts listed in the left
for damage or failure.
Repair I beam
Insert main pin or testing stick into I beam
hole.
Pull straight a thread between the centres of
the sticks
Observe if the thread aligns with two steel
spring positioning bolt holes.
I beam
Steering knuckle
Steering straight arm
String rod Main pin
Thrust bearing
Adjusting gasket and bushing
String rod ball
Main pin or testingstick
Thread
Steel spring positioning bolt
Observe if the two main pins or testing
sticks align with each other fromside view.
Inspect the main pin hole surface for any
deformation and wear.
Observe the damage situation of the
steering knuckle surface, especially of the
parts pointed by arrows in the fig.
Inspect with magnetic inspection
equipment.
Check contacting situation of steering
straight arm, Steering bend arm and ball
cone by colouring the contacting area.
The contacting area should be bigger than
3/4 of the total area.
Otherwise, change relevant parts.
The contacting area is
bigger than 3/4 of the total
area
Measure the clearance between
main pin and kingpin bush.
The clearance should be less
than 0.15mm.
Otherwise, change bush.
If the new bush is too tight after put in,
carefully machine the inside surface of the
bush with a reamer.
Concentricityof connection rod is 1mm.
Main operating steps of installation
Add proper amount of grease before
installationThrust bearing
Take care not to make wrong direction.
Housing
Top
Bottom
Measure the clearance between steering
knuckle and I beam fist so as to choose
gasket with appropriate thickness.
Standard clearance after installation of
gasket is 0 to 0.1mm.
Ensure notch on the main pin align with lock
bolt hole when installingmain pin.
Steering knuckle should turn freely after
filling grease.
Install lock bolt
Tighten it to specified torque.
Install main pin cover with an appropriate
round bar.
Tighten steering straight arm and steering
bend armto specified torque.
Screwstring rod ball to specified torque.
Steering
1
Steering
General
Specifications
Torque
Steering column and steering shaft
Steering gear disassembling
Power steering fluid filling and attention points
Trouble shooting
Steering
2
General
Steering gear
This model is provided with rotaryvalve type power steering gear
Steering
3
Steering linkage
Specifications
Steering column and shaft
Tiltable steering gear
Steering wheel mm
Back play
Steering shaft type
Adjustable range Back and forth
430
10 15
dual connector
11
Major specifications of the power steering gear
Max. applicable front shaft load
2500kg
Max. theoretical output torque
1580N.m
Steering round
4.2
Output angle
46
Output spline (ODgear)
17.536
Output spline big end ODgear
3536
Operating pressure
10.3Mpa
Applicable operating temp.
-40 135
Rated pumpflow
(8-11)L/min
Net weight
18kg
Steering
4
Torque Nm
Steering column
Steering
5
Device and tie rod
Steering
6
Steering column and steering shaft
Disassembling and assembling
Disassembling sequence just contrary to assembly sequence
1. Steering wheel assembly 12. Hex flanged face luck nut
2. Grouped switch assembly 13. Nylon limit bushing
3. Steering column handle cover 14. Bushing
4. Hex head bolt 15. Shaft sleeve
5. Flat gasket 16. Hex head bolt
6. Steering column handle 17. Steering column shaft sleeve assembly
7. Steering column adjusting lever nut 18. Adjustable steering support assembly
8. Spring 19. Steering column pipe dust cover
9. Limit support 20. Steering column pipe welding assembly
10. Adjusting piece 21. Steering drive shaft assembly
11. Adjusting nut 22. Steering column enclosure assembly
Steering
7
Important operation--Disassembling
Horn button
Pull out the horn button.
Steering wheel
Turn the steering wheel and steering shaft aside, make the mark, to
ensure that parts will be in the original positions during assembly.
Bolt: fix the worm shaft and steering knuckle
fork
(1) Tilt the cabin up, and support the cabin with the
strut.
(2) Make positioning marks on the steering knuckle
and worm.
(3) Remove the fixing bolts with pneumatic spanner or
fixed wrench, and then pull out the flange fork.
(4) Lower down the cabin slowly.
Inspection and repair
Necessary correction or parts replacement shall be made if any abrasion, damage or other
abnormalities are found during inspection.
positioning mark
fixing bolt
positioning
mark
Steering
8
Reassembling
The reassembling sequence is contrary to that of the disassembling.
Important operation--Assembling
Bolt: fix the wormshaft and the steering knuckle fork.
In fixing, alignment shall be made with the positioning
marks made
Steering wheel
Turn the steering wheel and steering shaft aside, make
the mark, to ensure that parts will be in the original
positions during assembly.
Important operation--Disassembling
Note: Before removing the steering gear assembly, take down the inlet/outlet hoses of the power
steering pipes first. At this time, pay special attention to the connector and screwplug, or seal the
oil injectionport with ribbonafter the oil pipe is takendown, to prevent dust or other foreignmatters
getting in.
Important operation--Assembling
Steering vertical arm
Align with the positioning mark.
Tightening torque range: torque (N.m) 250--270
positioning
mark (slot)
positioning
mark
positioning mark
Steering
9
Steering gear disassembling
Disassembling sequence
1 big nut elastic washer +rocker 2 side cover +rocker-armshaft assembly
3 locknut +adjusting nut assembly 4 thrust needle bearing
5 upper casing assembly 6 thrust ball bearing
7 rotary valve wormnut assembly 8 valve bush seal ring +valve bush seal washer
9 small O ring 10 Upper casing O ring
11 elastic retainer ring 12 input cup
13 steering nut seal washer +seal ring 14 lower casing assembly
15 output end cup +gasket 16 output end seal washer +seal ring
17 locknut 18 side cover assembly
19 rocker-armshaft assembly 20 side cover O ring
21 side cover cup
Steering
10
Important disassembling steps
1 Big nut +elastic washer +rocker
Turn the big nut counterclockwise by a torque
wrench, remove the elastic washer, and take
down the rocker arm.
Note: Do not hammer the rocker armwhen taking
down it, otherwise the side cover and rocker-arm
shaft assembly will be damaged; and do not
damage the small cone hole in the rocker arm.
2. Side cover assembly +rocker shaft assembly
Turn the input shaft to have the assembly in the
middle position (the drawing shows that marked
line on small end face of the rocker arm is
downward). Remove the fixing screws of the side
cover.
Hit the small end face of the rocker arm with a
rubber hammer, and take down the side cover
assemblyand the rocker-armshaft assembly.
18. Side cover assembly
19. Rocker-armshaft assembly
Turn the adjusting screw clockwise, and
takedown the rocker armshaft assemblyfromthe
side cover assembly.
Warning: Further disassembling of
rocker armassembly is not allowed, or it
will be damaged; the side cover
assembly cannot be further
disassembled except the O ring, or it
will get damaged.
3. Locknut +adjusting nut assembly
Use the tool shown in the drawing to remove the
locknut, take care not to damage the O ring.
Steering
11
3. Adjusting nut
Use the tool shownin the drawing to remove
the locknut, take care not to damage the O
ring on it.
5. Upper case assembly
7. Rotary valve wormnut assembly
When taking down the above 2 assemblies,
take care not to lose the thrust ball bearing
(4) and its different parts(6).
5. Upper case assembly
Disassembly sequence
1 elastic retainer ring for holes
2 cup on input side
4 upper case
6 upper case O ring
7 small O ring
Note: The needle bearing (3) and the
connector(5) shall not be taken down, or
they will be damaged.
14.Lower case assembly
Disassemblysequence
1 Cup on output side
2 Lower case
3 Seal ring on output side
4 Seal washer on output side
5 Dust ring assembly
Note: The needle bearing (7) shall not be
taken down, or it will be damaged.
Steering
12
Inspection and repair
Necessary repair or replacement shall be made if any parts abrasion; damage or other problems
are found during inspection.
lower case
rocker armassembly
rotary wormnut assembly
oil seal cup
bearing
O ring and seal ring
Visual inspection
Check for any abrasion, damage or other
problems of the following parts.
Turning of the wormnut
Turn the wormto see if its smooth. Check the
spiral chute, the valve bush seals and the nut
seal for anydamage.
Note: Do not disassemble the assembly and
do not damage the outer round surface of the
nut. If the valve bush seal or nut seal is
damaged, change themwith newones.
Rocker armassembly
Check the rocker tooth section and the bearing
support for any abnormal wear. If any, have
themchanged at the authorized service station
or manufacturer.
Clearance between rocker shaft and needle
bearing on output side
Limit mm 0.2
Clearance between nut and lower case piston
hole
Limit mm :0.15
Steering
13
Reassembling of steering gear
Reassembling sequence
1 output side cup+gasket 2 output side seal washer +seal ring
3 lower case assembly 4 side cover O ring
5 side cover cup 6 side cover assembly 6 side cover assembly
7 rocker shaft assembly 8 locknut
9 side cover assembly+rocker shaft assembly 10 input cup
11 steering nut seal washer+seal ring 12 rotary valve wormnut assembly
13 elastic retainer ring for holes 14 upper case O ring
15 valve bush seal ring +valve bush seal washer 16 upper case assembly
17 small O ring 18 thrust ball bearing
19 thrust needle bearing 20 locknut+adjusting nut assembly
21 big nut +elastic washer +rocker arm
Steering
14
Warning: The worm, nut, steel ball and valve components in the rotary valve worm
nut assembly are sophisticated parts that do not allow further disassembling;
otherwise, all the assembly will be damaged. And the screwed out length should
be controlled between the wormand nut, or the steel balls will fall out of the chute. All the
seals must be changed with new ones after disassembling.
9 upper case assembly
screwtightening torque 45Nm 55Nm
14 locknut
locking torque 180Nm 210Nm
15 rocker shaft assembly
18 side cover assembly
Turn the adjusting screw of the rocker shaft
assembly counterclockwise, until the rocker
shaft end gets contact with the side cover
bottom, and then turn 3-4 rounds backward.
Side cover assembly +rocker shaft assembly
Screwtightening torque 45Nm 55Nm
Warning: If the teeth are not installed
correctly, the steering gear will have
insufficient travel in one direction,
causing a steering accident. In fixing
the gear rack, check the spline for
any damage, to avoid scratches in
the oil seal of the cup.
Steering
15
Warning: If non specified power steering fluid is used or two kinds of fluids are
mixed, the sealing will fail, which causes no boosting for steering. If the steering
gear stays too long at a limit position during operation, the steering oil pump will get
damaged.
11 locknut side cover
Adjust the clearance between the rocker shaft
gear rack and nut rack
1 Fix the steering rocker arm
2 Have the steering gear in straight
forward position (middle)
3 Adjust the clearance to the specified
value
Gear clearance (mm) 0.33
4 Tighten the locknut
Tightening torque Nm 65 80
5 Check the start torque of the input shaft
Start torque Nm 0.4 1.2
21 Tighten the rocker arm
In fixing the rocker arm, ensure that the
tightening torque of the small end face of the
rocker armis:
250 Nm 280Nm
Steering
16
Power steering fluid filling and attention points
Oil filling: Fill the oil tank with oil first, start the engine, operate the drive pump at lowspeed to fill
the hydraulic systemwith oil. During the engine running, the oil level in the tank will go down
continuously, so, oil filling is needed all the time to avoid air suction into the pump. At the same
time, turnthe steering wheel right andleft to its limit positions repeatedlyfor several times, until the
oil in the tank stops going down.
Oil change: jack up the front axle and open the oil reservoir cover. Open the return oil port of the
steering gear, and start the engine in short time less than 15 seconds. Turn the steering wheel
right and left continuously to its limit positions to drain off all the oil inside, and then fill in oil as per
the filling procedure.
Exhaust: jack up the front axle, it will also do to remove the connecting rod, have the engine at
idling, and turn the steering wheel right and left to its limit positions for several times drain off the
air and vaporized oil. When bubbles are removed, the oil level inthe tank will go down, andnowoil
shall be added from time to time until the oil level gets stable. By now the exhaust process is
finished.
Attention:
1. It is forbidden to mix oils of different types for use.
2. The oil to be filled must pass the filter strainer in the oil reservoir of the steering system.
3.Oil must be added up to between the two specified scale marks on the measuringscale in the oil
reservoir (After the engine is started for 3-5 minutes, check the oil filling if it is between the
specified scale marks. If over-filled, oil will overflows after the engine is started; if under-filled, the
rotary blade pump will get burnt down).
4. In regular oil change, the oil reservoir and filter element inside shall be cleaned and washed,
without anyforeign matters allowed in. Take special care that no cotton fabric textiles are used
(such as cottonyarn and emerycloth, etc) to wipe the parts in order not to have anyof themtaken
into the systemand cause failures.
Steering
17
Trouble shooting
Not fully working
Correctio
YES
Oil pressure not enough
Check hose &connector for leakage
Loose hose coupling
Repair linkage per
Parts failure
Change
Check oil pumpcontrol
Clogge
Repair or
Damaged
Change
YES
Check oil pumpvalve
Broken Elasticity YES
Change
Check the piston ring
Damage
Change
YES
Change steering gear box
Check the
oil
Steering
18
Wandering
Check the bodyor chassis for any
Bodyor chassis deformed
Repair
YES
Check wheel bearings
YES Bearing gap too
Adjust
Bearing
Change
Check linkage
Connector gap too
big or fixed parts
Tighten or
YES Linkage
Change
Check front spring
Elasticity
Change
Valve plunger gap too big
Tighten
YES
Check the control
Valve plunger clog
Change steering gear box assembly
YES
Steering
19
Pump noises
Correctio
YES Pump noise
after
Check oil
YES Not enough
Refill
Check the hydraulic
loop for any air
Air trapped in the loop
Vent
Check the outlet &
filter for blockage
YES Outlet pipe or filter clogged
Clean or Check oil pump
YES Failure
Overhaul Change
Check steering gear
YES
Brake
1
Brake and Control System
General
Technical parameters
Tightening torque
Front brake assembly
Rear brake assembly
Parking brake assembly
Trouble shooting
Brake
2
General
Front brake assembly Rear brake assembly
Parking brake Vacuumbooster
Brake
3
Brake master cylinder
Brake pipe drawing
A oil pot B vacuumbooster, with serial master brake cylinder assembly C 5-wayconnector
D front wheel cylinder E oil pipe tee F rear wheel cylinder G. vacuumpump H vacuum
pipe tee I ventingaux. brake J . ventingaux. brake solenoidvalve K vacuumbarrel L vacuum
pipe connecting plate.
steel pipe connector
hose connector
vacuumhose
flexible hose
vacuumsteel pipe
brake oil pipe
rubber hose
Brake
4
Brake Specifications
Service brake
Front Rear
Type Dual leading shoe Duo duplex shoe
Brake drumID (mm) 320 320
Length (mm) 307 307
Width (mm) 75 75 Friction plate size
Thickness (mm) 8.1 8.1
Free length (mm) 208.0 208.0
Design length (mm) 224.0 224.0
Brake shoe return
spring
Design load (N) 225~275 225~275
Clearance between friction plate and brake
shoe (mm)
Below0.05 at rivet, below0.2 at side, below0.3
at end face
Brake master cylinder
ID (mm) 31.75
Piston stroke front +rear (mm) 18+15.5
Wheel cylinder
Front Rear
ID (mm) 30.16 30.16
Parking brake
Brake drum ID (mm) 178
Length (mm) 193
Width (mm) 35 Friction plate size
Thickness (mm) 5.0
Spring serial No. First Second
Free length (mm) 62 49
Design length (mm) 70 57
Brake shoe return
spring
Design load (N) 108 132 90 110
Vacuumbooster
Diaphragmdiameter (mm) 228+203
Stroke (mm) 35
Pedal
Free stroke (mm) 5 8
Brake
5
Fixed torque (Nm)
Front brake assembly (two leading shoe)
Rear brake assembly (two leading shoe)
Brake
6
Front brake assembly (two leading shoe)
Disassembling
Disassembling sequence
1. brake shoe spring rod, hold down spring and spring holder 9.oil cover
2. brake shoe return spring 10.locking claw
3. brake shoe assembly 11.shield
4. brake hose 12.piston
5. brake connecting pipe 13.adjusting screw
6. brake connecting pipe 14.piston cup
7. tee connector assembly 15.venting screwand its cover
8. wheel cylinder assembly 16.wheel cylinder body
Parts repair: wheel cylinder
Brake
7
Important operation
2 Remove the return spring of the
brake shoe.
4 Hose
Loosen the connecting nut , and take down
the clip and the hose.
Inspection and repair
Repair or replace the parts if they are
found worn out, damaged or with other problems
after inspection.
Visual inspection
Check the following parts for any abrasion,
corrosion, scratches or other problems.
Thickness of brake friction plates
Max. thickness: 1.0mm
brake drum
brake friction plate
wheel cylinder body
piston
piston cup
return spring
Brake
8
Return spring
Free length: 208.0mm
Design length: 224.0mm
Design load: 225 275N
Washing wheel cylinder parts
The wheel cylinder parts must be
washed and with clean brake fluid.
Do not use any mineral based cleaning
solution like gasoline, kerosene, and
acetone, paint thinner, CO
4
, etc.
Piston cup
Check the piston cup for any abrasion,
deformation, damage or other problems.
Clearance between wheel cylinder and
piston
Max: 0.15mm.
Brake drum
Standard Maximum
ID 320 321.5
Out-of-roundness 0.13
mm
Brake
9
Reassembling
Reassembling sequence
1. wheel cylinder body 9.whell cylinder assembly
2. piston brake shoe 10.tee connector assembly
3. piston cup 11.brake connecting pipe
4. shield 12.brake connecting pipe
5. adjusting screw 13.brake hose
6. venting screwand its cover 14.brake shoe assembly
7. locking claw 15.return spring
8. oil cover 16.brake shoe spring rod, hold down spring and its holder
Parts repair: wheel cylinder
Brake
10
Important operation
3. Piston cup
When fixing the piston cup, have its
butterfly side facing the cylinder. First, apply
clean brake fluid to the piston cup, take care not
to damage the cup lip. Apply rubber grease to
the piston shoulder.
4. Shield
To prevent water entry, apply clean
brake fluid to the shield inner surface.
6. Venting screw
Tightening torque 7 12Nm
9. Wheel cylinder assembly
Tightening torque 38 50Nm
10. Tee connector assembly
Tightening torque 14 23Nm
shield
piston piston cup
grease
Brake
11
11,12. Tee connector assembly
Tightening torque 13 19Nm
13. Hose
Fix the hose clip on the bracket, and tighten
the connecting nu .
14. Brake shoe
Apply a thin layer of heat resistance grease to
the brake shoe, wheel cylinder and the inner
surface of the back plate.
When fixing the brake shoes, have
their tip sides facing the wheel
cylinder and the adjuster.
Brake
12
Rear brake assembly (two leading show)
Disassembling
Disassembling sequence
1. brake shoe spring rod, hold down spring and spring holder 8.shield
2. brake shoe return spring 9.piston
3. brake shoe assembly 10.adjusting screw
4. brake connecting pipe 11.piston cup
5. brake connecting pipe 12.venting screwandits cover
6. wheel cylinder assembly 13.wheel cylinder body
7. locking claw
parts repair, wheel cylinder body
Brake
13
Inspection and repair
Repair or replace the parts if they are
found worn out, damaged or with other
problems after check.
Visual inspection
Check the following parts for any abrasion,
corrosion, scratches or other problems.
,
Thickness of brake shoe friction plate
Max. thickness: 1.0mm
Return spring
Free length 208.0mm
Design length 224.0mm
Design load 225 275N
brake drum
brake friction plate
wheel cylinder body
piston
piston cup
return spring
Brake
14
Washing wheel cylinder parts
The wheel cylinder parts must be
washed and with clean brake fluid.
Do not use any mineral based cleaning
solution like gasoline, kerosene, and
acetone, paint thinner, CO
4
, etc.
Piston cup
Check the piston cup for any abrasion,
deformation, damage or other problems.
Clearance between wheel cylinder and
piston
Max: 0.15mm.
Brake drum
Standard Limits
ID 320 321.5
Out-of-roundness 0.13
mm
Brake
15
Reassembling
Reassembling sequence
1. wheel cylinder body 8. wheel cylinder assembly
2. piston 9. piston brake connecting pipe
3. .piston cup 10. brake connecting pipe
4. shield 11 brake shoe assembly
5. adjusting screwbrake connecting pipe 12. brake shoe spring rod, hold down
6. venting screwand its cover spring and spring holder
7.locking claw 13. brake shoe return spring
parts repair, wheel cylinder body
Brake
16
Important operation
3. Piston cup
When fixing the piston cup, have its butterfly
side facing the cylinder. First, apply clean brake
fluid to the piston cup, then insert the cup. Take
care not to damage the cup lip. Apply rubber
grease to the piston shoulder.
4. Shield
To prevent water entry, apply clean
brake fluid to the shield inner surface.
5.Adjusting screw
When fixing the wheel cylinder adjuster, have
the shallowslot side face the outside.
6 Venting screw
Tightening torque 7 12Nm
9. Wheel cylinder assembly
Tightening torque 38 50Nm
shield piston piston cup
grease
Adjusting screw
Brake
17
9, 10. Brake connecting pipe
Tightening torque 13 19Nm
11. Brake shoe
Apply a thin layer of heat resistant
grease to the back plat between the brake
shoe and wheel cylinder as well as the inner
part B.
When fixing the brake shoes, have
the tips face the wheel cylinder and
adjuster.
Adjuster
Side
Narrow
Slot Side
Brake
18
Parking brake
Disassembling
Disassembling sequence
1. Parking brake handle 2. Parking brake control cable 3. Parking brake drum
4. Flange 5. Parking brake
3 4
5
1
2
Brake
19
Parking brake
Disassembling
Disassembling sequence
1. pull-rod spring 2. return spring 3. adjuster 4 adjusting spring 5. 2
nd
brake shoe and lever
assembly 6. 1
st
brake shoe assembly 7. hold down rod 8. control cable assembly
Disassembling steps
Loosen the adjusting nu , and remove
the control cable fromthe handle.
Loosen the nu before removing the handle.
Brake
20
Inspection and repair
Repair or replace the parts if they are found
worn out, damaged or with other problems after
check.
Brake drum
Thickness of brake friction plates
Measure the thickness of brake lining by
a vernier caliper. If it is less than 1mm
thick, the brake shoe assembly should be
changed.
Return spring
Free length 62.1mm
Design length 66.9mm
Design load 54 66N
Standard Limit
ID 178 179
Out-of-roundness 0.13
mm
free length
Brake
21
Reassembling
Reassembling sequence
1. control cable assembly 2. push rod 3. 1
st
brake shoe assembly 4.2
nd
brake shoe and lever
assembly 5. adjusting spring 6. adjuster 7. return spring 8. pull-rod spring
Adjustment of parking brake
Brake friction plate adjustment
Move the adjuster upward with a screw driver,
until the brake drumis locked. And then move the
adjuster back for about 25 notches. The
clearance between the brake drum and friction
plates is about 0.5mmby now.
Adjustment of the parking brake handle travel
Pull up the parking brake handle to the end
count the number of the gears in the brake lever. If the parking brake handle is pulled with a force
of 300N, its travel covers 9 to 14 notches. Adjust the parking brake if necessary.
Before adjustment of the parking brake, make sure that the clearance of the rear brake shoe is
alreadyadjusted.
1. Loosen the locknut, rotate the adjuster to adjust the travel distance.
2. Tighten the locknut.
Brake
22
Trouble shooting
NO YES
Check brake fluid Check operationof vacuumbooster
Change brake
Repair &change booster
Change
parts,
Check wheel cylinders Change damaged
Change necessaryparts Adjustment
NO YES
Check brake drum&friction disc
Checkthe hose onthe booster
YES NO
NO YES
NO YES
YES NO
Brake not working
Check the margin of brake pedal
Brake
23
Brake
Check the free travel &
margin of the brake
Necessary Check driving brake friction
disc gap and brake pedal
Check for blockage in return
hole of brake master cylinder
Check driving brake disc
Necessary
YES NO
YES NO
All wheels dragging One wheel
Check wheel
cylinders, piston
NO
Adjust the clearance,
or change the return
Noise frombrake
Parts cleaning
Check friction disc
Brake
24
Brake not working
Check free travel of the pedal
NO YES
Check brake
Check brake fluid
Add brake fluid and
vent air fromthe pipes
Clean or
change the
Change parts
Check if the
Check for
leakage of brake
NO YES
YES NO
YES
Check brake drum&friction Change necessary
NO
Change necessary
NO
Adjust brake
Brake
25
Brake
Check side abrasionof tires
Change the parts
YES NO
Check wheel positioning
YES NO
Adjust &repair Check for anyleakage of brake
YES NO
Change necessary Check the wheel
cylinder operation
Check frictiondisc of brake drum
NO
Check the brake returnspring
YES
NO
Change or repair the parts
NO
YES
Electrical System
1
Electrical System
General
I . Operation table
II. Electric diagramidentification
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 solenoidvalve
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. Vacuumalarm
21 .Various relays
22 .Combined switches
23. Combined instrument
24 .CDplayer
25. Idle speed boost device
26. Exhaust brake controller
27. Electrical device
Electrical System
2
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
Headlamp
Two abnormal shape crystal
headlamps
B B
Fog lamp B B
Speedometer B B
Thermometer B B
Fuel meter B B
Illuminator Meter board B B
Direction indicator and hazard
lamp
B B
Far beamindicator B B
Parking brake indicator B B
Brake liquid level indicator B B
Heating plug indicator B B
Oil pressure indicator B B
Exhaust brake indicator B B
Indicator and caution
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
CDplayer and stereo
radio cassette player
B O
Buzzer Vacuumwarning buzzer B B
Warmair 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
Electrical System
3
II. Electric diagramidentification
1. Wire code identification:
Specifications and colors of wires on the wiring diagramare distinguished bydifferent
codes. As different countries use different color codes for the wires, J AC product
users and maintenance personnel should identify the wires according to Wire Color
Code in Electric Maintenance Manual of J AC automobile.
E.g.: 1.5GR
1.5----------Section of wire conductor is 1.5 mm
2
G-----------Color of insulating layer is green
R-----------Color strip is red
Color codes of cables
Applicationcircuit
Vinyloninsulatedwire
Starter motor
Black(B)
Black- white
(BW)
Black- yellow
(BY)
Black- red
(BR)
Chargingcircuit
White(W)
White- red
(WR)
White- black
(WB)
White- blue
(WL)
White-
Green(WG)
Lampcircuit
Red(R)
Red- white
(RW)
Red- black
(RB)
Red- yellow
(RY)
Red- green
(RG)
Red- blue
(RL)
Signal circuit
Green(G)
Green- white
(GW)
Green- red
(GR)
Green-
yellow(GY)
Green-
black(GB)
Green-
orange
(GO)
Metering circuit
Yellow(Y)
Yellow- red
(YR)
Yellow- black
(YB)
Yellow-
black(YB)
Blue-
yellow(LY)
Wiper circuit
Blue (L)
Blue- white
(LW)
Blue- red(LR)
Blue- black
(LB)
Blue-
orange (LO)
Lampgreen
(Lg)
Lampgreen-
black(LgB)
Lampgreen-
red(LgR)
Miscellaneous
Brown(Br)
Brown- white
(BrW)
Brown- red
(BrR)
Brown-
yellow(BrY)
Wire conductor section -Insulating layer ground color
Color strip
1.5 G R
Cross-section area
Ground color
Color strip
Electrical System
4
2 . Electrical component identification:
Electrical components in the J AC automobile electrical diagrams are indicated in
common general signs. Refer to CommonAutomobile Electrical Signs for details.
Batteryunit Fuse Relay Flasher Button
switch
Solenoid
valve
Electric
horn
Illuminator,
indicator
Speaker Fuel gauge
Combination
lamp
Buzzer General
hand
switch sign
Radio
cassette
player
Thermometer
Motor Voltage
regulator
Semiconductor
diode
Twin-filament
lamp
Amperemeter
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 byJ AC, 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
M
U
Electrical System
5
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 batteryof
sixcells 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.
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.
Batteryinspection:
1. Check the terminal post for
looseness and corrosion
Keep the connection reliable. Remove
any corrosive mark and keep the
connection clean.
2. Check the electrolyte level of the
battery
If the electrolyte level is too low
please add distilled water to the max.
liquid level
Max. level
Max. level
Min. level
Electrical System
6
Starter structure:
Starter operating circuit:
Mainpower switchcoil Combinedswitch(key) Earth
Power supply Mainpower switchcontact Ampere meter Combinedswitch(start) Starting relaycoil Earth
Fuse Starting relay contact Electromagnetic switch Starter
Earth
The maintenance personnel should carry out inspection and repair for the lines
indicated bythe 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 120
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
Clutch
Shift yoke
Screw
Movingcore
Adjustingshim
Reset spring Electromagneticswitch
Conductingstrip
Brush
Drivinggear
Middlesupport
plate
Armature Reverser Magnetic
Electrical System
7
composed of three phaseAC motor and silicon diode rectifier. Minus earth is adopted.
Do not connect otherwise, or the generator maybe damaged.
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 waveformis 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 solenoidvalve. Its functionis the same withthat
Stator
R
o
t
o
r
w
i
n
d
i
n
g
R
o
t
o
r
W
i
n
d
i
n
g
E
l
e
c
t
r
i
c
i
t
y
c
o
n
s
u
m
e
r
s
B
a
t
t
e
r
y
Electrical System
8
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 keyto shutdownposition, so the fuel cutoff
solenoid valve is power off and the seal iron cut the fuel path bythe 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) Lowspeedwiping Whenthe power switchis ONandthe variable speedswitchis
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
swings fast when the motor is running at high speed.
c) Shutdown and reset. The automatic reset mechanismof 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
Electrical System
9
1-Power switch; 2-Fusing element; 3 5-Auto reset contactor; 4, 6-Contact;
7, 9-Auto reset slide ring (copper ring); 8-Wormwheel; 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 bottomedge 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 posit
turns to the position shown inFig. 1 21 (a) and contact 4and6 connects withcopper
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 windingis opposite to that of external supplyvoltage, the current flows in the
d brake
torque) to make the motor stop immediately. Here the rubber brush is just reset to the
bottomedge 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 Bottomedge 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
Electrical System
10
b. Functional requirements
I. Three operation modes of high speed, lowspeed 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
8 .Washer
Dust or dirt mayget onto the windshieldglass during the driving. To ensure good sight
of the driver, most vehicles have windshield glass washer.
Whenthe washingengine 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
Wiper motor
H
i
g
h
s
p
e
e
d
r
e
l
a
y
Washer
motor
Diode
S
l
o
w
s
p
e
e
d
r
e
l
a
y
Combined
switch
Earth
High
speed Slow
speed
Motor
Electrical System
11
pump rotor also rotates. The pump rotor pumps the washing liquid fromthe 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 washingpump shouldnot 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 fromthe group switch.
If the lamp is not ON, please check in the following sequence.
Step Inspection content Method
1
Check if the fuse is
blown
If the fuse is blown, replace it after the cause is
found. If not, check the next item.
2
Check if the lamp relay
operates normally
Turn on the lamp switch to see if the headlamp relay
operates. Or use a universal meter to check if the
relayterminal is OK.
3
Check the headlamp
bulb
If the result of the above checks is acceptable,
please check if the bulb is damaged. If not, check
the next step.
4
Check if the wiring
connectors are reliable
Check if all the terminals are reliably connected
according to the wiring diagram.
5
Check the combined
switch (lamp switch)
Check if the lamp switch on the group switch can be
normallyturned on
Electrical System
12
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 Relaycoil Combined switch Earth
Relaycontact 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 relaywhen you check the relay.
11. License lamp
The license lamp is onthe plate support on the rear of the vehicle. The license lampis
ON when the lamplight switch is in anyposition.
The trouble shooting method is the same with that of small lamp.
Headlamp
circuit
Mainpower supply
Long-distance
beamrelay
Short-distance
beamrelay
Left
headlamp
Headlamp
long-dista
nce beam
indicator
Right
headlamp
Combined
switch
Small
lamp
Headl
amp Lamplight
switch
Lamplight
switch Flicker
Short-
distance
beam
Long-
distance
beam
Short-
distance
beam
Short-
distance
beam
Long-
distance
beam
Electrical System
13
Licenselamp
To replace the bulb, remove
onescrewfixingthelens.
Check for fault according to the license lamp operating circuit:
Power supply Fuse Relaycoil Combined switch Earth
Relaycontact 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 warningswitch. 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 bottomof 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 Relaycoil Combined switch Earth
Relaycontact 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 combinationlamp
To replace the bulb,
unscrew the four bolts
fixingthelens.
Electrical System
14
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 reversinglamp shares the same fuse withbrake lampandroof lamp. Please
payattention 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
Interior lampswitchposition
ON
OFF
Interior lamp
Door switch
Electrical System
15
16. Brake lamp and switch
Brake lamp positionis the same with that of rear lamp. The brake lamplight is redand
the brightness is higher thanthat of rear lamp. The brake lampworks together withthe
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 reversinglampand roof lamp. Please
payattention 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, andthe 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:
18 Fog lamp and switch
The fog lamp is combined with the headlamp and its light color is yellow. The working
principle of foglamp is: when you drive ona foggyday, first switch on anylamponthe
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 Relaycoil Combined switch Earth
Relaycontact 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.
ON OFF Door
P
Electrical System
16
If the horn does not sound or sounds
abnormally when you press the horn
button, check theline and battery voltage
beforethefollowingitems:
1. Check if thefuseis blown. At thesame
time, checkif thewireconnectionistight.
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 andthesteeringshaft thread.
a. Nosound--- Poor contact betweenhorn
contact of the combined switch and the
steeringwheel bottom.
b. Sound--- Thehornswitchisat fault.
If the horn sounds without stop, the
source of trouble may be the horn switch
or badreset contact ring.
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 relaycoil Horn button Earth
Relaycontact 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:
Horn specifications:
Structural
shape
Diaphragm
diameter mm
Sound level
dB (A)
Base frequency
range Hz
Volume range
fitting (dual tone)
Disc type >115 105~125 250~650 4: 5
Wiringdiagram
Relay Horn
Horn
Switch
Horn
Electrical System
17
20. Vacuumalarm
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
alarmbuzzer and alarmlamp 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.
Alarmlamp identification:
21 .Various relays
The relays for this vehicle include lamp relay, horn relay, warmair relay, starting relay
and preheating relay. As the lamp, horn and warmair 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. Fromleft 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
and power
Working gear
B
ACC
220W
ON
240W
R
60W
ST
220W
P1
40W
P2
40W
B1
R1
60W
R2
Remark
s
Wire color
Specificationmm
B
5.0
L
3.0
BY
3.0
BR
3.0
BW
3.0
LY
1.0
LW
1.0
L
1.0
R
0.75
Y
0.75
LOCK
ACC
Electrical System
18
ON
START Automa
tic reset
Keyin Power
switch
Keyout
2 Lamp switch beamselection and overtaking signal conduction diagram
Contact code BT E J B BH HU
Rated power 80W 120W 10W 150W 150W
OFF
Overtaking
Small lamp
Overtaking
Short-distance
beam
Overtaking
G
e
a
r
H
e
a
d
l
a
m
pLong-distance
beam
Electrical System
19
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
switch
Direction
switch
L
OFF OFF
R
ON
L
OFF
R
OFF Exhaust
brake
switch
ON
Horn
4 Wiper switch and water spraying switch
Water
spraying
Wiping 11 E1 12 AS L H E2 W E3
OFF
INT
LO
OFF
HI
ON
OFF INT
LO HI
EZ
Electrical System
20
23. Combined instrument
Instrument
Disassembling and reassembling
Disassembling sequence:
1. Transparent top cover 6.Pointer component
2. Instrument decorative ringA 7.Gauge plate
3. Instrument decorative ringB 8.Middle cover
4. Black frame 9.Circuit board parts
5. Reset rod 10.Bottomcover
Disassembling sequence:
Followthe reverse order of disassembling to reassemble.
Electrical System
21
1 Instrument indicator:
No. Designation Function Color
1 Engine oil pressure alarm
lamp
ON when the engine oil pressure is too
low
Red
2 Charging indicator ON when the batterydischarges Red
3 Parking brake alarmlamp ON when the parking brake is switched
on
Red
4 Preheat indicator ON during the preheating Yellow
5 Exhaust brake indicator ON when the exhaust brake is switched
on
Yellow
6 Left/right direction indicator ON when the direction lamp is switched
on
Green
7 Beamindicator lamp ON when the headlamp is switched on Blue
8 Fog lamp indicator ON when the fog lamp is switched on Yellow
9 Hazard alarmlamp indicator ON when the hazard alarmis switched
on
Red
10 Fuel oil level alarmlamp 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 alarmlamp ON when the door is open Red
13 ABS alarmlamp ON when theABS systemis at fault Yellow
14 Brake fault alarmlamp ON when the brake is at fault or the
brake fluid is low
Red
1) Main component installation
Main component Model Mounting position
Combined
instrument
Stepping motor type Under dashboard
Speed
meter/odometer
Middle of combined instrument
Odometer sensor
Electronic
On gearboxoutput shaft
Engine oil pressure
sensor
Varistor type On engine oil pipe
Water temperature
sensor
Thermister On engine water inlet pipe
Electrical System
22
Fuel oil sensor Varistor type Inside oil tank
Electrical System
23
2) Indicator and warning switch:
I ndicator switchposition
Engineoil pressureindicator switch
Wiringdiagram
Switchspecification
Workingpressure: 0.3- 0.5KSC.
Whentheoil pressureis as lowas the
switch action pressure, the indicator
isON.
Electrical System
24
Vacuumalarmswitch
Wiringdiagram
Its position is the inner side of the left
pedal inthecab.
Switchspecification
Stampingsign: 350
Negativepressure(mmhg): 320- 380
Note: Theswitch has workingnegative
pressure mark. Make sure that you
replace it with switch of the same
negativepressurewhennecessary.
arkingbrakeswitch
Wiringdiagram
Alarmbuzzer
Switch Vacuum
ON
OFF
Switch
Electrical System
25
2 Technical requirements:
Technical requirements of combined instrument
3801910D800 Combined instrument assembly
The basic deviation requirements are as follows:
Basic deviation
Indicated speed
Km/h
20 40 60 80 100 120 140 160
Allowable
deviation Km/h
3
+5
0
+5
0
+5
0
+5
0
+6
0
+7
0
Speedometer
(stepping motor
type)
Transmitting
ratio
1:637 Interface mode Sensor type
Indicated mark E 1/2 F
Basic resistance
( )
97 32.5 6
Allowable
deviation ( )
16 6.5 3
Fuel gauge
(stepping motor
type)
Sensor Designation Fuel oil
sensor
Model RG1164B1
Indicated mark
( )
C (50) 100 H (115)
Basic resistance
( )
230 40.4 26.4
Allowable
deviation ( )
30 5 1.5
Water
temperature
gauge
(stepping motor
type) Sensor Designation Water
temperature
sensor
Model WG1371
All alarmindication systems of 3801910D800 instruments conformto GB4094 - 1999
Signs of automobile controls, indicators and signal devices.
DJ Y7121-1.6-20;DJ Y7141-1.6-20;DJ Y7121A-1.6-20 combined socket is adopted for
the instruments.
24 .CDplayer
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 fixthe trouble.
Electrical System
26
Please send the player to the maintenance service station if the fault cannot be fixed.
Do not disassemble the player to repair it byyourself.
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 verylow
Raise the volume.
Check the front and rear, left and right balance setting of the horn.
Check the antenna and connection.
Horn volume lowers byitself
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 fullydrawn 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 supplyto this antenna.
CD
CDERROR is displayed:
Checkif the CDis correctlyinserted, andmake sure that the CDis not broken or dirty.
Distortion of sound
CDcannot be read, damaged or dirty.
CDplayer 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 CDor NO DISC is displayed.
Check if there is CDin the CDplayer.
Electrical System
27
25. Idle speed boost device
Asolenoid valve calledidle speedboost device is fittedonthe rear end(left side of the
chassis) of the vacuumpumponthe engine. Whenthe engine is at idle speed and the
air conditioner is switched on, it boosts the idle speed of 700r/min to 85050r /min, so
that the power generation meets the requirements of the air-conditioner. Its functional
diagramis as follows:
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
vacuummembrane, the fuel uplever is pushedbythe pushrodto the fuel up direction,
so that the engine idle is raised to 85050r /min. The wiring diagramis as follows:
Wire1
Wire2
Connectingrubber tube2 Enginethrottlelever
Drawbar
Connectingrubber tube1
Vacuum
pumppipe
SolenoidvalveDF156(Suctionvoltage<9V, Releasevoltage>1V)
Fuse Air conditioner switch
Compressor
electromagneticclutch
Idlespeedboost valve
Vacuummembranebox
Electrical System
28
26. Exhaust brake controller
1. Wiring diagram
2. Switching diagram
3. Accelerator and clutch switch:
Maximumstroke: 4mm;
Working stroke: 2.0-2.8mm.
4.Position of exhaust brake solenoid valve
(left arrow)
Exhaust brakeswitch
Acceleration
switch
Clutch
switch
Alarm
buzzer
Vacuum
switch
Magnetic
valve
ON OFF
OFF
Max. travel
Electrical System
29
27. Electrical device
Disassemblyof linebundleconnector:
Please always both hands to cut the
connector. Drawing the connector with
single hand will result in rupture of the
wireterminal.
Note: press the lock plates on both sides
beforedrawingout theconnector tocut.
Connectionof linebundleconnector:
Clenchbothsides (maleandfemale) of the
connector andmakesurethat theconnector
terminal pins match and align with the
holes. Press both sides of the connector
carefullyuntil youhear aclear click.
Inspectionof linebundleconnector:
Use circuit tester to check the connector
continuity. Insert test probe fromside of
theconnector wire
Do not insert the test probein connector
openend
Wrong
Correct
Wrong
Probe
Correct
Probe
Electrical System
30
Inspectionof fuseline:
The fuse line is fitted on battery positive
terminal andstarter switchB terminal
If thereis over current, thefuseis blown to
protect the main power supply frombeing
overloaded. Please use universal meter to
checkthecontinuityof thecircuit.
Disassemblyof wireterminal
1. Insert a pin into the open end of the
connector shell
2. Pressthebarb(facingtheconnector wire
side) and pull the wire on the connector
wireside.
Insertionof wireterminal:
1. Check if thebarbiscompletelyopen.
2. Insert the terminal fromconnector wire
side and press it until the barb fixes it
firmly.
3. Pull thewiregentlytoreset theterminal.
Precautionsof linebundlearrangement:
Use jacket or sleeve to protect the line
bundleand avoid direct contact with sharp
edgeor surface.
Fuseline
Starter
switch
Starter motor
Pin
Barb
Wire
Openend
Terminal
Barb Wire
Terminal
Wrong
Correct
Electrical System
31
Fuse:
Fuse is the most used circuit protection of
vehicle circuit. When there is over current in
thecircuit thefuseisblowntoprevent thehigh
current fromdamagingother partsinthecircuit.
Findout thecauseof overloadcurrent andsolve
theproblembeforeyoureplacethefuse.
Usenewfuseof thesameamperetoreplacethe
original one. Otherwise, there will be line
burningor other seriousdamagetothecircuit.
Circuit breaker:
Breaker is a protective device to open the
circuit whentheload current exceeds therated
breaker capacity.
If there is short circuit or other form of
overload, theover current will openthecircuit
on both sides of the breaker. When the circuit
isopen, thebreaker buttonpopsup.
Thelinebundlebetweentheengineandchassis
should be long enough to avoid abrasion or
damageowingtovibration.
Thereshould besufficient clearancebetween
the line bundle and bracket. Use ethylene
sleeveand clip to protect thelinebundleand
avoiddirect contact.
Wrong
Correct
Clamp
Sleeve
Wrong
Correct
Normal Damaged
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Electrical System
34
Air heating &air conditioning equipment
Generator
Technical parameters
Disassembling and reassembling
Troubleshooting
Electrical System
35
General
1. Air conditioner refrigeration cycle
1.1 main parts of refrigeration system
Refrigeration cycle systemof integrated air conditioner (warming and cooling) of J AC
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 mediumtemperature 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 lowpressure, low
temperature liquid-gas mixture bythrottlingand depressurizingeffect of the valve, and
thenenters the evaporator. This mixed refrigerant will evaporate inthe 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 inair will condense to become dewthat will be drained outside the vehicle,
hence reducing temperature and humidity of air inside vehicle. Fig.1 shows air
conditioning refrigeration schematic diagram.
Fig.1Air conditioning refrigeration schematic diagram
Expansion
valve
Reservoir
Evaporator
Condenser
Compressor
Electrical System
36
2. Air conditioning warming cycle
2.1 Main parts of warming system
Warming cycle system of integrated air conditioner (warming and cooling) of J AC
vehicle mainly consists of warmair blower, engine, water pump, water valve, water
tank and pipelines etc.
2.2 Warming principle
Bymeans of a water pump, hot coolant of engine is pumpedinto warmair 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.
Fig.2Air 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(refrigeratingandwarmingparts).
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
Water pump
(water tank)
Warmair
blower core
Engine Water valve
Electrical System
37
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 systemhigh pressure falls to 2.5MPa or systemlow
pressure rises to 0.23MPa, this switch will be turned on, engaging compressor clutch
and starting the refrigeration system.
Technical parameters
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
Voltage 12V 3 Compressor
Displacement 138cm
3
/r
Condenser heat sinking
capacity
9000W
Voltage 12V
Maximumcurrent 15A
4
Condenser with
reservoir assembly
Air flow 1800m
3
/h
Refrigerating capacity 3900W
Heating capacity 4000W
Voltage 12V
Maximumcurrent 18A
5
Front evaporator/
heater assembly
Air flow 350m
3
/h
High pressure protection
characteristics
Disconnected at
3.14Mpa
Connected at 2.5Mpa
7
2-state pressure
switch
Low pressure protection Disconnected at
Electrical System
38
5
4
3
6
1
2
7
characteristics 0.2Mpa
Connected at 0.23Mpa
2. Structure of main parts of air conditioning
2.1 Heating equipment, blower equipment and evaporator
1. Lower cover; 2. Fuse and relaybox; 3. Ventilatingair duct; 4. Evaporator; 5. Blower;
6. Heating equipment; 7. Instrument stand
For removal of heating equipment, blower and evaporator from instrument stand,
followthis sequence: 1. lower cover 2. fuse and relaybox3. ventilating air duct 4.
evaporator 5. blower 6. heating equipment.
Electrical System
39
Sequence of assembling is the reverse of this sequence. For tightening torques, refer
to the table below:
Tightening torque (Nm)
Diameter of thread (mm) Pitch (mm) Standard
value
Maximum Minimum
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
event water leakage.
Sealant Butyl rubber (none-drytype)
Air conditioning panel
direction);
(INSIDE direction)
butterfly nut to bottomand fixcable on clip;
butterfly nut to bottomand fixcable on clip.
Hang control cable C on blower clip, press
butterflynut to bottomand fixcable on clip
Control cableA
Control cableB
Control cableC
Air heater
Blower
Electrical System
40
2.2 Structure of condenser assembly
1. Condenser damping pad sleeve; 2. Hexflanged face nut;
3. Pad; 4. Condenser core;
5. Condenser damping pad; 6. Condensing fan assembly;
7. Bolt combination
Important operations
1. When removing pipe fromeach device, avoid damaging connecting nut or the pipe.
2. Cover pipe port with plastic cloth to avoid ingress of dust in pipe.
Electrical System
41
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 fromeach 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 performdisassembling or repair.
1.2 Use of open flame or smoking is prohibited.
1.3Always wear working clothes during working. Ensure intact protective devices.
1.4 Performoperation in a weld ventilated environment.
1.5 Before starting the engine, confirmthat there is no tool, measuring instrument or
other part on movingand rotatingparts, andparts throughwhichelectric current flows.
1.6 Before start of engine, blowhorns to warn operating workers and confirmsafety.
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
Electrical System
42
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.
1.16When handlingrefrigerant gas, wear protective goggles to avoidinjuryof eyes. In
case such gas enters the eye, timelywash with large amount of clear water to prevent
frostbite; if serious, go to hospital at once.
Items that must be inspected beforeAC systemmaintenance 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.,
2.3And 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.
Electrical System
43
Blower motor rotates but no
hot air comes out from
outlet
Troubleshooting
YES
Hose sharp
twisting, bending or
clogging
Replace
Check water
hose
No air comes out from defroster
outlet
Check connecting pipe
between defroster &
heater
YES Wear
Check defroster door & control
cable
Replace
YES Replace &
adjust
Electrical System
44
Blower speed cannot be
adjusted
Check electric connector
YES Disconnect
Check control switch
Replace
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
Check engine motor
Replace
YES Faulty
Replace
Electrical System
45
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
Electrical System
46
Insufficient cooling
Check condenser
Check driving belt
Clean or
replace
YES
Slipping
Replace Check compressor
YES Faulty
Replace
Check expansion
YES Faulty
Replace
Check thermostat
YES Faulty
Replace
Check coolant
YES Insufficient or
Adjust