SHOP MANUAL

HFC1083KR1（E891）
1ST EDITION

JAC INTERNATIONAL

2008.03
JAC
HFC1083KR1（E891）
SHOP MANUAL
Foreword Contents
This shop manual was prepared
Group
as reference to properly carry out Name Page
Code
servicing and maintenance on JAC
vehicles. 0000 General
The contents, pictures and
technical parameters this manual 1000 Engine
supplied are the latest data. Because
of the continuously development and 1600 Clutch
renewal of technique and products,
1700 Gearbox
there may be some difference
between the explanations and the 2200 Driveshaft
vehicles.
The shop manual for the engine will 2400 Rear axle
be compiled separately.
2900 Suspension
This manual was prepared for
HFC1083KR1 （ E891 ） truck. 3000 Front axle
Configurations as follows ：
HFC1083KR1 ， identification code 3400 Steering gear
G109, CA4DF2-13 engine, LC6T46
3500 Brake
transmission, G1QZ rear axle ，
JAC new cabin. 5000 Cabin
Please inform Customer Service
Department of JAC International if
there is any mistake, and you will be
highly appreciated.
Tel：0086-0551-2296344
Fax：0086-0551-2296454
Email：[email protected]
 GENERAL
SPECIFICATIONS
VEHICLE MODEL
VIN
THE MECHANIC PERFORMANCE TABLE OF BOLTS IN CHINA
Specifications
Model 型号 HFC1083KR1
Serious Number 结构区别号 G109
Engine 发动机 CA4DF2
Type 型式 in line-4,ind-cooler turbocharged, diesel
Displacement (cc) 排量 4752
Compression Ratio 压缩比 17
Max Power (HP/rpm) 最大功率 95.6kw130/2500
Max Torque (N.m/rpm) 最大扭矩 390/1500
Transmission 变速器 LC6T46
6.314，3.913，2.262，1.393，1，
Speed Ratio 各档速比
0.728，R、5.874
Final gear ratio 后桥速比 G1QZ-5.714
Brake system 制动形式 air brake
Tyre 轮胎 7.50-20
Overall Dimensions（mm) （L*W*H)整车尺寸 8390*2270*2366
Cargo Dimensions（mm）(L*W*H) 货箱尺寸 6200*2110*550
Tread (front / rear )（mm）轮距（前/后） 1830/1724
Wheelbase（mm） 轴距 4700
Curb Weight （kg） 整备质量 4410
Max Load Capacity（kg） 额定载重 6000
Gross Vehicle Weight（kg） 最大质量 10605
Min Turing Radius（m） 最小转弯半径 9
Min Ground Clearance（mm） 最小离地间隙 233
Max Speed（km/h） 最大时速 98
Seating Capacity 额定成员数 3
Max Gradeability(%) 最大爬坡度 32
Frame Section Size（mm） 车架断面尺寸 230*75*6
Optional configuration 可选配置
Air Conditioner 空调 〇
Power Steering 动转 √
Pre-heater 预热 〇
Wind deflector 导流罩 〇
Side bumper 侧防护栏 √
Rear bumper 后防护栏 √
Power Assist of the clutch 离合助力器 √
Digital Radio 数字式收放机 √
Exhaust Braking 排气制动 √
Else 其它 Optional ABS
Remark:
√:Standard Equipment 〇:Optional ●Under develop ×:Not Available
▲ :CY4102BZLQ and CA4DF2-13 engines'emission standard attain Euro II
Vehicle Model

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.
 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
The mechanic performance table of bolts in China

Quality Grade( mark) 6.8 8.8 9.8 10.9 12.9

Tensile strength limit  b max (MPa) 600 800 900 1040 1220

Yield limit  s max (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.
 Introduction
This Service and Maintenance Manual systematically introduces main technical

parameters, measures to meet the emission standard, structural characteristics, service and

maintenance, methods of fault removal of CA4DF2-13 diesel engine for reference of auto

drivers and maintenance staff.

CA4DF2-13 Diesel Engine Service and Maintenance Manual

Compiled by FAW Jiefang Automobile Co., Ltd. Wuxi Diesel Engine Works

Address: No. 9 First Branch of Tangnan Road Wuxi Jiangsu

Post code: 214062 Telephone: 0510-85014990 Fax: 0510-85016785

Serial No. of production permit: XK06-205-00140

 Forward

CA4DF2-13 supercharge inter-cooling diesel engine is a newly developed type to meet

GB17691-2001 state emission standard, optimize performance and improve reliability. It is

manufactured per enterprise standard Q/320201AA55: CA4DF2 diesel engine.

The product has strong mating compatibility, good dynamic behavior and efficiency. It is

widely applied to mating with light track and 6-7m passenger car.

The manual introduces main technical parameters, measures to meet the emission standard,

structural characteristics, service and maintenance, methods of fault removal of CA4DF2-13

diesel engine. Correct use and maintenance is extremely important for safety driving and

prolonging service life. Drivers and maintenance staff should read the manual carefully, use and

maintain diesel engine according to regulations and requirements.

Diesel engine keeps improving. There may be some difference between your diesel engine

and the introduction. So the actual object shall be the standard. While purchasing fittings,

please tell us type on nameplate, order number and product number so that we can provide

fittings accurately.

FAW Jiefang Automobile Co., Ltd. Wuxi Diesel Engine Works

Jan. 2006
Compiled by Hu Weijia Chen Xiaoyang Du Jian

Checked by Tang Ting Quan Kaiyuan Gao Zhihong

Drawn by Wuxi Jiadeli Color Printing and Packaging Co., Ltd.

Examined by Bao Zhiyi Ding Hao Wang Yijiang

Approved by Huang Chenghai

 Contents
Appearance of CA4DF2-13 diesel engine … … … … … … … … … … … … … … … … … … … … . (1)
1. Main technical specifications and data of diesel engine … … … … … … … … … … … … … … (3)
1.1 Main technical specifications … … … … … … … … … … … … … … … … … … … … … … … . (3)
1.2 Data of adjustment and operation … … … … … … … … … … … … … … … … … … … … … .. (4)
1.3 Mating characteristics and wearing limits of main parts … … … … … … … … … … … … … (4)
1.4 Tightening torque of threaded connecting piece … … … … … … … … … … … … … … … … (6)
1.5 Adjusting parameters of oil supply of oil injecting pump … … … … … … … … … … … … .. (7)
2. technical measures to meet emission standard and points for attention in use … … … … … .. (8)
2.1 Main technical measures to meet emission standard … … … … … … … … … … … … … … . (8)
2.2 Points for attention in using emission standard … … … … … … … … … … … … … … … … . (8)
3. Structural introduction of diesel engine … … … … … … … … … … … … … … … … … … … … . (9)
3.1 Suspension of diesel engine and configuration of peripheral accessories … … … … … … . (9)
3.2 Lubricating system … … … … … … … … … … … … … … … … … … … … … … … … … … … . (9)
3.3 Cooling system … … … … … … … … … … … … … … … … … … … … … … … … … … … … . (11)
3.4 Fuel system … … … … … … … … … … … … … … … … … … … … … … … … … … … … … .. (13)
3.5 Intake and exhaust system … … … … … … … … … … … … … … … … … … … … … … … … (17)
3.6 Supercharge and inter-cooling system … … … … … … … … … … … … … … … … … … … . (17)
3.7 Electric system … … … … … … … … … … … … … … … … … … … … … … … … … … … … . (17)
4. point for attention in using diesel engine … … … … … … … … … … … … … … … … … … … . (21)
4.1 Selection of diesel oil … … … … … … … … … … … … … … … … … … … … … … … … … ... (21)
4.2 Selection of engine oil … … … … … … … … … … … … … … … … … … … … … … … … … .. (21)
4.3 Selection of cooling water … … … … … … … … … … … … … … … … … … … … … … … … (22)
4.4 Preparation before starting diesel engine … … … … … … … … … … … … … … … … … … . (23)
4.5 Starting procedure … … … … … … … … … … … … … … … … … … … … … … … … … … … (24)
4.6 Points for attention during operation … … … … … … … … … … … … … … … … … … … … (25)
4.7 Points for attention during shutdown … … … … … … … … … … … … … … … … … … … ... (26)
4.8 Points for attention during winter … … … … … … … … … … … … … … … … … … … … … (26)
5. requirements for maintenance of diesel engine … … … … … … … … … … … … … … … … … (27)
5.1 Running-in of new machine and technical maintenance … … … … … … … … … … … … .. (27)
5.2 Requirements for maintenance … … … … … … … … … … … … … … … … … … … … … … . (28)
5.3 Points for attention for new engine or after major repair … … … … … … … … … … … … . (35)
6. points for attention for assembling diesel engine … … … … … … … … … … … … … … … … . (36)
6.1 General technical requirements of overall assembly … … … … … … … … … … … … … … (36)
6.2 Assembly of cylinder sleeve … … … … … … … … … … … … … … … … … … … … … … … . (36)
 6.3 Assembly of crankshaft … … … … … … … … … … … … … … … … … … … … … … … … … (36)
6.4 Assembly of piston and connecting rod … … … … … … … … … … … … … … … … … … ... (38)
6.5 Assembly of camshaft … … … … … … … … … … … … … … … … … … … … … … … … … .. (39)
6.6 Assembly of gear system … … … … … … … … … … … … … … … … … … … … … … … … .. (39)
6.7 Assembly of cylinder cover and admission gear … … … … … … … … … … … … … … … .. (39)
6.8 Assembly of flywheel … … … … … … … … … … … … … … … … … … … … … … … … … ... (40)
6.9 Assembly of crankshaft torsional damper or front-end pulley … … … … … … … … … … . (41)
6.10 Assembly of peripheral accessories and overall adjustment … … … … … … … … … … .. (41)
7. diagnosis and remedy of common faults of diesel engine … … … … … … … … … … … … … (42)
7.1 Causes and remedy of difficult starting … … … … … … … … … … … … … … … … … … … (42)
7.2 Causes and remedy of under-power … … … … … … … … … … … … … … … … … … … … . (42)
7.3 Causes and remedy of runaway … … … … … … … … … … … … … … … … … … … … … … (43)
7.4 Causes and remedy of abrupt halt … … … … … … … … … … … … … … … … … … … … … (44)
7.5 Causes and remedy of abnormal running sound … … … … … … … … … … … … … … … .. (44)
7.6 Causes and remedy of unstable running … … … … … … … … … … … … … … … … … … ... (45)
7.7 Causes and remedy of abnormal color of exhausting fume … … … … … … … … … … … . (45)
7.8 Causes and remedy of overheat … … … … … … … … … … … … … … … … … … … … … … (46)
7.9 Causes and remedy of luboil dilution by diesel oil … … … … … … … … … … … … … … .. (46)
7.10 Causes and remedy of under pressure of engine oil … … … … … … … … … … … … … ... (46)
7.11 Causes and remedy of mixing of engine oil with cooling water … … … … … … … … … (47)
7.12 Causes and remedy of supercharger failure … … … … … … … … … … … … … … … … … (47)
7.13 Causes and remedy of starter failure … … … … … … … … … … … … … … … … … … … .. (48)
7.14 Causes and remedy of sprayer failure … … … … … … … … … … … … … … … … … … … (48)
7.15 Causes and remedy of injecting pump … … … … … … … … … … … … … … … … … … ... (49)
7.16 Causes and remedy of governor failure … … … … … … … … … … … … … … … … … … . (49)
7.17 Causes and remedy of compressed air pump … … … … … … … … … … … … … … … … . (50)
7.18 Causes and remedy of increased consumption of fuel … … … … … … … … … … … … ... (50)
7.19 Causes and remedy of increased consumption of engine oil … … … … … … … … … … . (50)
7.20 Causes and remedy of failure of flame preheater … … … … … … … … … … … … … … ... (51)
Appendix 1: A list of marketing agencies of FAW Jiefang Automobile Co., Ltd. Wuxi Diesel
Engine Works … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … ... (52)
Appendix 2: A list of automatic control central storage of fittings of FAW Jiefang Automobile
Co., Ltd. Wuxi Diesel Engine Works … … … … … … … … … … … … … … … … … … … … … ... (54)
CA4DF2-13

·1·
 CA4DF2-13

·2·
 1. Main technical specifications and data of diesel engine
1.1Main technical specifications
1.1.1 Main technical specifications of CA4DF2-13 diesel engine

Model 4DF2-13
Type Column, 4 stroke, water cooling, direct-injection combustion chamber
Aspiration mode Exhaust turbine supercharge, air inter-cooling
Compression ratio 16.8: 1
Cylinder number 4
Cylinder diameter (mm) 110
Piston stroke (mm) 125
Total piston displacement (L) 4.751
Rated power/rated speed 90/2500 96/2500 100/2500
(kW/r/min)
Maximum torque/speed 390/1500 390/1500 430/1500
(N·
m/r/min)
Rotary direction of crankshaf t
(facing flywheel) Anticlockwise
Ignition order 1-3-4-2 (cylinder is near fan end)
Lubricating mode Forced splash
Starting mode Electric starting
Minimum no-load stable speed 750±50
(r/min)
Stable governing ratio 10～14%
Full load minimum fuel ≤205
(g/kW·h)
Exhaust temperature (℃) ≤520
Fume (Rb) ≤2.5
Net mass (kg) 480 (not including clutch and inter-cooler)
Emission Conform to GB17691-2001 second phase state standard (European II)

·3·
1.2 Data of adjustment and operation
Type
Item 4DF2-13

Inlet valve 0.30

Cold valve clearance(mm)
Exhaust valve 0.35

Oil supply advance angle(crankshaft angle)(℃ A) 94-1

Deflection of fan belt (mm) 10 - 15(add 39.2N force hour)

Cooling water final temperature (℃) < 95

Pressure of engine oil (kPa) Rating speed: 343 - 490; idle speed: ≥ 98

Adjusting pressure of sprayer (kPa) 25 - 26

Sprayer head higher than basal plane of cylinder 3.4 - 3.9

cover(mm)
Ak valve conduit higher than spring holder hole of cylinder covex(mm) 18

Filling volume of lubricating oil for different types of oil drain pan
4DF2-13 oil drain pan Filling volume Representative type
(L)
Welding type 13.5 4DF2-13

Shallow pool 12.5 4DF2-13 -JH20

1.3 Mating characteristic s and wearing limits of main parts

Fitting Nominal Gap or shrink Limit
No. Name nature size range value
(mm) (mm) (mm)
1 Main journal of crankshaft with main Clearance 085 0.06 - 0.134 0.2
beating
2 ThruSt face with thrust plate of main Axial 37 0.105 - 0.309 0.4
journal of crankshaft clearance
3 Rod journal with rod bearing of Clearance 070 0.06 - 0.128 0.2
crankshaft
4 Rod joumal with rod big end of Axial 42 0.18 - 0.43 0.6
crankshaft clearance
5 Piston pin with rod wrist pin bush Clearance 042 0.027 - 0.057 0.12

6 Piston pin with pin hole Clearance 042 0.002 - 0.015 0.04

7 Piston skirt with cylinder bush Clearance 0110 0.15 - 0.175 0.35

8 Piston ring closed gap

First pressure ring Clearance 0.35 - 0.55 1.5

Second pressure ring Clearance 0.75 - 0.95 1.5

·4·
 Fitting Nominal size Gap or shrink range Limit value

No. Name nature (mm) (mm) (mm)

Oil ring Clearance 0.25 - 0.45 1.5

9 Piston ring with piston ring slot

First pressure ring with piston ring slot Axial clearance 0.095 - 0.145 0.25

Second pressure ring with piston ring slot Axial clearance 2.5 0.06 - 0.095 0.20

Oil ring with piston ring slot Axial clearance 4 0.04 - 0.075 0.15

10 Upper dead point of piston with basal plane of cylinder cover Clearance 0.9 - 1.1

11 Air valve conduit with cylinder cover Shrink range 015 0.015 - 0.051

12 Air inlet valve with air valve conduit Clearance 09 0.020 - 0.057 0.15

13 Exhaust valve with air valve conduit Clearance 09 0.045 - 0.082 15

14 Air inlet valve seat with cylinder cover Shrink range 049 0.045 - 0.086

15 Exhaust valve seat with cylinder cover Shrink range 046 0.045 - 0.086

16 Air inlet valve concavity in basal plane of cylinder cover Concave 1.0- 1.4 2.2

17 Exhaust valve concavity in basal plane of cylinder cover Concave 1.0- 1.4 2.2

18 Rocker-ann bush of air valve with rocker-arm hole Shrink range 026 0.034 - 0.076

19 Rocker-ann bush of air valve with rocker-arm axle Clearance 024 0.047 - O. 103 0.2

20 Cylinder bush shoulder higher than cylinder top surface Projection 0.05 - 0.10

21 Tappet with body hole Clearance 031 0.045 - 0.086 0.2

Outer diam-

22 Camshaft bush with body hole Shrink range eter of bush 0.036 - 0.085

064

23 Camshaft bush with camshaft journal Clearance 060 0.08 - 0.16 0.25

24 Camshaft with thrust plate Axial clearance 6 0.08 -0.218 0.35

25 Timing mid-gear (II) with bush Shrink range 052 0.03 - 0.076

26 Timing mid-gear (II) bush with gear shaft Clearance 048 0.04 - 0.10 0.2

27 Timing mid-gear (II) with gear shaft Axial clearance 38 0.18 - 0.292 0.4

28 Timing mid-gear (I) with timing mid-gear (II) Shrink range 068 0.002 - 0.052

29 Timing mid-gear (III) with bush Shrink range 036 0.034 - 0.076

30 Timing mid-gear (III) bush with gear shaft Clearance 032 0.03 - 0.086 0.2

31 Timing mid-gear (III) with gear shaft Axial clearance 027 0.12 - 0.293 0.4

32 Oil pump gear face with cover plate Axial clearance 40 0.025 - 0.089 0.15

33 Oil pump gear ex-circle with pump Radial clearance 049.5 0.025 - 0.08 0.15

34 Gear backlash ≥ 0.085 0.3

35 Pump impeller with pump shell Clearance 0.10 - 0.60

·5·
1.4 Tightening torque of threaded connecting piece
① Tightening torque of main threaded connecting pieces is listed in following table
Piece number or Part name Tightening torque Remarks
specification (N.m)

K- 1003046-1 Cylinder cover bolt M 14 196～235.2 Coat engine oil

K- 1003047-1
1004023-1/CK Connecting rod bolt M 13' 1.25 145～15 Coat thread glue

1002135-1AKZ Binding bolt of piston cooling nozzle 50±5 No glue coating

K-1005123 Flywheel bolt M14* 1.5 180～10 Coat thread glue

1005144-1K Main beating bolt M16 260～280 Coat engine oil

Torsional damper or tightening bolt of

K-1005123 crankshaft pulley M14* 1.5 180～10 Coat engine oil
Timing gear tightening bolt
K-1006023 camshaft M20* 1.5 200±15 Coat engine oil

Hex bolt M10 (tighten cylinder cover)

Q150B1030 33±6
Hex bolt M10 (tighten pump pulley)

Hex bolts M8 with various

specifications 19±6
(tighten intake manifold)
Q150B1060 Hex bolt M10 (tighten exhaust manifold) 32～10

Q340B10 Hex nut M10 type I (tighten exhaust 32±10

manifoldl
Q 150B 1230 Hex bolt M 12 (tighten front oil seal 57～10
seat)
Q150B0820 Hex bolt M8 (tighten rear oil seal seat) 19～6

Hex nut type I-M20* 1.5

Q341B20 (tighten drive gear of injection pump) 180～15 Coat engine oil
Q150B1285 Hex bolt M12 (tighten bracket of 57～10
injection pump)
Q150B0880 Hex bolt M 10 (tighten injection pump) 32～10

Q360B10 Hex nut type II M 10 (tight sprayer) 70～10

Q 150B 1075 Hex bolt M10 (tighten support of 41±10

rocker-arm shaftl
QI50B1022 Hex bolt M10 (tighten cover plate of
Q150B1030 gear chamber) 32～10
M12'1.5 or M20'1.5 Oil drain plug of oil drain pan 150～10

·6·
 ② Tightening torque of 4DF2-13 clutch threaded connecting pieces is listed in following
table
Bolt specification Φ350 clutch or below(N.m) Remarks
M8 28_+2 While installing clutch
M10 54+9 assembly, tighten bolts
M12 80-+9 diagonally

③ Tightening torque of other threaded connecting pieces is listed in following table

Grade 8.8 (common carbon steel) 10.9 (hardened and tempered
Thread diameter(mm) (N.m) steel) (N.m)
6 5±2 7-+2.5
8 12±5 15-+5
10 25±7 35 -+ 10
12 54±10 68 _+ 15
14 80±15 108 -+ 10
16 118±20 147 + 25
Note: Above ①②③ connecting pieces should be tightened with torque spanner. If you
use kg system spanner, convert per 1kgf·cm=9.8N.m
1.5 Adjusting parameters of oil supply of oil injecting pump
Oil volume adjusting parameters of 4DF2-13 diesel engine injection pump under conditions of standard
testing system refer to table 1.5. Users should pay special attention to the following items:
● Repair and adjustment of injection pump must be done by professional and capable units.
● Oil volume measured by different testing benches may be different, so oil volume listed in the table is only
for your reference. If users adjust oil volume per this table and black smoke comes out of diesel engine, put
injection pump on testing bench again, modify oil volume less and increase evenness degree of cylinders. Don't
increase oil volume and power at will, which is harmful to its reliability.
Table 1.5 Adjusting parameters of CA4DF2-13 injection pump
Type 4DF2-13
Behavior Rotation speed of Oil volume Non-uniformity % Pneumatic
oil pump r/min ml/200 times pressure MPa
Calibration 1250 27.5 + 0.9 ±5 0.1
Correction 750 24 + 0.8 ±3 0.1
Low speed 500 20 + 0.9
Starting 100 98
Function 1270
Idle speed 375 35±0.7 ±10
Oil 1460
disconnection

·7·
 2. technical measures to meet emission standard
and points for attention in use
CA4DF2-13 supercharge inter-cooling diesel engine has reached GB 17691 second phase (European II).
Main technical measures and points for attention in use are as follows.

2.1 Main technical measures to meet emission standard

Different types of diesel engine use different types of oil sprayer pump due to different power.
① Adopt type P sprayer
Because PE boost pump has powerful working capacity, type P sprayer is selected to match it to reduce
needle valve inertia, spray starts faster and oil is disconnected more completely. Besides, ex-circle of type P
sprayer is smaller, position of nozzle tip in cylinder cover is shifted nearer to cylinder center, mixture of oil and
gas is improved and combustion is thorough. Specification of nozzle coupler is 6*0.25mm
② Optimize supercharger
In order to reach optimum performance matching, high efficiency superchargers with exhaust valve and air
relief valve are selected for different types of diesel engine to guarantee emission standard, low fume, high and
low speed performance. Supercharger types for different types of diesel engine are different.
③ Improve combustion chamber
Select combustion chamber with stronger squish effect to improve mixture of oil and gas during low
velocity behavior and improve low velocity performance. In addition, increase compression ratio properly to
increase thermal efficiency, improve economic performance and starting performance.
④ Optimize admission gear
Through computing of work process by BOOST software, optimized design of cam mold line, admission
valve is decreased and that of exhaust valve I enlarged.
⑤ New type admission and exhaust channels for cylinder cover
Cylinder cover adopts admission channel with small eddy ratio and low resistance exhaust channel.

2.2 Points for attention about using eductor

① Users must select quality diesel oil and CF grade engine oil with low sulfur content per regulations of
this manual to guarantee emission standard.
② Users must guarantee advance angle of oil supply within the range specified in this manual because it
influences emission of pollutants.
③ Because emission standard of diesel engine is guaranteed through optimization of technical measures
mentioned in 2.1, during repair, spray pump, supercharger and sprayer must adopt original types manufactured
by the same factory. They can't be replaced arbitrarily. There are types of the three parts on name-plates (There
is embossed stamp on sprayer shell). Purchase products of same types and manufacture as the original.
④ Replacement of piston, piston ring, cylinder bush, camshaft, cylinder cover, air valve, air valve seat, air
valve lock and rocker-arm must be the same as the original.
While purchasing parts, please tell us type on nameplate, order number and serial number of products, so
that we can provide fittings correctly.

·8·
 3. Structural introduction of diesel engine
3.1 Suspension of diesel engine and configuration of peripheral accessories
Appearance of CA4DF2-13 diesel engine is shown on front page.

The diesel engine adopts four-point elastic support. Front suspension cushions are mounted on both sides
of front end of cylinder and rear suspension cushions are mounted on both sides of flywheel case.
Such accessories are installed by the sides of spray pump of diesel engine: admission pipe, air heater (or
flame pre-heater), sprayer, spray pump, high pressure oil pipe, oil cooler, drain switch, diesel oil filter,
compressed air pump, oil pressure sensor and fuel pipe.Following accessories are installed by the side of
exhaust pipe of diesel engine: generator, starter, exhaust pipe, supercharger, supercharger oil filter and oil
gauging tape.
Following accessories are installed at front end of diesel engine: water pump, pulley (or torsional damper),
fan and fan clutch, fan belt, economizer chamber (including economizer and water temperature sensor).

Filler of oil is on cylinder case.

Air inter-coolers are in front of water tank radiator, fan draft air and wind during driving lower temperature
of fresh air compressed by air compressor, the air is delivered to admission pipe of diesel engine (Refer to
drawing 3-4).

3.2 Lubricating system

Lubricating system consists of oil drain pan, oil collector, oil pump, oil filter, oil cooler, piston cooling
nozzle, main oil lead relief valve and pipeline. (Refer to drawing 3-1). Lubrication adopts composite lubrication
of pressure and splash.
Oil pump is under the last main bearing at rear end of generator cylinder. It is driven by crankshaft toothed
wheel. There is a pressure - limiter valve on oil pump. When discharge pressure exceeds 0.9~1.1Mpa, the valve
will open, some of lubricating oil will return to oil drain pan directly without passing through oil delivery pipe,
so that short time pressure borne by lubricating parts will not be too high during cold-shaft. Oil collector
suctions oil up from drain pan and forces oil into channel by pump side at front end through vent line assembly.
Oil enters the filter on cover plate of oil cooler first, filtered oil then enters oil cooler, main oil lead and into
main bearing through oil lead on cylinder baffle, then enters connecting rod bearing through oblique oil lead
on crankshaft. At the rear end of cylinder, there is a connecting oil lead which leads from main oil lead to idle
wheel bearing and last bearing hole of camshaft. Oil enters central oil lead of camshaft through this bearing
hole, which is connected with various journals of camshaft to lubricate camshaft bushing. Meanwhile, oil
passes through vertical oil lead from last bearing hole of camshaft to the cylinder bolt hole at the exhaust side of
4th cylinder, which is connected with rocker-arm seat hole. Finally, it passes through rocker-arm shaft hole to
lubricate rocker-arms and valve stem.

·9·
 Piston cooling nozzle is fixed on main oil lead of body cavity, position pin on cooling nozzle can
guarantee the sprayed oil to enter cooling cavity of inter-cooling piston to cool piston and piston ring. The
position pin shall be inserted into the position pin hole while installing the nozzle. There is a check valve in
binding bolt of piston cooling nozzle (oil begins to jet when oil pressure >200kpa), so the hollow bolt can't bear
too large tightening torque. If it is too tight, check valve will be seized and no oil will spray, piston can't be
cooled, major fault such as scuffing of cylinder bore will happen. Therefore tightening torque of binding bolt
should be strictly controlled within 50±5N.m. Besides, cooling nozzle and binding bolt of nozzle should be
assembled in pairs per original position.
Cam on camshaft is lubricated by oil bath, gear surface adopts splash lubrication.
There is pressure limiting valve of main oil lead at the lower part of oil injection pump to maintain
343~490kpa working oil pressure at main oil lead. Wearing of diesel engine will increase space between
bearing shells and liners and decrease oil pressure. When idle oil pressure is lower than 80kpa at hot state or
300kpa at no load high speed, check bearing space and change bearing shell.
4DF2-13 diesel engine leads oil out of rear end cam bearing, it is filtered by supercharge oil filter and then
lubricates supercharger. Its spill flows back to drain pan through return tube, while oil from cover plate of
cooler at admission side lubricates compressed air pump, its spill returns drain pan.
Oil pipe on main oil lead lubricates oil injection pump and returns drain pan through intermediate flange
between oil injection pump and cover plate of gear chamber.

·10·
 Drawing 3-2 is rotary oil filter. When core strainer is blocked by impurity and resistance increases to
150±30kpa or more, by-pass valve opens (oil enters main oil lead directly without passing through core
strainer). At this moment, alarm lamp in steering cabin is on to show that filter shall be maintained and core
strainer shall be replaced. But during cold-starting, by-pass valve will also open due to high oil viscosity.
Warning lamp will be off after diesel engine operates and oil gets hot. It is normal.
Water cooling finned oil cooler is used to decrease oil temperature and prevent early oxidation of oil due to
high temperature. There is a by-pass valve in the cooler. When cooling core is blocked by impurity or grease,
oil pressure difference before and after cooling increases, the by-pass valve will open and oil enters main oil
lead directly to ensure continuous oil supply. When oil temperature is high, check if cooling core is blocked

For 4DF2-13
Drawing 3-2 Oil filter
1. rubber gasket ring 2.rotary filter core

3.3 Cooling system

Cooling system consists of water pump, oil cooler, economizer, fan, drain switch, body and cover of
thermal economizer, radiating water tank in vehicle (Refer to drawing 3-3). Centrifugal water pump pumps
cooling water in radiating tank into inlet port at front cylinder, which passes through oil cooler and enters
cylinder cavities and cover, finally into thermal economizer chamber.
Working principle of thermal economizer in 4DF2-13 is that temperature of cooling water from
economizer chamber is lower than opening temperature of economizer, the economizer closes and cooling
water returns to water pump directly through minor circulation hose (not passing through radiator); when
temperature of cooling water reaches wide-open temperature of economizer, its control valve opens fully
(cooling water enters radiator, it is called major circulation). When outlet water temperature is between that of
open and wide-open, cooling water is between major and minor circulation. The engine adopts wax thermal
economizer. Its lift range is no less than 8mm when it is fully open. When it has fault, outlet water temperature
will rise sharply. Thermal economizer shall be changed timely. Users can do boiling test on economizer to see
whether it is normal.
Rotational speed of centrifugal vane pump is 3000r/min, flow rate is 240L/min, delivery lift is no less than
13.2m. Assembly of water pump and fan clutch refers to drawing 3-4.

·11·
 Figure No. of thermal economizer K-1306010

Open temperature (℃) 76±2

Wide-open temperature (℃) 86±2

Wide-open lift range (mm) ≥8

·12·
 Drawing 3-4 Assembly of water pump fan

Diameter of cooling fan and number of vane are determined by power of diesel engine and integral design
of matching cooling system. Diesel engine for trucks adopts suction fan. Don't install conversely. Function of
fan clutch is to sense cooling air temperature at rear end of tank radiator through temperature-sensitive element
at front end of clutch and to regulate slippage of silicon clutch to control fan speed (Fan speed is high when air
temperature is high). If temperature-sensitive element is damaged, users can lock the clutch with gate piece on
fan clutch, then rotational speed of fan is the same as that of water pump.
Water temperature induction plug on thermal economizer chamber is connected with water temperature
gauge in steering cabin to display outlet water temperature.

3.4 Fuel system

Fuel supply system consists of diesel oil filter, oil injection pump, high pressure oil pipe, diesel container,
return tube and oil tank and diesel pre-filter on vehicle. Oil injection pump assembly includes oil injection
pump, governor, injection pump gear and oil delivery pump. Governor is mechanical centrifugal type. Oil
delivery pump sucks fuel from oil tank, large particles are filtered by pre-filter on vehicle and minute impurities
are filtered by dieselfilter. Oil then enters low pressure cavity of oil injection pump. Plunger increases pressure
and forces oil out. Fuel injection pipe delivers it to oil sprayer. When oil pressure exceeds spray pressure,
needle valve of oil sprayer opens and oil injects into cylinder. Small amount of oil leaded from coupler gap
meets excessive oil in low pressure cavity of oil injection pump, then returns to fuel tank through return tube
(Refer to drawing 3-5).

·13·
 Drawing 3-5 Schematic drawing of fuel supply system
1. oil tank 2. diesel pre-filter 3. oil injection pump
4. low pressure oil pipe 5. diesel filter
6. fuel injection pipe 7. sprayer 8. return tube

3.4.1 Oil injection pump

In order to guarantee performance and emission standard, 4DF2-13 adopts PE reinforced pump with more
powerful working capacity.
Oil injection pump adopts pressure lubrication. Oil in injection pump and governor is replaced with
replacement of oil in drain pan.
While installing injection pump on 4DF2-13 diesel engine, first rotate flywheel to 35°in advance against
upper dead point of compression of first cylinder, align graduation on connecting disk face of injection pump
with mark "1" on injection pump gear, then turn one tooth clockwise, install injection pump into pump seat hole
of flywheel case. Finally tighten binding nut of connecting disk, check advance angle of oil supply (Refer to
drawing 5-6). If it is incorrect, loosen the binding nut and turn injection pump gently to adjust.

3.4.2 Sprayer
In order to guarantee performance and emission standard, 4DF2-13 diesel engine adopts P-shape nozzle
with low inertia and high pressure. Its structure refers to drawing 3-6. adjustment of P-shape nozzle is different
from S-shape nozzle which is adjusted by regulating bolt. It is adjusted by gaskets with different thickness (Part
label in drawing 3-6 is 3). Thickness varies from 1.0 to 2.0mm. There is one specification every 0.01mm (100
types in all). Its manufacturer usually adopts gaskets with thickness of 1.7-1.9mm. Clean coupler of sprayer and
P-shape nozzle during assembling. There should be no scratch or sundries on seal surface. Needle valve coupler
shall slip into the valve freely when in 45°inclination.

·14·
 Drawing 3-6 Structural diagram of P-shape sprayer
1. auto-clean-filter 2. sprayer 3. pressure relief gasket
4. pressure relief spring 5. spring seat 6. position pin 7. baffle
8. nozzle 9. nozzle tightening cap 10. copper seal gasket

Torque of sprayer cap is 35±5N.m. Too large torque will cause deformation of needle valve and jam of
coupling needle valve. There are 6 jet holes with aperture 0.25mm. To avoid dirt accumulation, sprayer should
have a sheath before installing into copper sleeve of cylinder cover. Sprayer is fixed in copper sleeve by
hold-down plate. Its bolt torque is 70±10N.m

3.4.3 Oil delivery pump

Plunger pump (refer to drawing 3-7) is installed by the side of oil injection pump. Its function is to suck up
diesel from fuel tank and deliver it to oil injection pump. Press pump handle to remove air in fuel system of
new engine.

·15·
 Drawing 3-7 Oil delivery pump
1. sucker connection screw 2. oil delivery pump
3. oil-out connection screw 4. pump handle

3.4.4 Diesel filter

Rotary diesel filter is seen in drawing 3-8. Its function is to filter mechanical impurity and water in diesel
to reduce wearing of injection pump and plunger coupler of sprayer and to guarantee service life.
Filter core should be replaced regularly. Tightening torque of connection screw should be controlled within
25±5N.m, neither too tight nor too loose.

Drawing 3-8 Rotary diesel filter for 4DF2-13

1. sucker connection screw 2. base frame 3. rotary filter core
4. drain plug 5. rubber seal ring 6. oil-out connection screw

·16·
3.5 Intake and exhaust system
The system consists of air filter, intake connection pipe, air heater (or flame pre-heater), admission pipe,
exhaust pipe, gaskets for admission and exhaust pipes, hold-down plate.Most air filters adopt dry duplex paper
filter, some vehicles use oil bath air filter to adapt to humid and rainy areas. Its specifications and types are
determined by power of diesel engine and service conditions. Blockage indicator on sucker connection pipe or
on filter can monitor blockage of filter core to remind users to clean or change the core (Refer to 5.2.2
Maintenance of air filter).
3.6 Supercharge inter-cooling system
The system mainly consists of supercharger, air inter-cooler, oil filter of supercharger and corresponding
oil inlet and outlet pipes.
Supercharger consists of waste gas turbine and air compressor. Its working principle is as follows: Turbine
casing is connected with exhaust manifold. High temperature exhaust with certain energy enters turbine cavity
at high speed and pushes the turbine and impeller at the same shaft to rotate at high speed, which increases flow
rate and pressure of fresh air in the cylinder and creates conditions for increasing power of diesel engine.
Structure of supercharger refers to drawing 3-9.

Drawing 3-9 Turbine supercharger

1. turbine casing 2. turbine part 3. turbine seal ring 4. non-loading bearing
5. inter-case 6. thrust bearing 7. air compressor casing 8. air compressor seal ring
9. air compressor vane 10. relief valve

Function of air inter-cooler at front end of tank radiator is to reduce air admission temperature and increase
admission density by using cooling fan of diesel engine and cool air while driving, improve power and
performance.
Because rotational speed of rotor shaft of supercharger turbine air compressor is as high as 100000r/min, it
is very important to guarantee lubrication of non-locating bearing and clean lubricating oil. Supercharge oil
filter core should be changed regularly.
3.7 Electric system
3.7.1 Electric components
Electric system is 24V and consists of starter, a.c. generator, air heater (or flane pre-heater), water
temperature induction plug, oil pressure alarm, oil pressure induction plug and indicator of filter blockage.
·17·
 Starting power is 5kw, working speed is 2500r/min to guarantee starting speed at 200r/min or more.
Rated voltage of a.c. generator is 28V. Rated current shall be selected per requirements of different
matching models. Adopt cathode overlap iron with intergral voltage regulator.

Drawing 3-10 Electric schematic drawing of 4DF2-13 generator

Water temperature induction plug: It works with water thermometer to indicate outlet temperature of
cooling water.
Oil pressure alarm is installed on main oil lead. It works with alarm lamp. When oil pressure of main oil
lead of engine lubricating system is lower than 80kpa, the alarm lamp is on to indicate the fault and check it.
Some engines have oil pressure induction plug, oil pressure is displayed by oil-pressure gauge in steering cabin.
3.7.2 Admission pre-heating
Our diesel engine can start above -5℃ without any pre-heating measures. But in cold winter, starting
becomes difficult with decrease of temperature. So we select one of the following pre-heating devices for
starting in winter.
① Air heater:
It heats air entering cylinder with resistance card to guarantee smooth starting at -5℃~-15℃. It is flap
resistance with 1.83kw consumed power. Before starting, continuous heating for 40 seconds is allowed (Too
long heating will burn resistance card). Its structure refers to drawing 3-11.
② Flame admission pre-heater
It injects flame directly into admission pipe to increase admission temperature greatly. Diesel engine can
start at -15℃~40℃. Its working principle is shown in drawing 3-12.
Before starting the engine, insert the key and turn it to position I. Storage battery supplies power to the
controller. If temperature of cooling water is lower than 0℃, thermal sensor sends the signal to the controller,
which supplies power to flame plug with 100% ratio and begins heating, the indicator lamp is on. Flame plug
becomes blazing hot after 30 seconds. After pre-heating is finished, the controller supplies power to flame plug
with 68% ratio for over-voltage protection.

·18·
 After pre-heating, indicator lamp flashes to tell the driver to start engine.
Press start button, controller sends signals to supply power to solenoid valve, oil flows to flame plug to
form flame.
connect with earth wire connect with pre-heater switch

Drawing 3-11 Air heater

Drawing 3-12 Connecting diagram of flame pre-heater switch

K1---ignition switch NO gear position K2---ignition switch ST gear position
P---pre-heating plug DL---pre-heating indicator lamp D---oil supply solenoid valve
D+---connect with D+ end of generator K---pre-heating relay Rt---pre-heating thermal sensor

At the same time, controller begins timing. If the driver doesn't start or starting fails in 30 seconds, the
controller can't receive D+ signal from magnetic field, it will cut off pre-heating loop, solenoid loop and signal
indicator lamp loop automatically for overtime protection.
Generator begins working after engine starts. Magnetic-acoustic D+ enters the controller to cancel D+ 30
seconds delay protection. Power supply ratio decreases from 68% to 50% for voltage protection of generator to
supply power to pre-heating plug directly.

·19·
 After engine runs steadily, driver should withdraw the key switch to pre-starting position to stop working
of flame plug.
Points for attention in using flame pre-heater:
1. With decrease of air temperature, first check if your oil and lubricating oil conform to cryogenic oil
specified in this manual. Storage battery should adopt corresponding cryogenic battery. (Discharge capacity of
common battery will decrease greatly in low temperature environment, normal starting can't be guaranteed).
2. Time to press start button shall not exceed 30 seconds. If ignition fails, time can be extended but not
exceeding 45 seconds to avoid damage of starter. If starting speed is very low, stop starting at once, check if oil
viscosity is too dense, battery voltage is normal. Take starter apart and apply power to it to check if rotational
speed is too low and engaging stroke is normal.
3. After pre-heating is finished, if diesel engine doesn't run after pressing starting button for 3 seconds, let
off starting button and start again within 5.5 seconds at low temperature. The device will still go on working.
4. If pre-heating indicator lamp has flashed for 30 seconds, starting button is not pressed or starting fails,
flame admission pre-heater will stop working automatically. At this moment, pause for two minutes and start
again.
5. After cold-start succeeded, rotational speed of engine shall be controlled at 800-1000r/min, keep stable
running for several minutes until indicator lamp is off, then put it into normal operation.
6. When water temperature is higher than 0℃, flame pre-heater works and indicator lamp is not on. It
means that it is unnecessary to use flame pre-heater at such temperature. Users can start diesel engine directly.

·20·
 4. points for attention in using diesel engine
4.1 Selection of diesel oil
Determine diesel grade according to air temperature. Select diesel with low freezing point in winter and
diesel with high freezing point in summer. Users can select from table 4-1. For example: When ambient
temperature is -27℃, select -35 grade diesel.
Table 4-1 Diesel grade and applicable air temperature

Diesel grade 10 0 -10 -20 -35

Cetane valve 50 50 50 45 43

Freezing point (~C) +10 0 -10 -20 -35

Applicable minimum temperature(ambient

working temperature of diesel engine) (~C) +18 +8 -2 -12 -27

After diesel grade is determined, users should select high quality diesel with 10w sulfur content (state
standard lower than 0.5%). It is beneficial to improve emission and reduce corrosion and wearing to related
parts.
In addition, keep diesel oil clean, avoid pollution by dust in air and impurities in oil tank. Before filling oil
into oil tank, stew for 72 hours and use upper diesel oil. It is very important to prevent early wearing of plunger.
4.2 Selection of engine oil
4DF2-13 is super-charge inter-cooling diesel engine, its mechanical and thermal load of motion parts is
quite high. In order to guarantee normal operation and service life, improve emission, CF grade engine oil
should be used. Besides, oil grade shall be determined by working ambient temperature (Refer to table 4-2). For
example, select 15W/40 engine oil for -10℃. Oil suitable for low temperature has low viscosity. Oil pressure
tends to be lower at high temperature but oil suitable for high temperature has low viscosity, starting is difficult
at low temperature, increase of oil pressure is slow and oil pressure is high. Such conditions interfere reliable
operation of diesel engine.
Table 4-2

Grade L-ECF 10W Sw 10w 15w 15w 20w 20w 30 40

/30 /30 /30 /40 /40 /20

Ambient temperature -20～ -25～ -20～ -10～ -10～ -10～ -10～ 5～30 >25
for diesel engine (℃) -5 25 20 25 35 30 10

Keep engine oil clean, prevent pollution by dust and impurities. After filling oil, check oil level in drain
pan. Take out oil gauging tape, clean it with gauze and insert into oil again, then take it out to see if oil level is
between upper and lower limiting marks. Anyway oil level can't be lower than the lower limit.

·21·
 Drawing 4-1 Oil filling method

4.3 Selection of cooling water

Cooling system should use soft water (river water, rain water or running water from rivers and lakes). Hard
water (from wells and springs) can't be used, because hard water contains calcium carbonate and magnesium
carbonate, such substances will deposit after being heated, forming scale on engine body, water cavity, cylinder
outer surface and internal cavity of radiator, increasing water flow resistance and influencing heat radiation of
cooling system.
Hard water can be used only after softening. Put Na3PO4 into water (add 2 grams of sodium phosphate in
one liter of water), or boil hard water then use it.Cooing water must be clean, otherwise, impurity in water will
cause wearing of vane and water seal and blockage of pipe of radiator.
Use NL emulsified rust preventing oil to increase anti-corrosive capability of cylinder sleeve and pump
vane. Add 3-4kg rust preventing oil into 96-97kg water and mix them.
When ambient temperature is below 0℃, add anti-freezing fluid into cooling water to prevent frost crack
of engine body. There are three types of anti-freezing fluid: alcohol-water, glycerine-water and glycol-water.
There proportion with water is different and freezing point is also different. Their formula are listed in table 4-3.

Table 4-3 Formula of anti-freezing fluid

Freezing point Alcohol-water Glycerine-water Glycol-water

(℃) (alcohol mass %) (glycerine mass %) (glycol mass %)
-5 10 21
-10 20 32 28
-15 25 43 32
-20 30 51 38
-25 35 58 45
-30 40 64 48
-40 55 73 55
-50 70 60

·22·
 Points for attention in using anti-freezing fluid:
① Anti-freezing fluid is toxic. Don't put it into mouth.
② With temperature rise, anti-freezing fluid has large thermal expansion. So filling volume shall be 8%
less than of water to avoid bursting of tank
③ Never use inferior anti-freezing fluid which would corrode the engine. Don't mix anti-freezing fluids
with different formula or brands.
4.4 Preparation before starting diesel engine
4.4.1 Preparatory jobs before starting
Check oil gauge and observe oil level in drain pan
Check oil storage in fuel tank and turn on its switch
Check if cooling water is full in heat radiating tank and secondary tank
For new engine, remove air in fuel system and cooling system
4.4.2 Remove air in fuel system
If air enters fuel system, oil supply to injection pump becomes abnormal, causing difficult starting,
unstable running and even shutdown of diesel engine. After refilling oil or disassembly and assembly of
injection pump, diesel filter and delivery line, air must be removed from the fuel system.
Steps are as follows:
Turn relief screw loose on diesel filter, press oil pump handle up and down repeatedly until there is no
bubble in diesel oil flowing out of relief screw, then tighten relief screw while pressing oil pump handle. (Refer
to drawing 4-2)

Note: Diesel filter for 4DF2-13 is single stage type at the right side of oil pump.
Drawing 4-2 Remove air in fuel system

·23·
 4.4.3 Remove air in cooling system
When filling cooling water, air shall be removed from cooling system, otherwise air would result in "air
expansion", overheating of diesel engine and serious fault of scuffing of cylinder bore. Steps are as follows:
Turn loose hex plug screw near thermal economizer, fill cooling water to cooling system until there is no
bubble in cooling water flowing out of thread of hex plug screw, then tighten the hex plug screw (Refer to
drawing 4-3). If anti-freezing fluid is used, gather outflow fluid to avoid waste or pollution.

Drawing 4-3 Remove air in cooling system

4.4.4 Fill lubricating oil to supercharger

Before starting of new engine or engine unused for a long time, take a part sucker of supercharger, fill
clean diesel oil to oil-in and filter of supercharger to guarantee lubrication of supercharger bearing during
starting. Lubricating oil shall also be filled when disassembling supercharger or replacing its filter (Refer to
drawing 4-4). Oil must be clean and its brand should be the same as original one.
4.5 Starting procedure
During starting, gearbox shall be at free position and clutch is declutched.
Slide lock switch to connect power supply.
Press start button and loosen it as soon as diesel engine is started, turn back lock switch.
Pressing time shall not exceed 15 seconds to protect starter and battery. If starting fails, start again after 60
seconds. If it fails for 3 times continuously, find out the reason, remove the fault and start again.
Check oil pressure immediately after starting.
Oil pressure should be ≥98kpa at idle speed. Oil pressure alarm would warn when oil pressure ≤80kpa.
At this moment, stop the engine and check. Check oil level in drain pan of new diesel engine or after oil is filled.
Add or discharge some oil if necessary. Oil level should be between upper and lower marks of oil gauge.

·24·
 Drawing 4-4 Fill lubricating oil to supercharger
1. supercharger filter 2. filter sucker
3. supercharger return oil pipe 4. supercharger sucker

4.6 Points for attention in operation

After starting, diesel engine can't have full load operation. It is necessary to run at low and moderate speed
for some time until water temperature reaches 60℃. Here are points for special attention:
① In winter some users heat the engine at idle speed, it is harmful to service life.
② Some users are used to "bombarding throttle", it is detrimental to friction pairs. Because oil pressure
hasn't been established on friction pairs during starting, sudden running at high speed would damage friction
pairs, especially in winter, supercharger bearing would bite easily.
Observe oil pressure and cooling water temperature regularly during operation. When the engine runs at
high or moderate speed, oil pressure shall be 245~490kpa, outlet temperature of cooling water shall be 75~90℃.
Check if there is abnormal sound or fault after starting or before shutdown. If there is, find out the reason
and remove the trouble, then start again.
Pay attention to sealing of water line, oil line and air line. If there is leakage, remove the fault at once.
New engine or engine after major repair shall have running-in operation for 2000km (or 40 hours) at moderate
or low speed with light load, then it can be used at full speed with full load.
Too low outlet water temperature is unfavorable to wearing and efficiency. Opening of thermal economizer
would be reduced. Bimetallic thermal sensor on silicon fan clutch would lower fan speed automatically due to
low air temperature behind heat radiating tank to reduce volume of cooling air. In very cold regions, users can
open fabric of hear radiating tank to further reduce air volume and increase water temperature.
In summer where temperature exceeds 35℃, users should reduce load of vehicle to keep outlet water
temperature below 100℃.
Oil injection pump has been adjusted and limit screw is lead sealed before diesel engines leave the factory.
Users shall not take lead seal apart and adjust arbitrarily.

·25·
4.7 Points for attention during shutdown
Before shutdown, unload and run at moderate or low speed for several minutes, water temperature
decreases to 60℃, rotational speed of supercharger decreases greatly. It can protect diesel engine and
supercharger.
Piston, piston ring and cylinder cover are very hot during full load running, abrupt running at idle speed
would make cooling water temperature rise quickly even to "boiling" because cooling water and air volume is
very small and large amount of heat would transmit to cooling water. So it is necessary to run at moderate or
low speed with no-load for several minutes (especially in summer).
Never adopt "acceleration- extinction –free position gliding" for supercharge diesel engine.
When ambient temperature is below 0℃ and anti-freezing liquid is not used, drain cooling water after
shutdown to prevent frost crack. Drain switch of 4DF2-13 is on cover plate of oil cooler.
Keep engine clean if it will not be used for some time. Drain cooling water and take oil seal measures to
prevent rust.
4.8 Points for attention in winter
When temperature is below 5℃, give special maintenance to diesel engine. Use engine oil and diesel oil
for winter (Refer to tables 4-1, 4-2). There should be no water in diesel oil to prevent blockage of oil line.
When changing cryogenic oil, drain oil in drain pan and injection pump, clean filter, drain pan and oil
collector, then fill cryogenic oil to diesel engine, supercharger and injection pump.
Shorten oil replacing time when ambient temperature is below -10℃.
Anti-freezing fluid should be used for cooling water (Refer to table 4-3). But be careful when its mixture
ratio exceeds 30% unless temperature remains below -35℃, because too thick anti-freezing fluid would cause
gelatination and block of water line in cooling system. Supplement water while adding anti-freezing fluid.
During shutdown in winter, if no anti-freezing fluid is added, drain water after water temperature decreases
to 40℃~50℃.
Don't park vehicles in open air in very cold region, otherwise drain pan shall be heated before starting so
that oil would not be too thick. If anti-freezing fluid is not used, add hot water to water tank, use air heater or
flame air pre-heater for easy starting.

·26·
 5. requirements for maintenance of diesel engine
Correct maintenance is decisive to good performance and service life of diesel engine. It is also necessary
conditions for reliable and long-term work as well as its service efficiency. So users should strictly follow
instructions of this manual.
5.1 New engine running-in and technical maintenance
Maintenance is classified into new engine running-in and technical maintenance after formal operation
(usually called 3-stage maintenance). Maintenance items refer to tables 5-1 and 5-2.
The purpose of new engine running-in is enable motion part friction pairs to reach matching state after low
load and low speed test-run for 2000km. after running-in period, maintain diesel engine per table 5-1 and then
put it into normal operation.

Table 5-1 Maintenance items after running-in stage

Time interval No. Maintenance contents

1 Drain all oil in drain pan, clean drain pan, change lubricating oil

2 Clean filter screen of oil collector

3 Check drive gear nut of oil pump and tighten torque

4 Check main bearing bolt and tighten torque

End of running-in 5 Check connecting rod bolt and tighten torque

period (2000km 6 Check cylinder cover bolt and tighten torque

or 40 hours) 7 Check and adjust valve clearance

8 Change diesel filter and engine oil filter core, clean dust on air filter
core
9 Check oil supply advance angle

10 Check tensity of fan belt

11 Check if suspension cushion has cracks and if nut is loose

After normal running of diesel engine, carry out routine and three-stage maintenance per service time
listed below.

·27·
5.2 Maintenance requirements

Time interval No. Maintenance contents

1 Check oil level in drain pan and cooling water volume in water tank
Routine maintenance 2 Check leak-tightness of water line, oil line and air line
3 Do cleaning
4 Remove faults and abnormalities
1-4 The same as routine maintenance
First stage mainte- 5 Check tensity of fan belt
nance (2500km or 50 6 Remove dust on air filter core
hours) 7 Check leak-tightness of pipe connection of supercharge inter-cooling
system
1-7 The same as the first stage maintenance
8 Clean drain pan and oil collector, change drain pan and oil in injection
pump
9 Change oil filter core and supercharger oil filter core
Second stage mainte- 10 Change diesel oil filter core
nance (1000km or 2013 11 Clean diesel oil tank, oil-line pump filter screen and diesel pipe
hours) 12 Check and adjust valve clearance
13 Check and adjust oil supply advance angle of injection pump
14 Check.injection pressure and atomization of sprayer
1 -14 The same as the second stage maintenance
Third stage mainte- 15 Clean oil cooler
nance (50000km or 16 Check tightness of cylinder cover bolt, connecting rod bolt and main
bearing bolt
1000 hours) 17 Determine whether to dismantle abrasive air valve of cylinder cover
based on running conditions
18 Determine whether to send injection pump to professional unit for
adjustment based on running conditions
19 Clean accumulated carbon on supercharger air compressor, turbine rotor,
vane and body case
Here we emphasize that air filter, diesel oil filter and engine oil filter are
Remarks very important to service life of diesel engine. Users must select filter cores
manufactured by the same factory as used in original engine.

5.2.1 Check oil level in drain pan

Keep diesel engine horizontally and check oil level during shutdown. Pull out oil gauge tape, clean it with
gauze, insert oil gauge to the bottom, then pull it out again, check if oil level display is between upper and
lower limits at tail end of oil gauge. If oil level approaches lower limit mark or is lower than that, fill oil at once

·28·
and try to reach the upper limit. If oil level exceeds upper limit too much, drain excessive oil from screw plug
of drain pan, otherwise oil will overflow from front and rear oil seal. (Refer to drawing 5-1).

Drawing 5-1 Check oil level in drain pan

5.2.2 Maintenance of air filter
Maintain air filter carefully and timely, prevent dust from entering cylinder. It is very important to service
life of cylinder sleeve, piston, oil cork ring and air valve. Maintenance period of air filter is determined by dust
in working environment. If it works in dusty area, maintenance period is short.There is a block indicator on air
filter. If it is an induction type indicator and signal lamp is on in steering cabin, the air filter must be maintained.
If it is a mechanical indicator, stop the car and open hood, pull throttle to no-load high speed. Observe if the
maintenance indicator is at the red mark, filter core should be maintained.
The paper two-step air filter commonly used now has a main core and a safety core. During maintenance,
first open the filter cover and take out filter core, hit both ends of filter core with hand or wooden stick gently to
shake off dust. Compressed air less than 600kpa can be used to blow off dust inside filter core. Check safety
core (the small core in main filter core) and clean dust.
Generally, main filter core shall be replaced after being maintained 6 times, safety core shall be replaced
accordingly. If safety core is full of dust, it means that the main core is damaged and should be replaced (Refer
to drawing 5-2).
While maintaining paper core, be careful not to damage it by oil or water. While assembling, check if
rubber seals are intact and there is missing core to prevent short circuit of air filter.
For oil bath air filter, first shut down for one hour to drip oil from metal core, then clean core and shell
with clean diesel oil, fill clean engine oil again. Oil level should be within the limit. If too high, oil will be
sucked into cylinder or stain paper filter core and damage it. (Refer to drawing 5-3).
We stress here, whatever type air filter may be, its core, rubber gasket, rubber tube and other connecting
parts must be sealed. Otherwise dust would enter the cylinder. Hardness of sand particle silicon oxide is twice
as that of cylinder sleeve. It will wear cylinder sleeve and piston ring. So users in dusty area should maintain air
filter regularly and select quality cores from original manufacturer, buy cars with large capacity of air filter or
two filters or with cyclone scrubber.

·29·
 compressed air

separation between main filter

core and cyclone case pat main filter core blow main filter core

Drawing 5-2 Maintenance of paper air filter

1---rubber gasket (two) 2---cyclone case 3---main filter core
4---safety core 5---rubber gasket (two) 6---automatic dust exhaustor

5-3 Maintenance of oil bath air filter

1---air filter body 2---upper filter core 3---rubber gasket ring (two)
4---lower filter core 5---oil conservator

·30·
 5.2.3 Check tightness of fan belt
If fan belt is too tight, it will damage bearing of water pump and generator earlier. If it is too loose, belt
will skid and become hot, reducing service life.
Check tightness of belt per methods shown in drawing 5-4. Press down single belt with 40N (-4kgf), belt
deflection shall be 10-15mm. If it doesn't conform, adjust relative position between generator and regulating
arm. In order to guarantee same tightness of two belts, change two belts at the same time. Don't use one new
and one old. Don't use belt manufactured by different factories.

pressure 40N.m

normal belt

loose belt

Drawing 5-4 Adjustment of fan belts

5.2.4 Maintenance of diesel oil filter

Diesel filter adopts primary rotary filter core which can't be cleaned and used again. Clean diesel oil
without impurity enters injection pump and sprayer. Filter core should be changed after vehicle has run for
10000km.
Various impurities may deposit in oil tank, filter screen of oil-line pump and diesel pipeline. Clean these
parts every 10000km.
5.2.5 Check and adjust air valve clearance
Correct air valve clearance can guarantee normal performance of diesel engine and reliable function of air
valve. Methods of adjustment are as follows:
When the primary cylinder is at upper dead-center, adjust its air valve clearance. For 4DF2-13 model, turn
180°striking angle of crankshaft, adjust clearance of cylinders 1-3-4-2 per ignition sequence. Adjust clearance
per article 1.2 with thickness gauge (Refer to drawing 5-5).
After adjustment, check again and then start diesel engine, at idle speed, check if adjustment is correct by
observation and hand feeling.
5.2.6 Change engine oil
While diesel engine is running, high temperature makes oil age and modify, abrasive metal impurity will
contaminate oil. So regular change of engine oil is very important to prolong its service life. Mileage for
changing oil in such cold area as below -10℃ shall be shortened to 5000km.

·31·
 Change engine oil while diesel engine is hot. Hot oil can bring its impurity out easily. After old oil is
drained, tighten drain plug (change new gasket ring) and then fill new oil.

Drawing 5-5 Check and adjust air valve clearance

5.2.7 Check oil supply advance angle of injection pump

There is no definite period for checking the advance angle. When performance of diesel engine is failing,
first check oil supply advance angle. After injection pump is installed again, oil supply advance angle shall be
checked too.
Methods of checking refer to drawing 5-6.

a) Before oil supply, oil level in oil-out valve adapter

b) Oil supply begins, oil level fluctuates in oil-out valve adapter
Drawing 5-6 Check oil supply advance angle of injection pump

Turn flywheel to 30°-40°in advance of upper dead point of primary cylinder compression.
① Take apart fuel injection pipe of primary injection pump, absorb diesel oil in oil-out valve adapter with
clean gauze.
② Turn crankshaft anticlockwise, observe whether there is oil level fluctuation in oil-out valve adapter of
injection pump (when oil level begins to rise), stop turning of crankshaft.

·32·
 ③ Check advance angle indicator on pulley end or flywheel case to see if it conforms to the value
specified in article 1-2. If not, adjust the angle.
④ Oil supply advance angle is important for meeting emission standard. Adjust it very carefully.
5.2.8 Check oil injection pressure and atomization quality of sprayer
Check sprayer on special testing bench. Pump oil with 30r/min and 25-26Mpa, mist should be uniform and
oil cut-off should be complete, special clear sound can be heard ( Refer to drawing5-7)

poor atomization good atomization

Drawing 5-7 Check atomization quality of sprayer

If atomization is poor, clean needle valve coupler in diesel oil and adjust pressure to specified value.
Sprayers of different cylinders are not interchangeable, guarantee height of sprayer tip protrusion above
cylinder cover plane within permitted range. Adjust protrusion height of new sprayer with copper pad, assemble
coupler valve and needle valve in original pairs.
5.2.9 Maintenance of supercharge system
Connection between supercharger, exhaust pipe and inter-cooler pipe must be airtight. If there is leakage
between exhaust pipe and supercharger, efficiency of supercharger will decrease greatly and exhaust
temperature will rise sharply. If there is leakage between inter-cooler pipe and air intake pipe of diesel engine,
intake pressure will decrease, lowering power of diesel engine and increasing exhaust temperature.
If exhaust pipe leaks, running sound is abnormal and leaking part has carbon deposit.
Because pressure inside intake pipes is larger than that of outside, users can coat water on connecting parts
to check air-tightness. The method can be applied to inter-cooler testing.
Before starting a new engine, fill clean oil in supercharger and supercharge filter to guarantee lubrication
of supercharger bearing as soon as diesel engine is started. Change supercharger oil and filter core after the car
has run for 8000~10000km.
Run diesel engine at idle speed for 3-5 minutes before it stops to decrease rotational speed and temperature
of supercharger. If there is jam or wearing sound, send the supercharger to a qualified maintenance station.
After working for 500 hours or 30000km, check if clearance of supercharger rotor shaft is normal, clean
scale or carbon on air compressor, turbine rotor and case. Take apart supercharger.

·33·
Don't use mechanical method to remove scale, which would cause deformation of vane androtor. Use gasoline
or cleaning solution. Don't damage or deform rotation parts of supercharger and rubber gaskets. Change gaskets
between supercharger and exhaust pipe during re-assembly.
Control opening of by-pass valve according to pressure of air compressor. When pressure exceeds
specified value, action rod of regulator opens the by-pass valve to discharge partial cylinder exhaust to muffler.
It can improve low-speed performance and prevent high-speed roughness and more oil consumption.
Supercharger regulator with by-pass valve has been strictly adjusted before leaving the factory. Users shall
not adjust by themselves, nor shall they lift the supercharger with action rod of regulator or make by-pass valve
regulator deformed.
Check axial clearance:
Put contactor of dial indicator close to end of turbine driving shaft, push rotor shaft to dial indicator, record
the indicating value, then push the shaft in opposite direction, then record the value. Their difference is axilal
clearance, which shall not exceed 0.20mm.
Check radial clearance
Put contactor of dial indicator close to vane top, press down vane gently and record the value, then lift
vane and record the value. Their difference is radial clearance, which shall not exceed 0.65mm.
5.2.10 Points for attention of throttle limit screw of injection pump
PE reinforced pump of 4DF2-13 diesel engine adopts R801 global governor (Refer to drawing 5-8). Limit
screw has been adjusted and lead sealed before leaving the factory. Users shall not open and adjust it. Injection
pump should be repaired by professional units and lead sealed after adjustment per oil volume.

Drawing 5-8 Handle of injection pump

1---oil cut-off handle 2---pipe connection screw of supercharger compensator 3---throttle handle

·34·
5.3 Points for attention for starting new engine or after major repair
New engine or engine after major repair must have running-in for 2000km (or 40 hours) at low or
moderate speed without load in first 200km, with 70% or less of rated load in 1500km and 90% of rated load
after 1500km.
After running in period, maintain diesel engine per table 5-1 and then put it into normal operation.

·35·
 6. points for attention during assembling diesel engine
Users must follow the technical requirements of assembly specified in this manual to guarantee reliable
operation of diesel engine.
6.1 General technical requirements of overall assembly
(1) When assembling the engine again, clean all parts, blow lubricating oil pipe with compressed air to
guarantee no iron scurf, oil scale or sundries. Keep part surface clean.
(2) Change sealing pads and rubber gasket rings or guarantee no defect of original pieces.
(3) Coat lubricating oil on motion surface before assembly.
(4) Tighten key binding parts per torque specification and in proper sequence and tighten the rest per bolt
torque. Coat thread locking glue on bolts and nuts of connecting rod, flywheel and torsional damper to prevent
loosening.
(5) Pay attention to assembling direction and marks (such as main bearing cap, connecting rod big end cap
and crankshaft thrust piece. Assemble main bearing cap and connecting rod per cylinder pairs to prevent
gripping. Don't confuse cylinder sequence of piston, cylinder sleeve, piston ring, connecting rod and air valve
bush to ensure good run-in state of motion pairs.
(6) Coat seal gum evenly and properly per instructions to prevent oil or water leakage.
(7) After assembling one main motion part (such as crankshaft, connecting rod piston, camshaft or gear) or
after overall assembly, rotate diesel engine several rounds to check if something is wrong.
(8) In order to guarantee emission standard, injection advance angle, jet pressure of sprayer and height of
protrusion above cylinder cover must follow requirements of this manual.
6.2 Assembly of cylinder sleeve
(1) Install "0"-shape rubber gasket into cylinder recess. Don't twist gasket, coat soap water on gasket
surface to prevent from damage when cylinder sleeve is pressed down.
(2) Install cylinder sleeves of the same unit (with different bore size) vertically into cylinder, tap gently
with clean wooden hammer to make sleeve shoulder binding with cylinder mouth tightly.
(3) Sleeve shoulder shall be 0.045~0.105mm higher than upper surface of cylinder. Height difference
between two adjacent cylinder sleeves shall be less than 0.03mm.
6.3 Assembly of crankshaft
(1) With basal plane upward, install upper bearing shell into main bearing seat in turns (insert bearing lip
into bearing seat recess), oil hole of main bearing seat shall be open to oil hole of main bearing shell, coat
engine oil on shell surface. Install thrust bearing on rear thrust surface of last bearing seat. The wear-resistant
alloy surface with two recesses shall contact with motion surface of crankshaft. Two elastic position pins
supporting thrust bearing shall be 2~2.5mm higher than body surface or main bearing cover.
(2) Put clean crankshaft into main bearing shell, coat oil on journal, turn crankshaft several rounds to have
good binding with bearing shell.

·36·
 (3) Assembly of main bearing cover
Install lower bearing shells into bearing covers, then assemble two thrust bearings on two end faces of the
7th main bearing cover (recess outward). Elastic straight pin shall be 0.5~0.8mm concave in thrust bearing.
Put main bearing covers into corresponding main bearing seats according to steel stamps of matching
sequence and front convex mark (Don't assemble inversely) (Refer to drawing 6-1). Tap main bearing cover
gently with wooden hammer to bine with engine body. There should be no misplacement of cover sides with
seat sides, especially the last main bearing cover with thrust bearing.
(4) Coat oil on bolt threads of main bearing, put it into thread hole, tighten main bearing cover from
middle to both ends in sequence shown in the drawing (Refer to drawing 6-1). Turn crankshaft freely, push
crankshaft forward, insert thickness gauge into front thrust sheet to check if its axial clearance is
0.105~0.309mm.

4DF2-13 body
Drawing 6-1 Tightening sequence of main bearing cover bolts

·37·
 6.4 Assembly of piston connecting rod unit
Assemble piston connecting rods according to weight group. Difference of piston weight on one diesel
engine shall not be less than 8g and that of connecting rod shall be less than 15g.
Don't confuse matching marks of connecting rod and big end cap, small bulb mark at the side of big end
cap and arrowhead at piton top shall direct to fan end of engine to guarantee correct position of piston
combustion chamber (Refer to drawing 6-2). Heat piston in boiling water before installing piston pin for easy
assembly. Clamp elastic baffle ring at piston ends into slot.

Drawing 6-2 Assembly of piston connecting rod

The first piston ring is single keystone ring with cone upward. The second pressure ring is negative twisted
ring with internal chamfer facing downward (Side with top mark upward). Insert conformable oil ring into ring
slot and connect with lap mouth. Put oil ring on to expansion ring with 180°between opening and lapping.
Piston ring shall turn freely in ring slot, opening of the first ring shall form 30°included angle with piston pin
axle. Openings of the second and third ring shall be staggered 120℃ (Refer to drawing 6-3).

Drawing 6-3 Assembly of piston ring

·38·
 Coat oil on connecting rod bush, crankshaft journal, piston and piston ring when inserting them into
crankshaft. Pay attention to cylinder sequence, assembly direction and position of piston ring opening. Bush
with 1004026 is upper bush and with 1004028 is lower bush.
Upper end of connecting rod bolt is asymmetric. Relative position of bolt head and rod shall follow
requirements of drawing 6-2. Tighten connecting rod nut twice and symmetricly.

6.5 Assembly of camshaft

Sleeve thrust on camshaft first, then install semicircular key and timing gear (the face with timing mark
outward), tighten bolt and lock holding plate (Refer to drawing 6-4). Insert camshaft assembly into cylinder
sleeve gently, then bind camshaft thrust on cylinder.

Drawing 6-4 Assembly of camshaft

1. binding bolt 2. lock washer 3. delay gear
4. thrust 5. semicircular key 6. camshaft

6.6 Assembly of gear system

After assembling of crankshaft and camshaft, install timing mid-gears in turn. Corresponding mating
marks on gear face shall conform to drawing 6-6. Fill lubricating oil to timing mid-gear shaft (II), (III), bush
and gear-face.
Gear mating marks shall direct toward flywheel end. But limit mark of timing mid-gear (II) (small gear
with 26 teeth) is at the back due to structure. We coat white paint on gear top as assembling mark. If users find
falling off of white paint, coat paint at position with stamp mark for easy assembly.

6.7 Assembly of cylinder cover and admission gear

6.7.1 Assemble cylinder cover
(1) Grind pairs of air valve and valve seat (with continuous sealing strip) before assembling cylinder cover,
clean the abrased cover and valve. Air valves of different cylinders can't be changed.

·39·
 Drawing 6-5 Assembly of gear system
1---crankshaft driving gear 2---oil pump drive gear 3---crankshaft oil pump gear
4---timing mid-gear (I) 5---timing mid-gear (II) 6---oil injection pump gear
7---steering pump gear 8---camshaft gear 9---timing mid-gear (III)
(2) Install lower spring seat, press valve guide gasket into upper guide
(3) Install exhaust valve, valve spring, upper spring holder and air valve gate piece. Guarantee binding of
gate piece and upper spring holder of air valve (Hit air valve top with wooder hammer) so that air valve lock
drops correctly.
(4) Tightening torque of hold-down nut of sprayer shall be 70±10N.m, height of sprayer tip protruding
lower surface of cylinder cover shall be 3.4~3.9mm.
6.7.2 Coat oil on tappet and install it in tappet hole of cylinder. Check if it can slide upward and downward
freely.
6.7.3 Install position pin on upper surface of cylinder and cylinder pad (Caution: two position pins of
4DF2-13 have the functions of water flow direction and cooling, align the end with hole on cylinder face
toward admission side). Align cylinder cover and position pins, tighten all bolts from middle in sequence (Refer
to drawing 6-5)
(7) Assemble push rod of air valve and rocker-arm, adjust admission and exhaust valve clearance to
specified value, turn diesel engine to check air valve clearance of cylinders and if push rod is bent.

6.8 Assembly of flywheel

Output torque of diesel engine is transmitted by flywheel, so tightening torque of flywheel bolt must
conform to specification of this manual. Tighten bolts diagonally. There are 6 flywheel bolts which adopt single
thick washer.

·40·
 6.9 Assembly of crankshaft torsional damper or front-end pulley
Function of crankshaft torsional damper is to reduce its vibration amplitude. Because crankshaft of
4DF2-13 is short, amplitude is small. Our factory determines if torsional damper is necessary according to front
drive power.
Tighten binding bolts of torsional damper (or front end damper) per torque specified in this manual.

4DF2-13 cylinder cover

Drawing 6-6 Drawing of tightening sequence of cylinder cover bolts

6.10 Assembly of peripheral parts and overall adjustment

Peripheral parts of diesel engine include injection pump, water pump, admission and exhaust pipes,
supercharger, engine oil filter, diesel oil filter, air compression pump, generator, starter, fan and various pipe
adapters. All parts should be clean during assembly. There should be no foreign materials in supercharger, air
tube of cylinder cover, admission and exhaust pipes. Joining points should be correct and sealed.
After general assembly, adjust according to technical data specified in this manual.

·41·
 7. diagnosis and remedy of common faults of diesel engine
Fault is unavoidable in using diesel engine. Major accident would occur if fault is not detected and
removed timely. Following reasons of faults and remedies are for your reference.

7.1 Difficult starting

Causes Remedy
Air in fuel system Check if there is air leakage in fuel pipe, remove air
in the system with oil-line pump
Blockage of fuel system Dismantle and clean oil pipeline
No oil supply or intermittent supply by Check if plunger and non-return valve are sealed,
oil-line pump spring is broken or loses elasticity
Shift of oil supply advance angle Check and adjust
Poor atomization or too low pressure of Clean sprayer coupler, adjust jet pressure, check
sprayer wearing of plunger and oil-out valve, check if valve
spring is broken
Wearing of injection pump plunger Change the plunger
Serious wearing of piston ring and cylinder Change piston ring and cylinder sleeve
sleeve,piston ring clamping or broken, loose
sealing
Air leakage of air valve Check wearing of air valve and sealing cone of valve
seat, grind valve sealing surface, adjust valve
clearance
Low temperature in winter Adopt electric heater or tame admission preheater
Low voltage of battery, engine can't reach Recharge battery to specified requirements
minimum starting speed
Loose connection of electric circuit Check wiring and tighten it
Start gear fails to insert in flywheel geared Check and repair iron attraction device of starter
ring
Failure of oil cut-off solenoid valve, Check wiring and solenoid valve
injection pump can't supply oil

7.2 Under-power of diesel engine

Causes Remedy

Blockage of air filter insufficient air Clean dust on filter core or change filter core
admission
Blockage of fuel line or oil filter, Clean fuel line or change filter core
insufficient oil supply
Shift of oil supply advance angle Check and adjust

·42·
 Causes Remedy

Incorrect air valve clearance Checkandadjust

Poor atomization, jet hole block and Check, clean or change sprayer coupler, adjust jet pressure
needle valve biting again
Insufficient oil supply of injection pump Check wearing of plunger coupler and oil-out valve, change
it if necessary
Overheat of generator Check cooling system, clean scale and dirt in passage
Carbon deposit in exhaust pipe or muffler Remove carbon deposit
Check tightness of air valve and valve seat, wearing of
Low pressure of cylinder compression piston
ring, cylinder sleeve and piston. If necessary, grind
valvecone
or change cylinder sleeve, piston and piston ring

Poor fuel quality Change fuel conforming to requirement

Too high ambient temperature, run at high Decrease of actual power, lower service load in such condi-
altitude tions
Supercharger beating wear, large Repair or change supercharger
clearance,vane deformation or shaft
biting
Poor sealing of admission pipe connection Check and remove leakage, or change intercooler
or leakage of inter-cooler

7.3 Abrupt stop of diesel engine

Causes Remedy
Air in fuel system Remove air in fuel system

Blockage of fuel pipe or diesel filter Clean blocked part or change filter core

Failure of fuel transfer pump Repair or change transfer pump

Crankshaft seizure (determined by Insufficient oil supply or oil cut-off. Check oil pump and
crankshaft rotation) pipeline, change crankshaft shell
Water cut-off of water tank or pump failure, check tank
Seizure of piston and cylinder sleeve and belt tensity, check pump, send sprayer, injection pump
and supercharger to professional unit to repair. If piston
cooling noozle bites, charge it

·43·
7.4 Runaway of diesel engine
Causes Remedy
Govemor failure Check and repair governor
Broken governing spring Change spring
Clamp of regulating toothed bar and geared ring Check and repair oil injection pump
Caution: ① Cut off oil line at once during runaway, block admission port. Switch off exhaust brake valve to
force shutdown of diesel engine.
② While running down a steep slope using gear dragging, gear box shall increase gear position with
increasing down speed to prevent reverse dragging of diesel engine, over-speed running will cause knockout of
valve gate and bending of push rod.

7.5 Abnormal running sound of diesel engine

Causes Remedy

Too large clearance between air valve and Check related parts and adjust and valve clearance
rocker-ann, broken single valve spring or
bend push rod,metal hitting sound at
cylinder cover
Too early oil supply, rhythemic and clear Check and adjust oil supply advance angle
metal sound in cylinder
Too late oil supply, low but clear sound in Check and adjust oil supply advance angle
cylinder
Too large clearance between piston and Change worn out piston, piston ring and cylinder sleeve
cylinder,bumping sound in cylinder which
decreases with temperature rise of diesel
engine
Too large clearance between piston pin Change piston pin and small end lining of connecting rod
and small end of connecting rod, light but to guarantee clearance
sharp sound, more clear at idle speed
Too large clearance between main bearing
shell and connecting rod beating shell,
metal bumping sound wheneng'me lowers Change main bearing shell, connecting rod bush and crank-
rotation speed abruptly, dull but forceful shaft to guarantee clearance
sound at low speed
Gear wearing, too large clearance, mental Change all gears
bumping sound heard outside gear chamber
when speed is lowered abruptly
Too large axial clearance of crankshaft or Change crankshaft or camshaft thrust to guarantee
camshaft, bumping sound of forward and clearance
backward running at idle speed
Damage of pump axle bearing or genera- Change water pump and generator assembly
tor bearing, continuous sound
Bend of supercharger rotor shaft or vane Check and replace
deformation, rubbing of vane and volute

·44·
7.6 Unstable running of diesel engine

Causes Remedy
More water in diesel oil Check water content in fuel, change qualified oil
Poor function of sprayer Check, clean or change sprayer
Poor sealing of fuel pipeline Check tightness of fuel line from oil tank to
sprayer
Drive rack running of injection pump, uneven oil Check and adjust oil injection pump
supply to cylinders
Broken plunger spring of injection pump Change spring
Governor sliding Check and repair governor

7.7 Abnormal exhaust color of diesel engine

Causes Remedy
Overload running Remove overload
Poor spray or too low spray Clean sprayer coupler or change it, adjust pressure of
pressure sprayer
Incorrect oil supply advance Adjust advance angle
angle
Black Poor fuel quality Change specified fuel
smoke Block of air filter, abnormal Clean filter core or change it, check supercharger
supercharger and air supply
Incorrect air valve clearance,
valve rod sticking in pipe due Check air valve clearance, clean valve and pipe hole,
to scale or leakage of valve check and grind sealing cone of valve
cone sealing

Piston ring opening at same side Stagger 120~C for three-ring lapping, assemble again
Claming or over-wearing of Clean or change piston ring
piston ring
Blue Drop or damage of oil seal of air Change oil seal
valve pipe
smoke Oil seal failure of Repair supercharger and guarantee tightness
supercharger
Seal failure of piston ring of Check and repair compressed air pump
compressed
air pump, oil leaks into
cylinder
White Water leakage in cylinder Check sealing of cylinder pad, crack on cylinder cover,
smoke corrosion hole or crack on cylinder sleeve
More water in oil Change specified oil

·45·
7.8 Overheat of diesel engine

Causes Remedy
High oil Heavy load and hot weather Reduce load
tempera- Block of cooler core and oil line, Clean or change cooler core, check
ture failure of by-pass valve and clean by-pass valve
Too much duct on radiator Clean radiator
High Low water level in tank Add cooling water
tempera- Failure of thermal economizer Change thermal economizer
ture of Pump failure or loose pump belt Check pump vane and adjust belt tightness
cooling Block of cooling water tank and water line by Clean water tank and blocked part
water dirt
Hot weather, overload Reduce load and speed

7.9 Dilution of lubricating oil by diesel oil

Causes Remedy
Piston ring wear beyond limit, diesel oil in Clean gel from piston, change worn-out piston
cylinder leaks to engine oil
Diesel oil not conforming to specification Change specified oil
Too low spray pressure or coupling clamp, Check and adjust spray pressure or change spray
oil isn't atomized coupler
Wear of injection pump plunger, internal Change plunger or oil transfer pump, adjust oil pump
leakage, diesel oil in drain pan with return again
oil

7.10 Underpressure of engine oil

Causes Remedy
Too little oil in drain pan Add oil
Inaccuracy of pressure gauge or sensor Change oil pressure gauge or sensor
Too large clearance between crankshaft jour-
nal and main connecting rod bearing bush Change worn-out bearing bush or crankshaft
Wear of internal gear, journal and shell Change oil pump
surface
Broken of pressure limit valve spring of oil Change spring of pressure limit valve
pump
Incorrect oil brand, low viscosity, oil Change specified engine oil
diluted by diesel oil
Blockage of oil filter or oil cooler Clean or change filter core or oil cooler core

·46·
 Causes Remedy
Block of oil collector Clean it
Damage or drop of piston cooling nozzle Check and change cooling nozzle

7.11 Mixture of oil with cooling water

Causes Remedy
Cooling water creeps into drain pan, lubricating oil
level rises and turns white:
Crack or cavitation wear of cylinder sleeve Change cylinder sleeve
Damage of water-seal loop Change water-seal loop
Crack of cylinder body or cover Change cylinder body or cover
Ablation of cylinder pad Change cylinder pad
Oil in cooling water:
Crack and leakage of oil cooler core Change oil cooler core
Damage of packing washer of oil cooler Change packing washer
Cylinder bolt hole defect of rocker-arm at exhaust Change cylinder cover or lay bush in bolt hole
side of 4th cylinder

7.12 Supercharger failure

Causes Remedy
Too low supercharge pressure:
Leakage of admission and exhaust pipes Check if there is crack in admission or exhaust pipe,
rubber adapter or gasket is sealed. Change damaged
part
Damage of supercharger bearing Check or change beating
Rust and leakage of intercooler Change intercooler
Abnormal sound and vibration of supercharger:
Deformation or damage of exhaust turbine or Check and change damaged part
vane of air compressor
Poor lubrication of supercharger bearing, Check and repair, check if lubricating oil line is
shaft seizure normal
Foreign material entering supercharger vane Check and repair
Axial or radial clearance of supercharger Check and repair
exceeds limit

·47·
7.13 Starter failure

Causes Remedy
Starter doesn't run:
Short circuit of magnetizing coil Repair or change
Short circuit of armature coil Repair or change
Damage or ablation of electric brush Repair or change
Damage of solenoid switch Repair or change
Damage of starter switch Repair or change
Starter revolving without force:
Wear of bearing liner Change new bearing liner
Poor contact of electric brush Clean contact surface of commutator
Dirty commutator or singeing Clean contact surface of commutator and polish with fine
sand belt
Terminal sealing-off Weld again
One-way clutch skidding Adjust friction torque of clutch
Insufficient charger or too small capacity Recharge or change battery
of battery
Difficult gear withdrawal, burn and cement Repair switch
of switch contacl

7.14 Sprayer failure

Causes Remedy
Little or no oil injection:
Seizure of sprayer coupler Clean, grind or change coupler, cap tightening torque can't
be too high
Serious wear ofsprayercoupler Change coupler
Low spray pressure:
Deformation or break of sprayer spring Change spring
High spray pressure:
Seizure of sprayer coupler Clean, grind or change
Block of nozzle opening Clean
Severe oil leakage of sprayer:
Broken spring of sprayer Change spring
Damage of coupler needle valve and Change coupler
valve seal
Deformation or crack of sprayer cap Change cap

·48·
7.15 Injection pump failure

Causes Remedy

No oil supply or insufficient supply:

Air in oil supply system Eliminate air
Clamping of check valve or broken spring Check, clean or change spring
Clamping of oil-out valve or broken spring Check, clean or change spring
Wear of oil-out valve rod and sealing Check and change
surface
Wear of plunger coupler or broken spring Change damaged part
Block of oil filter, low oil-in pressure Change oil filter core
Loosening of plunger geared ring screw Adjust oil volume, tighten geared ring screw
Wear of plunger coupler or internal leak of Check injection pump, change plunger
injec-tion pump, oil leaks into drain pan; coupler or injection pump
oil level rises

7.16 Governor failure

Causes Remedy
Unstable or too high idle speed:
Control ann is not at bottom Check and adjust
Clamp of geared ring and regulating toothed bar Check and adjust
Sliding:
Permanent deformation of governor spring Change spring
Non-conforming expanding and gathering distance of fly-ball Check and adjust
Wear of floating lever rod, too large clearance Check and repair
Runaway:
Loose high speed limit screw Adjust again
Broken governor spring Change spring
Clamp of regulating toothed bar or loose geared ring Check and repair

·49·
7.17 Compressed air pump failure

Causes Remedy
Scale in exhaust valve, broken air valve
spring and piston ring, wear of cylinder Remove scale, change damaged part
sleeve, insuf-ficient air pumping
Clamp or break of piston ring, wear of
cylinder sleeve, block of return oil line, Check and change damaged part
oil leakage
Serious wear of crankshaft and bearing piston Check and change damaged part
bumps cylinder cover, abnormal sound

7.18 Increase of fuel consumption

Causes Remedy
Increase resistance of admission system Check air filter core
Serious leakage of fuel system Repair tightness of fuel pipeline
Incorrect advance angle of injection pump Check and adjust oil supply advance angle
Sprayer failure Check sprayer, repair or change coupler
Running of regulating oil volume Check and adjust oil volume of injection pump on testing
bench
Abnormal supercharger, non-sealing, broken Check and repair supercharger and inter-cooling
or leak supercharge inter-cooling system pipeline
Serious wear of motion parts Check wearing of cylinder sleeve, piston, piston ring,
check tightness of air valve and valve seat. Check
wearing of motion parts and repair

7.19 Increase of engine oil consumption

Causes Remedy
Serious oil leak-out Check leaking points and oil seals of crankshaft,
change damaged part
Block of air Illter core, large negative Clean or change air filter core
pressure of air compressor or supercharger,
oil leaks into cylinder
Filter core block of crankshaft riser vent Clean or change filter core of riser vent
Over-wear of air valve guide, damage of valve Change valve guide or valve rod seal
rod seal
Too much oil leakage of air compressor Repair air compressor
Failure of supercharger ring seal Change supercharger ring seal
Piston ring gel, serious wear of cylinder Check and clean, change damaged part
sleeve or piston ring

·50·
7.20 Failure of admission flame pre-heater

Unsuccessful starting,
check temperature of Causes Remedy
pre-heating plug by hand
feeling
Check electric circuit, controller, inserter,
Cold No power supply wire of pre-heating plug and relay
Damage 0f pre-healing Change pre-heating plug
plug
Solenoid valve doesn't Check if solenoid valve is damaged, power supply
Hot work line is separated, controller has output signal
Block of pre-heating Clean filter screen and nozzle orifice
plug pipeline
Motor fault Check if diesel oil line is free
Very hot Short circuit and bum Change pre-heating plug
of pre-heating plug

·51·
·52·
·53·
·54·
 CLUTCH

CLUTCH
ⅠGENERAL

ⅡMAIN DATA AND SPECIFICATIONS

Ⅲ DISASSEMBLY AND ASSEMBLY OF CLUTCH

Ⅳ ASSEMBLY AND DISASSEMBLY OF CLUTCH CONTROL DEVICE

Ⅴ CLUTCH MAIN CYLINDER

Ⅵ CLUTCH CYLINDER DISASSEMBLY AND ASSEMBLY

Ⅶ DRIVEN DISK ASSEMBLY

 CLUTCH

ⅠGENERAL
1. CLUTCH ASSEMBLY

2. PRESSURE PLATE AND DRIVEN PLATE

 CLUTCH

3. MASTER CYLINDER

4. BOOSTER

5. CONTROL DEVICE
 CLUTCH

ⅡMAIN DATA AND SPECIFICATIONS

1. Clutch
Pre-press force
Pressure plate mode Slice spring
Driven plate mode Dry plate attaching damp spring
Quantity of damp spring 12
Liner：
Interior diameter(mm)×exterior diameter (mm)
Thickness
Master cylinder：
Diameter (mm)×stroke (mm)
Slave cylinder：
Diameter (mm)×stroke (mm)
Clutch booster device：
Power piston diameter (mm)×stroke (mm)
Hydraulic piston diameter (mm)×stroke (mm)
Stroke of pedal (mm)
Free stroke of pedal (mm)
Height of pedal (mm)

2. Maintenance standard
Items Standard Limit
Clearance between master cylinder body and piston (mm) 0.13~0.11 0.12
Clearance between slave cylinder body and piston (mm) 0.02~0.10 0.15
Distortion of pressure plate (mm) 0.05 0.30
Pre-compress pressure of pressure disc (N)
Height of diaphragm spring separator finger (mm)
Distance from rivet head to surface (mm) 0.2
Distortion of driven plate (mm) ≤0.7 1.0
Abrasion of driven plate spline (mm) 1.8~2.4
 CLUTCH

Ⅲ DISASSEMBLY AND ASSEMBLY OF CLUTCH

1. Disassembly

Disassembly sequence
⑴ Transmission assembly 1
⑵ Clutch pressure plate 3
⑶ Clutch drive plate 2
⑷ Release sleeve 4
⑸ Release fork 5
CLUTCH

Disassembly steps:
Support vehicle and hold it safely.
Note: do not let brake liquid flow on painted surface
in disassembly process.
If having, wipe off immediately.
1． Dismantle gearbox (referring to the operation
about gearbox in this manual).
2． Pressure plate assembly
3． Driven plate assembly
Prevent driven plate assembly from sliding with a
guiding shaft.
Make marks on flywheel and pressure plate, and
head these marks in re-assembly.
4． Dismantle clutch separator fork.
5． Separate sleeve assembly
Dismantle separator sleeve together with return
spring.
Inspection and repair
If excessive abrasion and damage have been found
in checking process, it is necessary to adjust, repair
or change parts.
Check abrasion and heat crack of pressure plate
with eyes, if there is any excessive abrasion or
too-deep heat crack, it is necessary to change
pressure plate.
Distortion of pressure plate
Measure plane degree of friction surface of pressure
plate, if it exceeds limit, change pressure plate
assembly. Using limit: 0.3mm
Clutch cover
Check the abrasion, crack and other damages on
whole clutch cover with eyes, if there is any
excessive abrasion, crack or other damages, change
the cover.
CLUTCH

Assembly pressure of clutch

1） Reverse clutch pressure plate.
2） Put a metal block with depth of 8.3mm on
pressure plate.
3） Press down pressure plate until distance “B”has
reached 0 mm.
4） Record pressure reading on meter.
Standard pressure：480 kg
Height of film-sheet spring separator finger
1) Put a metal block with depth of 8.3mm under
pressure plate.
2) 2) Press down pressure plate until distance “B”
has reached 0 mm.. Two methods could be
used:
a． Press down it from the top of pressure plate.
b． Screw assembly bolts of pressure plate.
3) Measure the height from base surface to
separator finger end. Standard height mm

Driven plate assembly

Check whether torsion spring has been loosened,
softened or ruptured with eyes.
If there is any situation above, it is necessary to
change driven plate assembly.
Check whether there is any crack, grease or
excessive scorch on friction surface with eyes.
If there is any situation above, it is necessary to
clean or change driven plate assembly. Check
whether driven plate assembly could slide on spline
of one shaft of gearbox.

Distortion of driven plate

Insert guiding shaft in spline hub.
Guiding shaft should be level and straight.
Install a scale meter on exterior circle of driven plate.
Turn driven plate assembly slowing, and read the
scale on meter.
If measured value exceeds limit, it is necessary to
change driven plate assembly.
Limit 1.0mm
CLUTCH

Abrasion of driven plate spline hub

Clean inner part of spline hub.
Install driven plate on spline of one shaft of gearbox.
Install a surface measuring meter on exterior circle
of driven plate.
Turn driven plate slowly, and measure the change of
exterior circle.
If measured value exceeds limit, it is necessary to
change driven plate assembly.
Abrasion limit of driven plate slpine hub 1.0mm

Depth of rivet head of driven plate

Measure the distance from rivet head to friction
surface with a depth gauge.
Measure two sides.
If measured value exceeds limit, it is necessary to
change driven plate assembly.
Depth limit of rivet head of driven plate 0.2mm
Release fork and supporting
Check the surface contacting with release sleeve
and supporting on release fork with eyes.
If there is any excessive abrasion or surface
roughness, it is necessary to change parts.

Release sleeve assembly

Check the abrasion and roughness of release sleeve
assembly before separating sleeve assembly.
a. There is any surface roughness of release
bearing or noise caused by rotation under light
press.
b. There is surface roughness or damage. (With
contacting surface of release fork and front cover
surface of release bearing)
Warning: for release bearing has been installed with
lubricant, do not put it in solvent to wash, this could
dissolve lubricant. Note if there is any problem, do
not disassemble the sleeve. Check whether return
spring has been ruptured or softened. If there is any
situation above, it is necessary to change parts.
 CLUTCH

Reassembly

Re-assembly sequence
1． Clutch release fork 2；
2． Release sleeve assembly 3；
3． Driven plate assembly 4；
4． Pressure plate assembly 5；
5． Gearbox 6.
CLUTCH

Re-assembly step
1． Release fork
Apply multi-purpose lubricating grease (molybdenum
disulfide) on the surface which contacts with release
sleeve assembly and supporting on release fork.

2． Release sleeve assembly

Install release sleeve together with return spring.
3． Driven plate assembly
4． Pressure plate assembly
Apply multi-purpose lubricating grease (molybdenum
disulfide) in spline hub of driven plate.
Install driven plate assembly with guiding shaft.

Screw assembly bolts of pressure plate tightly by

numeric sequence.
Tightening torque of assembly bolts of pressure plate
1.8kgf.m.

Warning: after screwing assembly bolts of pressure

plate, take off steel wires used for protecting
diaphragm spring.
 CLUTCH

Ⅳ ASSEMBLY AND DISASSEMBLY OF CLUTCH CONTROL DEVICE

1. Disassembly

Steps of removing:
1． Hard pipe and hose of clutch
2． Clutch pedal and bracket assembly
3． Clutch switch or limiting screw
4． Pedal shaft
5． Push rod fork pin
6． Return spring
7． Clutch pedal
8． Clutch master cylinder
 CLUTCH

9． Hose
10．Clutch booster
Preparation
Dismantle instrument shell and instrument.
Disassembly step of clutch control equipment
Drain out brake liquid in hydraulic pressure pipeline of clutch.
Warning: do not let brake liquid remain on the surface with paint, if having, wipe off immediately.
Inspection and repair
If there is any excessive abrasion or damage about parts in checking process, it is necessary to
adjust, repair or change those parts.

2. Reassembly

Steps of installation:
10. Clutch booster
9. Hose
 CLUTCH

8. Clutch master cylinder

7. Clutch pedal
6. Return spring
5. Push rod fork pin
4. Pedal shaft
3. Clutch switch or limiting screw
2. Clutch pedal and bracket assembly
1. Hard pipe and hose of clutch
Re-assembly step
1. Clutch cylinder
Tightening torque of assembly bolts of clutch cylinder
1.6 kgf·m
Adjust handspike of clutch cylinder rightly before
installing return spring of clutch cylinder.
Unscrew locking nuts of clutch handspike.
Turn handspike until supporting separator fork.
Turn back handspike for 1.5 circles. (Free travel of
separator fork is about 2 mm)
Screw locking nuts.
Tightening torque of locking nut 1.9 kgf.m
1. Clutch hose
2. Clutch main cylinder
Install clutch main cylinder on clutch panel and
bracket. Tightening torque of assembly nut 1.3
kgf.m.
3. Clutch panel
4. Return spring
5. Pin and shaft
6. Clutch switch or limit bolt
7. Clutch panel and bracket assembly
Tightening torque of clutch panel and bracket
assembly bolt 3.8 kgf.m
After those assemblies above, it is necessary to
adjust clutch control equipment
Height and travel of clutch panel
1) Unscrew locking nuts of clutch main pump
handspike
2) Turn handspike to adjust panel.
Height of clutch panel A: mm
Travel of clutch panel B: mm
3) Tightening torque of locking nuts of clutch main
pump handspike 1.3 kgfm
4) Re-install instrument to adjust free travel of clutch
CLUTCH

panel, unscrew clutch switch or panel limit bolt,

Adjust clutch switch or panel limit bolt to make free
travel of clutch panel is 3— 5mm.
Deflation of clutch pipeline should be made by
following steps:
1. Strain park arrester.
2. Put brake liquid in oil storage pot until reaching
maximal liquid level. It is necessary to note
whether there is any brake liquid in oil storage
pot.
3. Dismantle bleed screw rubber cap on clutch
cylinder, link plastic pipe on bleed screw, and
insert the other end of plastic pipe into
translucent vessel with brake liquid.
4. After stepping down clutch panel for several
times continually, step on clutch panel.
5. When keeping on stepping on penal, unscrew
bleed screw to discharge air, then screw bleed
screw.
6. Repeat those operations above, until the air in
pipeline has been drained out completely.
After deflation operation, intake brake liquid until ＂
MAX＂ mark in oil storage pot.
 CLUTCH

Ⅴ CLUTCH MAIN CYLINDER

1. Disassembly

Disassembly sequence Re-assembly sequence

1. Pipe tie-in 1.Pump body
2. Handspike fork 2. Return spring
3. Locking nut 3. Piston assembly
4. Dustproof cover 4. Handspike
5. Clamp ring 5. Limit block
6. Limit block 6. Clamp ring
7. Handspike 7.Dustproof cover
8. Piston assembly 8. Locking nut
9. Return spring 9. Handspike fork
10.Pump body 10. Pipe tie-in
Disassembly Steps of removing：
Refer to prior introduction.
Removing of snap spring:
When remove the snap spring, hold the piston with
hands in case of the piston jumping.
Inspection and repair Inspection and repair：
If there found any excessive abrasion or damage in
inspection, repair or replace the parts if necessary.
CLUTCH

Inspection of master cylinder：

1. Wash clutch master cylinder body with brake
liquid
2. Check whether the oil return hole is blocked, if
necessary, wash it.
3. Measure the interior diameter of master cylinder
body
Interior diameter of master cylinder：

Clearance between piston and master cylinder：

standard limit
0.03~0.11 0.12
If there found any excessive abrasion or damage
in inspection, the master cylinder assembly must be
replaced.
Note：If the clutch master cylinder is dismantled, a
set of parts must be replaced （ piston
assembly 、 limiting device 、 snap spring 、
dustproof cover）
Steps of installation：
Steps of installation are introduced as before
Items to notice in installation：
1. Dip the pump body and piston with clean brake
liquid before re-assembly.
2. Apply a sheet of thin lubricating grease on
rubber cup.
3. Prevent the lips of rubber cup from being
damaged in installation.
Tightening torque of push rod lock nut:：

Tightening torque of pipe joint：

 CLUTCH

Ⅵ CLUTCH CYLINDER DISASSEMBLY AND ASSEMBLY

1. Disassembly

Disassembly sequence
1. Handspike 2. Dustproof cover 3. Piston assembly 4. Deflation screw 5. Cylinder body
Inspection and repair

Clutch cylinder assembly

Wash clutch cylinder body with brake liquid.
Measure the inner diameter of cylinder body.
Inner diameter of cylinder body： mm
Clearance between clutch cylinder piston and inner
diameter of cylinder body: mm(limit)
Warning: for disassembled clutch cylinder, it is
necessary to change repair bag.
 CLUTCH

2. Reassembly

Re-assembly sequence
1. Cylinder body 2. Deflation screw 3. Piston assembly 4. Dustproof cover 5. Handspike
Re-assembly notes:
1．Dip the pump body and piston with clean brake liquid before re-assembly.
2．Spread a sheet of thin lubricating grease on skin bowl.
3．It is necessary to note prevent the lip of skin bowl from being damaged in assembly process.
 CLUTCH

Ⅶ DRIVEN DISK ASSEMBLY

Steps of removal： Steps of installation：

1. rivet 3. Plate
2. liner 2. Liner
3. plate 1. Rivet
Important work:
Gasket riveting
● Directions of the rivet and the drift punch are
illustrated in the left diagram
● Riveting pressure of the rivet is kg.
● Diameter of the rivet
Diameter of the rivet 4
 Transmission

Maintenance manual of LC6T46 automobile gearbox

Data of maintenance
1. Parameters of gear box ：
Type LC6T46

Model 6 Forward gears, 1 Reward gear (synchronic devices are equipped to 2-6 gears)

Gear type Remote control manual shift

1. R gear Spur gear

Shift type
2～6 gear Helical gear

3rd 4th 5th 6th

1st gear 2nd gear R gear
Speed ratio gear gear gear gear

6.314 3.913 2.262 1.393 1.000 0.788 5.874

Number of tooth 3rd 4th 5th 6th R Small

1st gear 2nd gear
like parts gear gear gear gear gear reverse

( main shaft lay

43/13 41/20 32/27 27/37 22/42 19/46 40/23 23/13
shaft )

Dosage of 5.2 L

lubricating oil ( L )
 Transmission

2. Maintenance data：

Unit ：mm
item Standard Limit Memo
Space between gear-select and gear-shift-head 0.1～0.4 0.8
(mm)
Space between gear-shaft-head and spline of 0.05～0.11 0.5
Upper cover of the gear box

gear-shift rearing. (mm)

Space between gear-shift-head and block (mm). 0.7～1.0 1.4
Space between upper cover and shaft shift 0.1～0.2 0.8
(mm)
Space between upper cover and gear-select 0.04～0.07 0.1
rearing (mm)
Pressure of yoke spindle lock ball spring （N） 80.71 Compressed to 26.1mm
37.46 Compressed to 19.6mm
Pressure of resistance pin lock ball spring （N）
26.48 Compressed to 19.3mm
Pressure or resistance spring of the resistance 43.35 Compressed to 34.5mm
pin （N） 36.29 Compressed to 39.5mm
Pressure of neutral limiting spring（N） 147.11 Compressed to 20.8mm
Space between gear-shift shaft and synchronic 0.1～0.29 1.0
sleeve (mm)
Side clearance of gear 0.09～0.20 0.50
Inherent parameters

Main Ⅰ. Main Ⅱ 0.28～0.70 0.80

Axial clearance
Main Ⅲ. Main Ⅳ 0.26～0.70 0.80
between each main
Main Ⅵ 0.26～0.70 0.80
shaft
Main reverse 0.21～0.64 0.80
Axial clearance between each small reverse gear 0.28～0.42 0.70
Reverse 0.20～0.30 0.50
Radial clearance
1/2 gear 0.20～0.30 0.50
between hub and
3/4 gear 0.20～0.30 0.50
sleeve
5/6 gear 0.20～0.30 0.50
Axial movement of 0.20～0.30 0.50
ball bearing
 Transmission

3. Torque:
Unit ：N·m(Kg·m)

Name Torque Name Torque

Clutch housing bolt 57～75（5.8～7.7） Power take off bolt 57～76(5.8～7.7)
Top cover bolt 4.1～5.3(0.41～0.55) Back cover bolt 33～42(3.3～4.3)
Upper cover bolt 33～42(3.3～4.3) Reverse gear locking 19～25(1.9～2.6)
bolt
Guiding board bolt 16～21(1.6～2.1) Bolt 35～45(3.5～4.6)
Fork fixing bolt 16～21(1.6～2.1) Bolt 89～118(9.1～12)
Light swift for backing 29～49(3.0～5.0) Bolt 9～13(0.9～1.3)
Gap gear swift 110～127(11～13) Nut 393～500(40～51)
Snail 16～21(1.6～2.1) Bolt. Nut 84～98(8.6～10)
Drawing off-oil snail. 98～127(10～13) Spring 55～75(5.6～7.6)
input –oil snail
Bolt for cover side 35～45(3.5～4.6)
 Transmission

Dismantling
1. Dismantling order of transmission:

No. Name Memo

1 transmission cover assembly

2 flange

3 rear cover assembly

4 radial ball bearing

5 clutch housing assembly

6 primary shaft assembly

7 main shaft assembly

8 counter shaft assembly

9 reversing gear assembly

 Transmission

2. Dismantling order of transmission upper cover:

No. Name Memo

1 Backing light switch
2 Neutral indicator switch
3 Blocking cover
4 5/6 shaft shift subassembly
5 3/4 shaft shift subassembly
6 1/2 shaft shift subassembly
7 Backing and reversing shaft shift subassembly
8 guide board assembly
9 steel ball / lock ball spring
10 gear selector assembly
11 Left resistance pin subassembly
12 Right resistance pin subassembly
13 Straight pin
14 plug
15 Shift rocker arm subassembly
16 Shift head
 Transmission

3. Housing clutch / primary shaft assembly:

No. Name Memo

Release bearing seat
1
subassembly
2 Release fork

3 Bolt
4 Upper cover
5 Oil seal
6 Bearing snap ring
7 Roller bearing
8 Synchronism ring
9 Needle bearing
 Transmission

4. Dismantling order of housing and components:

No. Name Memo No. Name Memo

Center shaft front
1 Nut 10
bearing
Center shaft rear
2 “O”Sealing ring 11
bearing
2nd shaft ball
3 Flange plate 12
bearing
4 bolt （rear cover） 13 bolt （side cover）
5 Top plate 14 Side cover
bolt （backing
6 bolt （odometer） 15
shaft）
The course table
7 passive tooth and 16 Backing gear /axle
leads the wrap
8 Rear cover gasket
9 odometer drive gear
 Transmission

5. Dismantling order of 2nd shaft assembly:

No. Name Memo No. Name Memo No. Name Memo

th rd
1 8 6 gear, main 15 3 gear,
Backing gear
shaft main shaft
2 Bearing snap 9 16 Bearing
Bearing snap ring
ring snap ring
3 10 17 2nd gear
Reverse
Steel Ball push
hub/Sleeve
washer
4 11 4th gear, main 18
1st gear Steel Ball
shaft
5 1/2 12 19
3/4Synchrotron 2nd gear,
Synchrotron
ring main shaft
assembly
6 5/6 13 20
3/4 Synchrotron
Synchrotron
assembly
assembly
7 5/6 14
3/4 Synchrotron
Synchrotron
gear ring
gear ring
 Transmission

6. Dismantling order of countershaft assembly:

No. Name Memo

1 Bearing snap ring

Counter shaft constant
2
engaging gear
3 Flat key
4 Center shaft 6th gear
5 Center shaft 4th gear
6 Flat key
7 3/4 gear jacket
8 3rd Gear
9 Woof ruff Key

Installation of transmission
The Installation sequence of transmission is just the opposite of removal, so in transmission
removing, you should make marks to indicate the sequences and directions for right and smooth
reinstallation after maintenance.
Installation process of transmission assembly: Ellipsis.
 Transmission

Maintenance of transmission assembly

Items to notice in removing transmission assembly

Before removing the transmission assembly,

place the transmission assembly on the work
platform or other proper place and fix it reliably in
case of sliding or falling.

Put a 15mm-long and 1mm-in-dimeter fuse on

the gear surface by applying grease to the fuse.
Rotate the gear for a round, Survey and record
the side clearance of the gear flange.

Main shaft nut

Fix the gearbox reliably and not let it move and
then pry off the lock slice, release the Main shaft
nut.
Note: The Main shaft nut can not be used again
after dismantling.

Rear cover
Remove the rear cover only as oil leakage is
found. Abandon the damaged oil sealing and
replace it with new one.
Transmission

Small reverse gear assembly

Release and remove the lock slice, dismantle the
backing gear with the adaptor and the slide
hammer.

Primary shaft assembly

Make sure that the milling sides of the engaging
gear ring face downwards. Dismantle the primary
shaft assembly from the driven transmission
assembly.
Notes: Don’ t remove the needle bearing unless
it’
s necessary.

Main shaft assembly

Fasten the main shaft assembly up with cable,
and hoist it out of the gear box case with a crane
with the main shaft 6th gear inclining upwards.
Notes: Mark the synchrotron gear rings with
paper strips or other items for distinguishing.

Counter shaft assembly

Fasten the counter shaft assembly up with cable,
and hoist it out of the gear box case with a crane
with the counter shaft 6th gear inclining upwards.
 Transmission

Key points of main shaft dismantling

5/6 Synchrotron assembly

After dismantling 5/6 synchrotron sleeve and
slide block, pull down the hub.

Don’ t lose the synchrotron slide block and spring

when removing the sleeve.
1. 5/6 synchrotron spring
2. 5/6 synchrotron hub
3. Synchrotron slide block
4. 5/6 Synchrotron spring
5. 5/6 Synchrotron sleeve
6. 5/6 Synchrotron ring.
7. Main gears
Notes: Mark the synchrotron rings for
distinguishing.

3/4 Synchrotron assembly

Be sure not to lose spring when it’
s
disassembled
1. 3/4 Synchrotron ring 2. 3/4
Synchrotron spring
3. 3/4 synchrotron hub 4. Synchrotron
slide block
5. 3/4 Synchrotron spring 6. 3/4
Synchrotron ring
7. 3/4 Synchrotron sleeve

Notes: Mark the synchrotron rings with paper

strips or other items for distinguishing.

Steel ball
Note: don’ t lose steel balls.
 Transmission

Key points of dismantling counter shaft

Don’ t remove the main shaft unless there is
serious abrasion or gear breaking.
Counter drive Gear， counter 6th gear. counter
4th gear
Remove the counter shaft gears using the keys
in common together
Note: Prevent the counter shaft from dropping.

Key points of dismantling the upper cover assembly.

 All fork axles of 5/6 fork axle. 3/4 fork axle. 1/2 fork axle. Reverse fork axle can be removed in
any order, but take notice that if the lock pin isn’
t in neutral position, the lock pin and steel balls will
press upwards the upper cover, in which situation fork axles can not be taken apart.
 Note: be careful to stop the steel ball flying away

1. Reverse fork axle 2. Steel ball 3. lock ball spring 4. 1/2 fork axle
5. Lock pin 6. 3/4 fork axle
7. Steel ball 8. 5/6 fork axle 9. neutral-position switch
 Transmission

Inspection and Maintenance

 Clean up all the removed parts, check them carefully for scratches, cracking etc., and replace
all of them.
 If the component can not be maintained, repair or replace it.

Space between gear-select and shift joint (mm)

Standard Limit
0.1～0.4 0.8

Space between shift joint and spline of gear-shift

rearing (mm)

Standard Limit
0.05～0.11 0.5

Space between shift joint and block (mm).

Standard Limit
0.7～1.0 1.4

Space between gear-shift yoke and synchrotron

sleeve (mm)

Standard Limit

0.10～0.29 1.0
Transmission

Radial play of ball bearing (mm)

Standard Limit

0.5

Space between synchrotron ring and the gears

at each gear (mm)

Type Standard Limit

3/4 gear 1.05～2.25
0.5
5/6 gear 0.60～0.80

Space between synchrotron slide block and

synchrotron ring (mm)

Type Standard Limit

3/4 gear 4.49～4.85
———
5/6 gear 4.29～4.65

Space between synchrotron hub and slide block

(mm)

Standard Limit
0.04～0.19 ——
 Transmission

Reinstallation
Installation
Pay attention to the direction of every gear and washer.
Don’t mix the needle bearings and washers in different positions.
Apply clean gear oil on surfaces of rotating parts.
Rotate the gear by hand after installing to make sure that it’
s laid stably and there is no
abnormal noise
Use new oil sealing and “O”washer.
Key points of reinstalling the upper cover assembly

Safety slice Yoke fixing bolt Stopper slice, cover

Fold the four angles of the Screw the fixing bolts into each Press centers of the stopper
slice to avoid the bolt yoke and toggle block. Tighten slice and the cover slightly to
loosing after tightening the the bolt up after making sure make them deform after
bolt up. that it is in the shift fork axle installation to avoid oil leakage.
hole; then tie it up with lock line
in shape of “8”in case of
loosing.
 Transmission

Key points of reinstalling the counter shaft assembly

Flat key
Ensure the end with big chamfer to head the
gear impressing end and press the key into the
counter shaft.

4th. 6th gear

Make the long-ledged ends of the gears head the
front of the counter shaft and press them into it.

Counter drive gear

Make the long-ledged ends of the drive gears
head the counter shaft and press them into it
after laying the gears properly.

Snap ring
Choose a proper snap ring to make clearance of
the counter shaft smallest.
Thicknesses of the snap ring are 2.00mm and
2.15mm.
 Transmission

Key points of reinstalling the main shaft

Fix the main shaft in special fixture or table vice and make the front side of the main shaft upwards.

Gear washer
Make sure the side with a bigger chamfer of the
interior hole faces the main shaft.
Snap ring
Choose proper snap ring to adjust the axial
clearances between the gears and the
synchrotron. Thicknesses can be adopted are as
follows:

Location 2nd gear 3/4 synchrotron assembly

Thickness 3.50 3.65 3.80 2.00 2.15 2.30

Location 4th gear 5/6 synchrotron assembly Reverse hub

Thickness 2.50 2.65 2.80 1.80 1.95 2.10 2.00 2.15 2.30

3/4 synchrotron assembly

Install the synchrotron assembly according to
above diagram.
1. Synchrotron spring 2. 3/4 hub
3. Slide block 4. Synchrotron spring
5. 3/4 sleeve

Note: When press 3/4 synchrotron assembly

onto the main shaft, be sure not to lose parts
such as sleeve, synchrotron spring, slide block
etc.
Transmission

Main shaft 4th gear washer

When install the main shaft 4th gear
washer to the main shaft, keep the
opening oil groove face the 4th gear.

5/6 synchrotron assembly

Install the synchrotron assembly according
to above diagram.
1. Synchrotron spring 2. 5/6 hub
3. Slide block
4. Synchrotron spring
5. 5/6 sleeve

Note: When press 5/6 synchrotron

assembly onto the main shaft, be sure not
to lose parts such as sleeve, synchrotron
spring, slide block etc.

Reverse hub
When install the reverse hub, make the
outside circle cut groove face the main 1st
gear.
 Transmission

Measure the axial clearances among each gear of the main shaft. Standards are
as follows

Type Standard Limit

1st. 2nd gear 0.28～0.70 0.8
3rd. 4th gear 0.26～0.70 0.8
6th gear 0.26～0.70 0.8
Reverse 0.28～0.42 0.8

Key points of installing the transmission assembly

Counter shaft assembly

Main shaft assembly

Notes: prevent the reverse needle bearing and
sleeve from coming off.

Primary shaft assembly

Make sure that the milling side of the jointing
gear faces downwards.
Transmission

Reverse gear lock slice

Be sure that the gear groove which the reverse
lock slice faces and is pressed into faces
upwards.
1. Reverse gear. 2. Small reverse gear
3. Needle bearing. 4. Transmission case
5. “O”seal

Flange disc nut

1. Fix the gearbox in case of sliding when tighten
the flange disc nut.

2. Press the reed of the flange disc nut into the

main shaft groove to lock the nut.
3. Tightening torque of the nut: 392～500N·m
（40～51Kgf·m）
Adjusting shim
Install one or two adjusting shims and be sure
that the clearance between the shim and the
transmission shell surface is between 0.20 and
0.30mm。
Thicknesses of the adjusting shims are 0.1,
0.2, 0.3mm.

Transmission shell , cushion pad

Apply sealing liquid glue on the jointing surfaces
of the transmission shell and the clutch shell.

Installation
 Use special-purpose jack for transmission or
cable to install the transmission to the vehicle.
Adjust the primary shaft and make its keys come
into keys of the clutch friction disc.
Install transmission shaft, pull rod, draw bench,
cable and power take-off (if necessary), clutch
separate components etc. according to the
original locations.
 PROPELLER SHAFT

PROPELLER SHAFT
Ⅰ GENERAL

Ⅱ MAINTENANCE MOUNTED ONVEHICLE

Ⅲ PROPELLER SHAFT DISASSEMBLY AND ASSEMBLY

Ⅳ UNIT MAINTENANCE

1. Universal joint

2. Central bearing
PROPELLER SHAFT

Ⅰ GENERAL
 PROPELLER SHAFT

Ⅱ MAINTENANCE MOUNTED ONVEHICLE

Remove and install drive shaft

Steps of removal: Steps of installation:

1. Bolt, screw cap and spring gasket (at 6. Center drive shaft
the side of differential) 4. Screw cap and spring gasket (at the side of
2. Bolt, screw cap and spring gasket. transmission)
3. Rear drive shaft 7． Middle bearing bracket
4. Screw cap and spring gasket (at the 5. Bolt, screw cap and spring gasket
side of transmission) 3. Rear drive shaft
5. Bolt, screw cap and spring gasket 1. Bolt, screw cap and spring gasket (at the side of
6. Center drive shaft differential)
7． Middle bearing bracket 2. Bolt, screw cap and spring gasket.
Removal:
Preparing work:
Because transmission shaft requires dynamic
balance, you’ d better make marks on jointing
positions before removing for reinstallation
Steps of removal:
Steps of removal are introduced as above.
 PROPELLER SHAFT

Reinstallation:
Steps of reinstallation:
Steps of reinstallation are introduced as before.

Tightening torque of nut （ at the side of

transmission）
：
Torque 103 Nm

Tightening torque of nut （ at the side of center

support）：
Torque 103 Nm

Tightening torque of center support:

Torque 40 Nm

Tightening torque of nut（at the side of differential）

：
Torque 98-113Nm
 PROPELLER SHAFT

Ⅲ PROPELLER SHAFT DISASSEMBLY AND ASSEMBLY

1. Disassembly

Disassembly Sequence
1. Universal joint end ring 10. Dust cover
2. Needle bearing 11. Retainer
3. Flange yoke 12. Bearing
4. Crossing shaft 13. Buffer rubber
5. Washer and nut 14. Sleeve spline pipe assembly
6. Intermediate drive shaft flange assembly 15.Rear axle drive shaft bearing assembly
7. Grease nozzle 16. Dust cover
8. Middle supporting assembly 17. Oil seal
9. Intermediate drive shaft assembly 18. Spline tube
 PROPELLER SHAFT

Crossing shaft Check：

Needle bearing Visual check
Buffer rubber Check the following parts for abrasion, damages or
Spline tube assembly other unusual conditions.

Flange yoke
Bearing
Diameter of crossing shaft pin
Diameter of （mm）
crossing shaft pin

dimension limit
18.46 18.43

Check for maladjustment (only for reference)

Measure an unbalance value between crossing shaft
end.

Rate of unbalance
Dimension Tube
turning value
(mm) (mm)
(rpm) (g·cm)
706
(intermediate 69 3200 40
shaft)
 PROPELLER SHAFT

2. Assembly

Disassembly sequences
1. Spline tube 10. Intermediate drive shaft assembly
2. Oil seal 11. Middle supporting assembly
3. Dust cover 12. Grease nozzle
4. Rear axle drive shaft bearing assembly 13 Intermediate drive shaft flange assembly
5. Sleeve spline pipe assembly 14. Washer and nut
6. Buffer rubber 15. Crossing shaft
7. Bearing 16. Flange yoke
8. Retainer 17. Needle bearing
9. Dust cover 18. Universal joint end ring
Important assembly

Right 4. Rear axle drive shaft bearing assembly

13 Intermediate drive shaft flange assembly
16. Flange yoke

Wrong
 PROPELLER SHAFT

After applying the lubricating grease on the spline,

install the flange
7. Bearing
Supplement the lubricating grease.
After tightening flanges at two sides of drive shaft,
Supplement please tighten the intermediate bearing bracket.
lubricating grease

5. Washer and nut

Wrench : 30mm
Torque(N.m) 343-539

Use a new nut . Do not use the old one .

Make a marking stake on the nut .

Crossing shaft
Install the lubricating grease nozzle according to the
specified angle.

17. Needle bearing

Insert the crossing shaft into the flange yoke, and
install the needle bearing to the yoke hole by using a
wrench with soft surface.
1) Always use a new universal joint end ring
2) After installing end ring, check whether it is
correctly placed.
 PROPELLER SHAFT

Ⅳ UNIT MAINTENANCE

1. Universal joint

Steps of removing universal joint:

1. Grease fitting nipple
2. Snap ring
3. Needle bearing
4. Cross shaft
5. Flange yoke
Steps of installation are the opposite of steps
of removing.

Preparing work:
Because transmission shaft requires dynamic
balance, you’ d better make marks on jointing
positions before removing for reinstallation.

Steps of removing:
Steps of removing are the same with above.

Removing of needle bearing:

Hit end of the flange yoke to beat the bearing out.
 PROPELLER SHAFT

Inspection and repair:

1. Cross shaft
If there is abrasion, damage or any other abnormal
2. Needle bearing
situation found in inspection, repair or replace parts,
3. Flange yoke
if necessary.
4. Flange
Visual inspection:
5. Central bearing
Check the parts listed in the left form for abrasion,
6. Rubber bush
damage or any other abnormal situation.
7. Middle suspension

Diameter of cross shaft pin:

（mm）
Standard Limit

Concentricity of transmission shaft:

Set up two ends of transmission shaft; face dial
indicator to the center of transmission shaft to check
for concentricity.
（mm）
Standard Limit point
≤0.5 1.0

Clearance of spline rotating in normal direction:

Use gap gauge to check the clearance of
transmission shaft spline and sleeve rotating in
normal direction.
（mm）
Standard Limit
≤0.1 0.3

Apply lubricant on universal joint and slide sleeve of

transmission shaft:
Infuse lubricate grease with short lubricator until the
lubricate grease overflows. (Only applied to general
lubricate grease)
PROPELLER SHAFT

Steps of removing and reinstalling universal joint:

Steps of removing are introduced as before.

Installation of spline and universal joint slide yoke:

Pay attention to the arrowhead marks on slide yoke
and rear transmission shaft, arrowheads should
align with each other.

Installation of needle bearing:

Apply lubricants on oil seal and needle bearing, and
install cross shaft into flange yoke, Install needle
bearing into the hole of flange yoke with the guide of
cross shaft and beat the needle bearing with soft
hammer slightly.

Clearance of cross shaft end:

1. Measure width “A”of flange yoke
2. Measure width “B” of cross shaft with needle
bearings on two ends.
Clearance of cross shaft end=yoke width A － cross
shaft width B
A－B（mm） 0.02~0.08
Choose snap spring with suitable thickness by
measuring (notes: thickness of the snap springs
used at both sides must be the same, used snap
springs can not be used again and must be
replaced)

Specification of thickness of the snap spring:

Installations of cross shaft lubricate grease oil

mouth:
Install lubricate grease oil mouth to the cross shaft
by specified angle.
 PROPELLER SHAFT

2. Central bearing

Steps of removing central bearing: Steps of installing central bearing:

1. Locknut Installing is the reverse of dismantling.
2. Packing sheet
3. Flange disc
4. Central bearing
Steps of removing central bearing assembly:
Steps of removing are introduced as before.
Make marks on flange and shaft pipe in removing for
reinstallation.

Steps of installing central bearing assembly:

Steps of installing are the introduced as before.
Install central bearing with flange to avoid bearing
damage.
Quantity of lubricate grease:
Quantity of lubricate grease（g） 20~25
PROPELLER SHAFT

Installation of flange nut:

Fix flange disc with special tool, tighten flange nut to
specified torque with spanner, and rivet flange nut to
V-slot.

Torque of flange nut:（Nm）

Torque

Notes: used flange nut can not be used again

 REAR AXLE

REAR AXLE
I INTRODUCTION
1. Introduction of Rear Axle Structure（G1QZ-5.714）

2. Detailed List of Rear Axle Wearing Parts

3. Table of Main Bolts Tightening Torque

4. Table of Rear Axle Maintenance Parameters

Ⅱ DISASSEMBLY, ASSEMBLY, INSPECTION AND REPAIR
1. Disassembly and assembly of rear axle

2. Disassembly and assembly of rear wheel hub

3. Disassembly and assembly of main retarder`

4. Disassembly and assembly of differential

5. Disassembly、check and reassembly of drive gear

III. ASSEMBLY AND ADJUSTMENT
Ⅳ Trouble Shooting
1 Hub bearing dragging

2 Unsmooth wheel

3 Abnormal transmission sound

4 Lubricating oil leakage

5 Insufficient brake force

 REAR AXLE

I INTRODUCTION

1. Introduction of Rear Axle Structure（G1QZ-5.714）

Rear Axle Structure type

Item Content

Type of axle case Press-welding integral type

Type of axle shaft support Full floating type

Type of reduction gear Single-stage hypoid spiral bevel gear

Number of planetary gears 4 planetary gears

Rated axle load 7 tons

Maximum input torque 2500N·m

2. Detailed List of Rear Axle Wearing Parts

Description Quantity

Drive gear oil seal 1

Rear hub inner oil seal 2

Rear hub inner bearing 2

Rear hub outer bearing 2

Drive gear inner bearing 1

 REAR AXLE

Drive gear outer bearing 1

Axle shaft oil seal 2

Drive gear nut 1

Differential bearing 2

Left and right plate friction lining 2 pieces for each

O-ring 1

Drive gear, bearing seat adjusting washer According to actual need

3. Table of Main Bolts Tightening Torque

Bolt (nut) Name HF17030(N.m)

Drive gear nut 323~480

Drive gear bearing seat bolt 75~113

Bolt –driven gear 240~335

Differential casing bolt 240~335

Reduction casing bolt 78~115

Guide bearing guard plate bolt 16~26

Bearing cap bolt 210~300

16~26
Adjusting nut locking plate bolt

Rear brake back plate nut 146~205

Axle shaft bolt 78~115

Hub inner nut 396~480

6~12
Lock washer small hex bolt

Filler plug 44.1~53.9

Drain plug 44.1~53.9

199~270
 REAR AXLE

4. Table of Rear Axle Maintenance Parameters

Item Value

Drive and driven gear clearance 0.25～0.33mm

Planetary, axle shaft gear clearance 0-0.15 mm

Without oil seal

Drive gear rotational torque
Apply gear oil 10-20 Kgf·cm

Hyperbolic gear oil:（GL-5）85W/90

Rear axle gear oil
Volume: 5 L

Oil applied on the outer rim and lip of ZL-2 GB5671-85

the axle shaft oil seal, and drive gear oil
Automobile General Purpose Lithium Base Grease.
seal

Clearance between friction lining and 0.4-0.8 mm (Air brake)

brake drum
0.4-0.7 mm（Hydraulic brake）
 REAR AXLE

Ⅱ DISASSEMBLY, ASSEMBLY, INSPECTION AND REPAIR

1. Disassembly and assembly of rear axle

Disassembly steps: Reassembly steps:

1． Rear transmission shaft Reassembly steps is the reverse of disassembly
2． Shock absorber steps.
3． Nut and spring cushion
4． U-bolt
5． Rear axle assembly
Disassembly: Preparing work:
Stop the front wheel with an arrester, jack up the rear
axle and make the rear wheel off ground, and prop up
the vehicle on the shelf.
Disassembly steps:
Disassembly steps are introduced as before.
Disassembly of U-bolt nut:
Lubricate screw thread with some oil before
tightening U-bolts and U-nuts in case of screw thread
damage.
 REAR AXLE

Reassembly:
Reassembly steps：
Reassembly steps:
Reassembly steps are introduced as before.
Rubber
bushing Assembly of U-bolt nut:
When tightening U-bolt nut, must use some oil to
lubricate screw thread for avoid damage screw
thread.

Tightening torque of U-bolt:

Tightening torque

Assembly of rear shock absorber:

Refer to the chapter of rear suspension:

Tightening torque of shock absorber lower nut:

Tightening torque

Assembly of rear transmission shaft:

Refer to the chapter of transmission shaft:

Tightening torque of nut:（at the differential side）

：
Torque
 REAR AXLE

2. Disassembly and assembly of rear wheel hub

Disassembly steps: Disassembly steps of wheel Assembly steps:

1. Rear wheel hub and drum assembly: Assembly steps are the
2. Half shaft 7. Exterior bearing opposite of disassembly steps
3. Exterior oil seal 8. Elastic blocking ring
4. Fixing plate 9. Interior oil seal
5. Bearing nut 10. Interior bearing
6. Wheel hub and drum 11. Wheel hub and drum
assembly
 REAR AXLE

Disassembly:
Preparing work:
Stop the front wheel with an arrester, jack up the rear
axle to make the rear wheel off ground, and prop up
the vehicle on the bracket.

Disassembly steps:
Assembly steps are introduced as before.

Nut of wheel:
Screw thread of nut on the right wheel is
right-handed; while on the left wheel is left-handed.

Disassembly of half shaft:

Turn the bolt to thread hole of flange disc until half
shaft flange leave its original position.

Disassembly of exterior oil seal:

Disassemble it with screwdriver or oil seal remover.

Disassembly of bearing nut:

Disassemble it with special tools.
REAR AXLE

Exterior bearing:
If reuse the exterior bearing, you should hang
scutcheons indicating positions in case of misuse.

Disassembly of wheel hub and drum assembly:

Disassemble them with special tools.

Disassembly of exterior rings of the interior bearing

and the exterior bearing:
Remove exterior rings of the wheel hub bearing with
brass stick.

Disassembly of wheel bolt:

1. Dismantle wheel assembly first.
2. Remove connecting bolts and nuts of the wheel
hub and brake drum by rotating in opposite
direction.
3. Remove brake drum from wheel hub.

Attention: used wheel bolt and nut can not be reused,

and must be replaced.
Inspection and repair:
If there found abrasion, damage or any other
abnormal situation in inspection, repair or replace the
parts if necessary.
 REAR AXLE

Visual inspection:
1. Half shaft
Check the parts listed in the left form for abrasion,
2. Wheel hub
damage or any other abnormal situation.
3. Bearing
4. Lock plate
5. Bearing nut

Check half shaft spline:

Concentricity of half shaft:

Limit point（mm） 1.0

Jig degree of the half shaft flange:

Limit（mm） 0.05

Inspect the wheel hub:

Inspect oil seal and mounting surface of bearing.
Inspect screw thread.
 REAR AXLE

Reassembly:
Reassembly steps：
Steps of reassembly are introduced hereinbefore.
Assembly of wheel hub:
Clean the interior and the exterior surfaces of the
wheel hub and fill lubricate grease before installing
the wheel hub,.
Dosages of wheel hub lubricate grease to fill:
Dosage（g） 285

Assembly of wheel nut:

Tighten the wheel nut to specified tightening torque,
and rivet three positions on every nut to avoid
looseness.
Tightening torque of wheel nut:
Torque of nut（N. m）

Assembly of exterior ring of the wheel hub bearing:

Assemble it with special tools.

Assembly of bearing:
Apply sufficient bearing lubricate grease on space
between interior ring and rolling shelf before installing
the bearing.

Assembly of interior oil seal:

Apply lubricate grease in oil seal and skirt of the
exterior circle, and then install the oil seal with special
tools.
REAR AXLE

Assembly of wheel hub and braking drum:

1. Clean out oil and other dirts that inside the brake
drum.
2. Clean head of the half shaft sleeve.
3. Assemble wheel hub assembly to half shaft
sleeve.

Assembly of bearing nut:

Assemble with special tools.

Measuring and adjustment of wheel hub bearing

pre-tightening:
1. Turn the wheel hub around for several times and
make the bearing locations accord.
2. Tighten the bearing nut with special tools until it
can not be moved by hand.
3. Loose the bearing nut until wheel hub can turn
easily.

4. Hitch spring balance on wheel bolt.( shown in the

left diagram)
5. Measure pre-tightening of the bearing by pulling
the spring balance carefully and pay attention to
pull direction of the spring balance.
Pre-tightening of wheel hub bearing:
Pre-tightening（N）

6. Turn wheel hub around again for several times.

7. Measure pre-tightening of wheel hub bearing two
times.
8. Align the nearest nut incision with the axle casing
slot.

Notes: If it is difficult to align, tighten the bearing nut

slightly.
REAR AXLE

Assembly of fixing plate:

1. Install sawteeth of fixing plate to the axle casing
slot.
2. Assemble lock bolt to avoid bearing nut
looseness.
3. Check whether sawteeth of the fixing plate have
been inserted into the slot.

Assembly of half shaft:

1. Clean half shaft
2. Lubricate half shaft spline with gear oil.
3. Insert half shaft into sleeve, pay attention not to
damage oil seal.
4. Tighten half shaft nut to specified tightening
torque according to the left diagram.

Tightening torque of half shaft nut:

Tightening torque 54

Tightening torque of wheel nut:

Tightening torque 441
 REAR AXLE

3. Disassembly and assembly of main retarder`

1. Disassembly and assembly of main retarder on the vehicle

Disassembly steps: Assembly steps:

1. Transmission shaft 3. Differential housing assembly
2. Half shaft 2. Half shaft
3. Differential housing assembly 1. 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.

3. Use transmission jack to move main retarder

assembly.
 REAR AXLE

Assembly
Tightening torque of fixing nuts of main retarder shell
is
78－115 N·m
Tightening torque of transmission shaft assembly is
75-113 N·m

2. Disassembly and reassembly of main retarder

1. Main retarder shell assembly 2. Locking sheet 3. Bearing cap 4. Adjusting nut
5. Exterior loop of differential bearing 6. Differential assembly 7. Driving gear assembly
8. Adjusting washer of driving gear bearing seat 9. Retainer plate of guiding bearing 10.
Exterior ring of guiding bearing
REAR AXLE

Important works:

1．Before disassembly, make assembly marks on

bearing cap and main retarder shell to avoid any
mistake.

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.

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 hands or a
crane.
 REAR AXLE

4. Disassembly and assembly of differential

Disassembly sequence： Reassembly steps:

1. Differential right shell Reassembly steps are the reverse of disassembly
2. Half shaft gear steps.
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
Disassembly
Important works
To install left and right shell of differential on original
position in re-assembly process, make adjusting
Adjust mark marks on left and right shell body before dismantling
differential shell.
 REAR AXLE

5. Disassembly、check and reassembly of drive gear

Disassembly sequence ： Reassembly steps:

1. Flange nut 2. Flange plate 3. Drive Reassembly steps are the reverse of disassembly
gear bearing saddle 4. Bearing space steps.
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 driving gear assembly on table vice, and
dismantle flange nut with lengthened wrench.

Inspection and repair

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

Change driven gear

1. Place driving gear together with driven gear all the
time.
2. Tightening torque is 108-161 N·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.

Clearance between cross shaft and planetary gear

Limit: 0.09/2mm

Clearance between half shaft gear and differential

shell
Limit: 0.161/2 mm

Clearance between half shaft gear and half shaft

spline
Limit: 1.11/2 mm

Clearance between half shaft gear and planetary

gear
Limit: 0.18/2mm
 REAR AXLE

Reassembly:
Important works
Clean inner part of dustproof cover, and spread a
sheet of lubricating grease.
Spread a sheet of engine oil on sliding surface of
main gear oil seal.

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 seat is
1.0-2.3N·m

After adjusting main gear bearing preload,

operate by following steps:
1. Dismantle flange and install oil seal.

2. Install flange, then after screwing flange nut with

250-280 N·m torque, make two mark pegs on the nut.
 REAR AXLE

Key points for check-up during disassembling

1. Check the drive gear flange for any wearing or damage.

2. Check the bearing for any wearing or color change。

3. Check the gears for any crack.

4. Check the drive gear and driven gear for any wearing or crack.

5. Check the axle shaft gear, planetary gear, and planetary gear shaft for any wearing or crack.

6. Check the axle shaft spline for any wearing or damage.

 REAR AXLE

III. ASSEMBLY AND ADJUSTMENT

(Ⅰ)The assembling of the final reduction gear assembly is following the reverse procedure of the
above disassembling procedure, before assembling all the components shall be kept clean, free of
such foreign substances as oil dirt, iron dust etc. Apply NO.10 motor oil for lubrication during
assembling, and make adjustment as per the following requirements:
1、Drive gear inner and outer bearing preloading:

1.1 When assembling the final reduction gear, the conical roller bearing shall have certain
assembly preload, that is, to give certain preloading force on the basis of eliminating the bearing
clearance. The purpose of it is to reduce the axial replacement caused by the axial force
generated during the transmission process of conical gear, so as to increase the supporting rigidity
of the shaft, and ensure the normal engagement of the conical gear pair. But it also shall not be too
tight, if it is too tight, it will cause low transmission efficiency, and speed up the wearing of the
bearing.

1.2 Adjustment of the drive gear bearing preloading force: under the condition of drive gear flange nut
tightening torque, install the drive gear oil seal, the drive gear is not engaged with the driven gear, and
ensure the drive gear bearing preloading torque. The adjustment of preload is made by increasing and
reducing the drive gear bearing adjusting washers in between the drive gear inner and outer bearings .
Reduce the number of adjusting washers; the preloading torque is increased; while increase the number of
adjusting washers, the preloading torque is decreased.
G1QZ－ shim, pinion bearing seat 0.05 0.06 0.08 0.12 0.35 0.60
5.714 shim, pinion bearing 0.05 0.06 0.08 0.12 0.35 0.50

2. Differential bearing preload adjustment

2.1 Adjustment of differential bearing: the differential bearing shall be adjusted to have certain
preloading force, so as to obtain 0.01-0.02 interference on both sides of it, apply gear oil to the
bearing rotating part under the condition of no engagement between drive gear and driven gear,
the start up friction torque is 0.686-1.586N.m. The differential bearing preload adjustment is
realized through the tightening of the differential bearing nut. When adjusting, first put on the
bearing cap freely, when the adjusting ring can be turned smoothly, then tighten the bearing cap
bolt, and after that adjust the preloading force. The locking slot on the adjusting nut after the
adjustment shall be aligned with the locking plate. After adjustment, the driven gear shall not have
end float misalignment.

2.2 Differential gear clearance adjustment

Use dial gage to measure the differential gear meshing backlash on the planetary gear. Note: take
measurement from more than three points, the standard value is: 0～0.15mm; limit value: 0.3mm。
3. Adjustment of drive and driven gear backlash, and meshing mark
3.1 Adjustment of gear backlash
The normal meshing backlash and the gear backlash variables of the drive and driven gear is
 REAR AXLE

shown in table 5. When adjusting the gear backlash, the measurement shall be taken on four
positions which are evenly distributed along the circumference of the driven gear, the measuring
head of the micrometer shall be perpendicular to the surface of the measured point.
3.2 Adjustment of drive and driven gear meshing mark
First apply red lead to the teeth of drive gear, and then turn the drive and driven gear repeatedly by
hand, there will be red marks on the two working sides of the driven gear, if the marks on the
standard rotation and reverse rotation working sides of the driven gear are on the middle of the
tooth depth and closer to the small end, and occupies 60% of the tooth face, then it is a correct
meshing. The position of correct meshing marks is adjusted through the adjustment of the drive
gear bearing adjusting washer and the differential bearing adjusting nut.
In order to keep the adjusted differential bearing preload from being changed, the number of
circles of the adjusting nut being turned in on one side shall be equal to the number of circles of
the adjusting nut being turned out on the other side. Check and confirm the clearance again, and
then lock up the locking plate.
（II） The assembling of the rear hub with brake drum assembly is as per the reverse procedure of
disassembling, and the adjustment to be made during assembling is as follows:
1. Adjustment of rear hub bearing backlash
Tighten the bearing nut until the brake drum is no possible or difficult to move, and then slightly
loosen the bearing nut by 1/6-1/8 circle, turn the brake drum, under the condition of no contact
between brake friction disc and the brake drum, the tangent tensile force measured at the tyre bolt
shall be（3-5kg）, or the brake drum can be turned freely by hand.
（III） Rear brake braking clearance adjustment:
1. Liquid brake: for the two-way balanced type brake, first move the two brake chamber adjusting
gears respectively as per the arrow direction indicated at the back plate adjusting hole, so that the
brake drum is tightly against the brake lining, and then turn the brake chamber adjusting gear back
by 5-9 teeth, to allow the brake drum to move freely.
In the actual maintenance process, adjustment shall be made strictly according to the above
procedures and requirements.
 REAR AXLE

Tooth depth

Tooth length

Contact status of driven gear Adjusting method A-Adjust tooth face contact
Causes
working tooth face area
1. Driven gear away from the

Drive gear to too far drive gear

from the driven gear 2. Drive gear closer to driven

gear to achieve correct
Deviate to
backlash (add washer)
crest

1. Driven gear closer to the

Drive gear is too close drive gear
to the driven gear 2. Drive gear away from the
Deviate to driven gear to achieve correct
root backlash (reduce washer)

1. Driven gear away from the

drive gear
Driven gear is too close
2. Drive gear away from the
to the drive gear
Deviate to driven gear to achieve correct
small end backlash(reduce washer)

1. Driven gear closer to the

drive gear
Driven gear is too far
2. Drive gear closer to driven
from the drive gear
Deviate to gear to achieve correct
big end backlash (add washer)

Adjustment Method of Gear Meshing Backlash

 REAR AXLE

Ⅳ Trouble Shooting

1 Hub bearing dragging

Hub bearing
dragging

Excessive hub Bearing lack of Bearing is

preloading force lubrication or use wrong contaminated with
type of lubricating dust
grease

Adjust preload Add or replace Clean and add

lubricating grease lubricating grease

2 Unsmooth wheel

Unsmooth
wheel

Bad lubrication of camshaft or Brake shoe or air chamber return

adjusting arm does not return spring broken or fatigue
back

Add grease or rectify the faulty Replace the faulty

parts parts
 REAR AXLE

3 Abnormal transmission sound

Abnormal transmission
sound

Improper Excessive Drive gear Wear or damage of Too low oil

differential clearance bearing axle shaft gear, surface
gear between drive preload too planetary gear,
clearance and driven small cross shaft thrust
gears washer etc.

Replace the Replace the Adjust the Rectify or replace Add

washer or washer or gear preloading the faulty parts enough
gear force lubricating
oil

4 Lubricating oil leakage

Lubricating oil
leakage

Oil seal Final reduction Bearing Drain screw Axle Vent plug
worn, fixing bolt seat fixing loosen or casing blocked or
loosen or loosen or bolt the lining deformed damaged
damaged sealant loosen damaged due to
damaged. overload

Replace Tighten the bolt Tighten Tighten the Rectify or Clean or

the oil or re-apply the the bolt as screw or replace the replace
seal sealant per replace the axle the vent
specified lining casing plug
torque
 REAR AXLE

5 Insufficient brake force

Insufficient brake force

Unsmooth Improper Brake Improper Water in Oil on the

camshaft adjustment of the lining contact of brake contact
rotation brake air overheat brake surface of
chamber push or lining brake lining or
rod stroke degrade brake drum

Check Adjust the stroke Replace Rectify Step the Clean off the
the the the lining pedal oil or replace
working friction contact slightly in the brake
status of lining position driving, lining
the drain out
camshaft the water
 FRONT SUSPENSION
GENERAL

VEHICLE MAINTENANCE

TIGHTENING TORQUE

LUBRICATING POINTS
GENERAL
 VEHICLE MAINTENANCE
Steel spring

Disassembly sequence ： Assembly sequence ：

1. shock absorber 8. steel spring
2. U-nut and U-bolt 3. rubber buffer block
3. rubber buffer block 2. U-nut and U-bolt
4. steel spring pin, nut and washer 4. steel spring pin ,nut and washer
5. shackle pin, nut and washer 7. buffer block
6. suspension 6. suspension
7. rubber liner 5. shackle pin, nut and washer
8. steel spring 1. shock absorber
Disassembly
Preparing work
1. Stop the rear wheel with an arrester.
2. Jack the front axle up until the front wheel off the
ground.
3. Use chassis bracket on the safe position of the
vehicle framework.
Steps of removal:
Steps of removal are introduced hereinbefore.

Removal of U bolt and U nut:

If the corrosion of the U bolt is serious, lubricate the
thread with certain quantity of oil in case of thread
damage.

Removal of the leaf-spring pin, nut and washer:

Beat out the steel plate spring pin with a soft hammer
after removing the steel plate spring pin nut.

Inspection and repair:

If there is any wearing, damage or any other abnormal
Inspection and repair situation in checking process, repair or replace the parts
if necessary.
1. Leaf-spring pack Visual inspection:
2. Steel trap Inspect the parts listed in the left form for abrasion,
3. U bolt damage or any other abnormal situations
4. Center bolt Inspection of the shock absorber:
5. Steel plate pin 1. Inspect for oil leakage
6. Shackle pin 2. After movement, inspect the oil temperature. If the
7. Rubber cushion block oil temperature does not change, it indicates that the
8. Rubber bush function fails.
9. Shock absorber 3. Grip both ends of the shock absorber, compress
and stretch; you should feel a very big resistance. The
movement vanishes after several times of compression
and stretching. If the above condition is not satisfied, it
indicates that the function fails.
Replacement of the leaf spring assembly:
1. Before removing, make adjusting marks
across the leaf spring.
2. Before installing, apply grease on both
sides of the spring steel plates.
3. Abandon the used center bolt in the
assembly, and use new one.
Note: When replacing spring, uses the steel
plate whose surface having marks “A, B, C”
same curvature spring
Center bolt assembly:
Uses the press to exert certain load, causes
each piece of spring close contact, screws tight
the nut to the stipulation torque, and the riveting
flushes three center bolts to screw tight the
moment of force:

steel plate clamp bolts screw tight the moment

of force:：

Bushing replacement:
Uses the special-purpose tool to press in with
presser

Diameter survey of the spring pin and the

shackle pin：
Standard Limit
25 24.7

Clearance between the shackle pin and the

bushing：
Standard limit
0.1 0.5
Installation
Steps of installation:
The steps of installation are introduced
hereinbefore.

Installation of leaf spring:

Install the spring double volume ear on the front
side (referring to the left diagram）

Installation of U bolt:
When tighten the U nut and U bolt, lubricate the
thread with certain quantity of oil in case of
thread damage.
Tightening torque of U bolt and U nut:：(Nm)
287-346

Installation of the leaf spring pin nut and the

shackle pin nut:
Tighten the nuts for 2~3 tooth first or till you
aren’ t able to tighten; then let the vehicle fall on
the ground, tighten the nuts to specified
tightening torque.

Tightening torque of the nut：

name Torque
Steel spring pin nut
Shackle pin nut 176.4-196

Tightening torque of the shock absorber nut:

name torque
Upper fixing nut
Upper fixing lock nut
Lower fixing nut 243-285
TIGHTENING TORQUE（Nm）

1. 287-346, 4. 176.4-196, 6. 243-285

LUBRICATING POINTS
Apply multi-purpose grease to the following
points
1. Leaf spring pin

2. Shackle pin
 REAR SUSPENSION

GENERAL

DISASSEMBLY

CHECK AND REPAIR

ASSEMBLY
GENERAL
 DISASSEMBLY

Disassembly sequence： Assembly sequence:

1. Shock absorber 6. Leaf spring
2. U bolts, nuts and spring washers 2. U bolts, nuts and spring washers
3. Shackle pin, nut and spring washer 5. Leaf spring pin, nut and spring washer
4. Shackle 4. Shackle
5. Leaf spring pin, nut and spring washer 3. Shackle pin, nut and spring washer
6. Leaf spring 1. Shock absorber

DISASSEMBLY

Preparing work:
Stop the front wheel with an arrester, jack up
the rear axle and make the rear wheel off
ground, and prop up the vehicle on the shelf.
 Disassembly of U-bolt nut:
Lubricate screw thread with some oil before
tightening U-bolts and U-nuts in case of screw
thread damage.

After the disassembly of shackle pin, knock out

the rubber bush.

Disassembly of leaf spring pin, nut and spring

washer:
After the disassembly of leaf spring pin and nut,
knock out the leaf spring pin with soft hammer.

Inspection and repair:

If there is any wearing, damage or any other
abnormal situation in checking process, repair
or replace the parts if necessary.

INSPECTION AND REPAIR

1. Leaf-spring pack Visual inspection:
Inspect the parts listed in the left form for
2. Steel trap abrasion, damage or any other abnormal
3. U bolt situations
Inspection of the shock absorber:
4. Center bolt 1. Inspect for oil leakage
5. Steel plate pin 2. After movement, inspect the oil
temperature. If the oil temperature does not
6. Shackle pin change, it indicates that the function fails.
7. Rubber cushion block 3. Grip both ends of the shock absorber,
compress and stretch; you should feel a very
8. Rubber bush big resistance. The movement vanishes after
9. Shock absorber several times of compression and stretching. If
the above condition is not satisfied, it indicates
that the function fails.
Replacement of the leaf spring assembly:
1. Before removing, make adjusting marks
across the leaf spring.
2. Before installing, apply grease on both
sides of the spring steel plates.
3. Abandon the used center bolt in the
assembly, and use new one.
Note: When replacing spring, uses the steel
plate whose surface having marks “A, B, C”
same curvature spring
Center bolt assembly:
Uses the press to exert certain load, causes
each piece of spring close contact, screws tight
the nut to the stipulation torque, and the riveting
flushes three center bolts to screw tight the
moment of force:

steel plate clamp bolts screw tight the moment

of force:：

Bushing replacement:
Uses the special-purpose tool to press in with
presser

Diameter survey of the spring pin and the

shackle pin：
Standard Limit
25 24.7

Clearance between the shackle pin and the

bushing：
Standard limit
0.1 0.5
INSTALLATION
Steps of installation:
The steps of installation are introduced
hereinbefore.
Installation of leaf spring:
Install the spring double volume ear on the front
side (referring to the left diagram）

Installation of U bolt:
When tighten the U nut and U bolt, lubricate the
thread with certain quantity of oil in case of
thread damage.
Tightening torque of U bolt and U nut:：
450-500

Installation of the leaf spring pin nut and the

shackle pin nut:
Tighten the nuts for 2~3 tooth first or till you
aren’ t able to tighten; then let the vehicle fall on
the ground, tighten the nuts to specified
tightening torque.

Tightening torque of the nut：

name Torque
Steel spring pin nut 178-218
Shackle pin nut

Tightening torque of the shock absorber nut:

name torque
Upper fixing nut 243-285
Lower fixing nut
 FRONT AXLE

MAINTENANCE DATA

ADJUSTING OF FRONT WHEEL

FRONT AXLE
MAINTENANCE DATA
Main data and specifications
Model HFC1083KR1（D109）
Item （3000G101）
Tread 1830
Adjusting of front wheel（mm）
Front wheel toe-in 1～3（diagonal tyre） 1～3（Radial ply tyre）
Front wheel camber 1°
King pin caster 1°30′±1°
King pin inclination(KPI) 7°30′
Steering angle:
Outer 29°
inner 36°
Dosage of lubricating grease on one side
of the front wheel hub bearing (g) 230±10； 40±5 in cover.
Preload of the front wheel hub bearing
New bearing (N) 27.5～41.1
Old bearing (N) 15～41.1
Front suspension standard limit
external diameter of leaf spring pin 25 24.7
clearance between shackle pin and liner 0.1 0.5
ADJUSTING OF FRONT WHEEL
Measuring of the front wheel toe-in
(1) Stop the front wheel on even ground.
(2) Jack up the front axle.
(3) Make marks on central part of the tire tread with a
chalk.

(4) Place toe-in measuring equipment on

central position of the wheel.
(5) Score tyre central line by turning wheel.
(6) Let the vehicle fall on ground.
(7) Adjust height of the toe-in measuring
equipment pointing at the mark on tyre.
(8) Measure the distance between tyre central
lines (A).
(9) Jack up the front axle again.
(10) Turn each wheel by 180°.
(11) Make the toe-in measuring equipment point
at the mark on tyre.
(12) Measure the distance between tyre central
lines on rear side of the front
wheel（B）.
The toe-in value equivalents: B－A
Toe-in value:
Diagonal tire 1~3
Radial tire 0~2
Toe-in adjustment:
1. Loose the tie rod connecting lock nut
2. Rotate the tie rod to adjust the toe-in.
3. Tighten the lock nut to specified torque
Tightening torque of the lock nut:：
Tightening torque
Measuring of camber：
(1)Put a cushion block of the same thickness
with the steering angle measurer under each
rear wheel.
(2)Jack up the front wheel

(3) Put each front wheel on a steering angle

measurer.
Tire central line should align with the center of steering
angle measurer.

(4) Let the front wheel fall.

(5) Set the scale of the steering angler measurer to
zero.

(6) Remove the front wheel hub cover.

(7) Wipe the steering knuckle ends and clean
up all lubricating grease.
(8) Install upper front wheel--king pin camber
measurer and turn the steering knuckle left and
right horizontally.
(9) Read camber degree from the dial directly.
(10) Repeat step (8) and step (9) on another
steering knuckle.
If measured camber degree deviates the
specification: Adjust toe-in
Check whether the steering king pin, bearing
and the liner bushing have been abraded too
much.
Check whether the front wheel hub bearing has
loosed.
(c) Check the torsion and extroversion of the
front axle.
Camber degree of the front wheel：
1°
Measurement of the castor of the steering king
pin and K.P.I.
The castor of the steering king pin and the K.P.I
of the king pin can be measured by the front
wheel king pin camber measurer at the same
time.
(1) Adjust the scale of the steering angle measurer to
zero (after finishing the camber measuring).
(2) Turn the steering wheel right until the front wheel
has turned by 20 ° (measured by the steering semi
diameter measurer).

(3) Adjust the scale of the right king pin castor and K.P.I
of the front wheel to zero.
(4) Turn the steering wheel in opposite direction until
the front wheel has turned left by 20 °(measured by the
steering angle measurer).

(5) Read the degree of the right king pin castor and
K.P.I from the right scale directly.
(6) With the wheel turning left by 20 °, adjust the scale
of the left king pin castor and K.P.I of the front wheel
king pin camber to zero.
(7) Turn steering plate in opposite direction until front
wheel has turned left to 20 °(measured by the steering
angle measurer).
(8) Read the left king pin castor and K.P.I from the left
scale directly.
Caster angle and Inward inclination angle：
Caster angle 1°30'
Inward inclination angle 7°30'
If the degree of the king pin camber is measured to
deviate the specification：
(a) Check whether the steering knuckle, the bearing
and the liner bush have been abraded too much.
(b) Check the abrading situation of the front steel plate
spring.
(c) Check torsion and camber of the front axle.
Measuring of sideslip
Measuring of sideslip should be made after the
measuring and adjusting of the camber of toe-in and
king pin
(1) Roll the wheel across the sideslip measurer
as slowly as possible.
(2) Read out the reading indicating on the
sideslip measurer.
If sideslip value exceeds 5 mm/m, it is necessary
to adjust the wheel alignment again.
Measurement of the maximal steering angle
1. Stop the vehicle on even place.
2. Jack up the front wheel
3. Put each front wheel on a steering angle measurer.
Tire central line should align with the center of
steering angle measurer.
4. Let the front wheel fall.
5. Set the scale of the steering angle measurer to
zero.
6. Turn the steering wheel right until it is blocked.
7. Measure the steering angle
a--- Maximal steering angle of exterior wheel
b--- Maximal steering angle of interior wheel
8. Turn steering wheel left until it is blocked.
9. Measure the steering angle
a--- Maximal steering angle of exterior wheel
b--- Maximal steering angle of interior wheel

interior wheel and exterior wheel：

interior wheel 36°
exterior wheel 29°

If the steering angle is measured to deviate the

specification, please adjust it with steering knuckle stop
bolt.
FIXED TORQUE
DISASSEMBLY AND ASSEMBLY
Front axle

Disassembly sequence：
1. brake tube
2. shock absorber
3. drag link
4. steel spring U-bolt U-nut
Assembly sequence：
Just the opposite of the disassembly sequence
Disassembly
Re-assembly sequence：
As before mentioned

Removal of the drag link ：

Use special tools

Removal of the U-bolt：

If corrosion of the U bolt is serious, lubricate the
thread with certain quantity of oil, and then loose the
nut in case of thread damage.

Reinstallation
Reassembly sequence ：
As mentioned before

Assembly of U nut and U bolt ：

When tighten U bolt or U nut ，lubricate the thread
with certain quantity of oil in case of thread damage.

Tightening torque of U-bolt：Nm

Assembly of drag link ：

Tighten the drag link nut to specified torque, if the
nut opening does not align with the cotter hole,
increase the torque slightly to adjust it.
Tightening torque of the drag link nut：Nm

Assembly of rear shock absorber ：

Install shock absorber nut, gasket and rubber liner
bush according to the diagram.
Tightening torque of absorb nut ：Nm
Upper nut
Lower nut
 Knuckle and king pin

Disassembly sequence: Assembly sequence:

1. Wheel Assembly sequence is the reverse of
2. Hub cover disassembly sequence.
3. Cotter notch nut
4. Washer
5. hub and brake drum assembly
6. Hub oil seal seat
7. Hub outer bearing
8. Oil seal of hub inner bearing
9. Nut of hub inner bearing
10. Outer race of hub inner bearing
11. Outer race of hub outer bearing
12. Brake drum
13. Hub
14. Tire bolt
15. Tire inner nut
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 assembly

with an extractor.

5. Remove bearing bushing outer race.

1． Wheel hub
2． Wheel hub bearing, oil seal Inspection and repair

3． Knuckle groove Visual inspection of the parts listed in the left for
4． Brake drum damage or failure.

5． Brake shoe, gasket, etc.

Main operating steps of installation.

Add grease according to the fig.

Inside wheel hub 280 g

Grease 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:
New bearing：27.5-41.1N
Old bearing：15-41.1N
 Knuckle and king pin

Disassembly sequence ： Assembly step:

1. Oil retainer 13. I-beam
2. Brake shield plate 10. Knuckle
3. Steering knuckle tie rod and tension 12. Thrust bearing
bar attachment 11. Adjusting shim
4. Knuckle curved arm 9. King pin
5. Knuckle straight arm 7. Locking pin
6. King pin cap 6. King pin cap
7. Locking pin 8. Stops up covers
8. Stops up the lid 5. Knuckle straight arm
9. King pin 4. Knuckle curved arm
10. Knuckle 3. Steering knuckle tie rod and tension bar
11. Adjusting shim attachment
12. Thrust bearing 2. Brake shield plate
13. I-beam 1. Oil retainer
Disassembly
Preparation ：
Jack the vehicle up and support it on the chassis
platform

Steps of removal:
Steps of removal are introduced at before.
Removal of steering knuckle tie rod ball:
Remove with the special-purpose tool and the
hammer impact

Removal of the knuckle drop arm and the curved arm:

Removal of lock pin:

Remove it with the special-purpose tool.

Removal of the king pin:

Remove it with the special-purpose tool.

Removal of bushing and oil seal

1. I-beam Inspection and repair:
2. Knuckle When inspect, if find wearing, damage or any other
3. Changes the drop arm and the abnormal situations, Repair or replace the parts if
curved arm necessary.
4. Steering knuckle tie rod and tension
bar attachment Visual inspection：
5. King pin, bushing, thrust bearing and Check the parts listed in left form for wearing, damage
adjusting shim or any other abnormal situations
6. Universal joint ball
I-beam inspection:
1. Put the steering king pin (or inspection stick) into
the steering king pin hole.
2. Tighten a string (or inspection stick) between the
steering king pins.
3. The string should be consistent with the spring
holder center bolt hole as you look down from it.
4 From the side looked the king pin (or examines
stick), the king pin (or examines stick) to be supposed
to be at good vertical to the uneven condition
5 Inserts a new king pin into the pin hole and
inspect the cooperation situation of the steering king
pins in the steering king pin hole. If cooperation of the
king pins becomes less compact, the front axle must
replaced; if the upper of lower flange of the king pin
mounting hole is excessively worn, the front axle must
also be replaced.

5 Inserts a new king pin into the pin hole and

inspect the cooperation situation of the steering king
pins in the steering king pin hole. If cooperation of the
king pins becomes less compact, the front axle must
replaced; if the upper of lower flange of the king pin
mounting hole is excessively worn, the front axle must
also be replaced.
Inspection of the steering knuckle:
1. Check the knuckle for cracking or other damages
with the magnetic flaw detector

2. Surveys diameter of the bearing and oil seal

assembly surfaces A, B

Model A B
35mm 50mm

Concentricity of connection rod is 1mm.

Inspection of the universal joint ball:

Outer diameter survey
Axle model Standard Limit
39.0mm 38.5mm
1. Spreads light special mixture on the universal
joint ball cone-shape spot (mixture of red lead and
machine oil)
2. Installs the drop arm and the curved arm on the
universal joint ball
3. Inspect whether the universal joint ball contacts
well. The contacted area should not be shorter than
3/4 of the entire length.
4. If the universal joint ball does not contact well, it
must be repaired or replaced.

Diameter of the steering king pin：

（mm）
Model Standard Limit
30.0 29.9

Clearance between king pin and bushing：

Model Standard Limit
0.06mm 0.15mm

Notes: When install the bushing, its lubricant filler is

supposed to align with the filler of the universal
joint.

Inspection of cooperation of the steering king pin and

king pin bushing:
Put the king pin into the king pin bushing, and inspect
according to following method.

Along the king pin spool thread direction, bulldozes

end of the king pin with fingers, and inspect whether
the fingers can move smoothly.

If the king pin bushing is excessively tight, ream the

bushing with a reamer to ensure the concentricity of
the upper cotter hole and lower cotter hole of the
steering knuckle.
Steps of installation:
Steps of installation are introduced at before.
Installation of the thrust bearing:
1. Apply lubricating grease on the thrust bearing
2. Keep the dust cover surface upward.
3. Install the thrust bearing

Installation of the adjusting shim:

After installing the adjusting shim, inspect the
clearance between the steering knuckle and the front
axle.
Model Standard Limit
0~0.10mm 0.20mm

：Adjust specification of the shim:（mm）

Thickness 0.50、0.55、0.60、0.65、0.70、0.80、
0.90
Installation of king pin:
1. Apply the lubricating grease on the king pin and
the bushing
2. Align lock pin slot of the king pin and lock pin hole
of the front axle
3. Install the steering king pin, and inspect whether
the knuckle turns smoothly.
Tightening torque of the lock pin:：
32Nm

Installation of the drop arm and the curved arm:

Tighten the nut to specified tightening torque, caulk
the nut.

Tightening torque of the nut：

441Nm
Tightening torque of the tie rod jointing nut：
186Nm

Tightening torque of the brake back plate bolt

69Nm
 STEERING

GENERAL

DISASSEMBLY OF STEERING WHEEL, SHAFT AND COLUMN

INSPECTION

ASSEMBLY

DEFLATION

TIGHTENING TORQUE

DRAG LINK
 GENERAL
Main data and specifications
Steering column and steering shaft
Diameter of steering wheel 500
Play mm Manual steering 10~40
Power steering 10~60
Type of steering shaft Double-ball type
Adjustable coverage Vertical 40
Fore and aft 60
Manual steering mechanism
Type Recirculating-ball type
Quantity of recirculating ball 28
Gear ratio 27.7~31.7
Threaded pitch of recirculating ball screw arbor mm 9.525
recirculating ball screw arbor line line 1
Outside diameter of the gear segment shaft 34.295
Recommended lubricants Gear oil GL-3 or GL-4
Oil capacity liter 1.0
Power steering mechanism
Type Recirculating-ball type
Quantity of recirculating ball 28
Gear ratio 16.1~18.8
Threaded pitch of recirculating ball screw arbor mm 14.288
recirculating ball screw arbor line line 1
plug valid area cm 2 63.6
Torsion bar spring constant number Kg.mm/degree 180
Valve work angle degree ±8.5°
Adjusting oil pressure ML/ c ㎡ 125
Adjusting oil flow L/min 8
Recommended lubricants Automatic conduction fluid
Oil capacity liter 3.0
Power steering oil pump mechanism
Type Vane type
Theoretical transportation cm3/rotation 17.5
Adjusting oil flow liter/minutes 12
adjusting oil pressure liter/c ㎡ 105
Max. Speed Rotations/Minutes 3700
Maintenance standard
Item Standard Limit
Power Outside diameter of the gear segment shaft 39.975 39.925
Steering Clearance between gear segment shaft and bearing 0.12
Back clearance between gear segment shaft and ball nut 0.05~0.25
Free play of the steering wheel 10~50
Power steering oil pressure （engine idles） kPa 10297
Manual Outside diameter of the gear segment shaft 38.100 38.000
Steering Clearance between gear segment shaft and needle bearing 0.2
Axial clearance of the ball nut 0.1
Starting torque of Without gear segment shaft 0.29~0.69
worm shaft With gear segment shaft 0.98 or less
Back clearance between gear segment shaft and ball nut 0.5 or less
Free play of the steering wheel 10~30
DISASSEMBLY OF STEERING WHEEL, SHAFT AND COLUMN

Steps of removal： Steps of installation：

1. steering cover 7. Steering column
2. horn button 6. Steering shaft assembly
3. steering wheel 5. Tilt adjusting device
4. start switch assembly 4. Start switch assembly
5. Tilt adjusting device 3. Steering wheel
6. Steering shaft assembly 2. Horn button
7. steering column 1. Steering cover
Removal

Steps of removal：
Steps of removal are introduced hereinbefore.
Removal of horn button：
Pull out the horn button with hands

Removal of the steering wheel：

Make marks across the steering wheel and the

steering shaft to ensure that the parts can be
reinstalled in their original positions.

Removal of start switch assembly：

1. Loose the tightening screw with a
screwdriver
2. Remove the snap spring with a snap spring
pincer.

3. Remove the harness connection

Removal of tilt adjusting device：

1. Remove stay bolts on the brackets of the
steering adjusting device and the steering
column

2. Tilt the steering column and remove the tilt

spring
Removal of steering shaft：
Make locating marks on the universal joint yoke
and the worm shaft. Remove the bolts, and then
pull out the flange yoke of the worm shaft.

Removal of the steering shaft and the steering

column.：
Draw the steering shaft out of the steering
column.

Removal of the spline shaft and the spline

column：
Before removing, make locating marks across
the spline shaft and the spline column so that
they can be reinstalled in original positions.
Inspection and repair

Inspection and repair：

Clean the dismantled parts and inspect each
part carefully.

Inspection of steering shaft：

1. Whether the steering shaft bends.
2. Whether the universal joint yoke cracks or
deforms, whether there is an abnormal
noise in the jointing position of the universal
joint.
3. Whether the spline shaft makes an
abnormal noise when turn the steering
shaft.
Notes：Universal joint cannot be repaired.

Inspection of steering column：

1. Whether there is serious deformation inside
the steering column.
2. Whether the shaft bush wears out or gets
ageing
Installation
Steps of installation：
Steps of installation are introduced at prior
Installation of steering shaft：
Install the steering shaft to the steering worm
shaft according to the marks made during
removal.
Tightening torque of the bolt：Nm

Installation of the start switch：

Fix the switch on the steering column with bolts
and insert clip reed into it.

Installation of the tilt adjusting device：

1. Install lower-sided holding bolts and nuts of
the steering column and tighten them to
specified torque.
2. Install and tighten nuts of the tilt-adjusting
device to specified torque, then install the
operation handle and tighten the bolts of the
operation handle to specified torque.
tightening torque of the lower holding bolts and
nuts：

tightening torque of nuts and bolts of the tilt

adjusting device：
Nut
Bolt
Installation of the steering wheel：
Install the combination switch at first, then
install the steering wheel according to the
locating marks made during disassembly, and
tighten the nuts to specified torque.
tightening torque of the steering wheel nut：
Replacement of the steering gear oil

Replacement of the manual steering gear oil:

1. Remove the oil filler bolts

2. Fill specified gear oil to the lowest position of

the oil filler.
3. Install and tighten the oil filler bolts

Replacement of power steering oil：

1. Jack up the front wheel to make it off the
ground.
2. Cut off the oil pipes between the steering
and the oilcan as well as between the oil
pump and the oilcan.
3. Turn the steering wheel in two directions for
several times to displace oil of the hydraulic
system.

Replacement of the hose：

Replace the hose after replacing oil for two
times.
Deflation
Air deflation of the power steering duct:
1. Fill oil to the oilcan, jack up the front wheel off the
ground, turn the steering wheel slowly, and lock it
in two directions for several times.
2. Start the engine and keep it running idling for 2~3
minutes.
3. Turn the steering wheel slowly, and lock it in two
directions for several times. Turn the steering
wheel anti-clockwise to lock it, and then loose
the oil pipe joint to deflate air. Repeating above
operation till air bubbles vanish.
4. Turn the steering wheel anti-clockwise to lock it,
and then do air deflation operation continuously.

5. Put down the front wheel and turn the steering

wheel in two directions as the engine is running
at a middle speed. If there isn’ t any abnormal
noise in steering operation, it’ s thought that the
air has been deflated completely.
6. If there is any abnormal noise, turn the steering
wheel till the oil temperature reaches 60~80℃,
and keep the engine running for about 10
minutes, then repeat the air deflation operation.
7. After finishing the air exhaust operation, check
the steering device and pipes for leakage.
Notes: In air deflation operation, you should check
the oil level regularly; add oil if necessary to keep a
normal oil level.
Inspection of the oil level of power steering device：
Rotate off the oil can cover from the power steering
oil can, and check the oil level indicating on the
scale.

Operation test of the power steering system:

After finishing installing the power steering system to
the vehicle, make an operation test according to
following methods to check if the power steering
system works normally.
1. Measure the force needed in doing the steering
operation.
Inspect the steering force as the front wheel is jacked
off the ground and the parking brake works reliably.
Keep the tensiometer hooked on the steering wheel
flange to measure the needed force to turn the
steering wheel. Start the engine and keep it running
idling till the oil temperature reaches to 50~60℃,
then measure the force needed to turn the steering
wheel with a tensiometer. When the tensiometer
reading is lower than half of the measured value as
the engine stays, it can be thought that the power
steering system can work normally. If the
tensiometer reading is too high, inspect the power
steering system and steering pump again.
2. Measuret the oil pressure
⑴ Prepare proper oil pressure gauge and cut-off valve,
and make the wheel head straight forward.
⑵ Connect the oil gauge to side oil pipe of the oil pump.
⑶ Connect the open end of the cut-off valve to side oil
pipe of the power steering device.
⑷ Open the cut-off valve completely and make the
engine run idling for 2 minutes.
⑸ Measure the oil pressure as the engine runs idling,
and it should indicate around 490kPa. If the oil pressure
reads above 490kPa, it indicates that the control valve
or the duct fouls.
⑹ Increase the engine rotation speed to 1500 r/min,
watching the oil pressure shown in oil pressure gauge
rise, and tightening the cut-off valve slowly.
⑺ pressure of the pressure reduction valve is set as
9310kPa in manufacturing. If it reads beyond specified
coverage, maybe the cause of failure lies in that the
pressure reduction valve has faults. If it doesn’ t
indicate that the pressure increases, maybe the cause
of failure lies in that spring damages or oil pump
defaults.
Notes: Do not close the cut-off valve for over 10s, or the
over high oil temperature will lead to defaults.
⑻Open the cut-off valve completely, keep the engine
idling and turn the steering wheel left to the utmost
position, watching the highest oil pressure; Then turn
the steering wheel right to the utmost position, watching
the highest oil pressure. If the oil pressure is lower than
the specified value, the power steering device defaults
and must be replaced or repaired.
Notes: The front wheel corner should conform to the
technical standard and must complete the test within 5s.
Specified pressure (engine idles):
KPa
 Inspection of the free turning of the steering wheel:
1. The front wheel should keep straight ahead, turn
the steering wheel left and right till the front wheel
begins to run, the quantity measured at which time
is free turning of the steering wheel.
Notes: If it is power steering device, the engine should
keep running when you inspect the free turning of
the steering wheel.
Free turning of the steering wheel:
Manual steering Power steering

Adjustment of the free turning of the steering wheel：

1. Make the front wheel keep straight ahead
2. Loose the lock nuts and adjust the adjusting screws.
3. Rotate the adjusting screws clockwise, the
clearance decreases; rotate the adjusting screws
anti-clockwise, the clearance increases.
4. After the free turning is satisfied, tighten the lock
nuts to specified torque.
tightening torque of the lock nuts：
Manual steering Power steering

Notes: When adjust the free turning of the steering

wheel, Inspect whether there is free clearance of
the steering shaft, gimbals etc. If these parts are
normal, do adjusting with the adjusting screws.

1. looseness or shock of the

steering wheel Inspection of steering function：
2. swinging of steering Inspect items listed in the left form
3. heavy steering
4. return of steering
 FIXED TORQUE
Manual steering, manual steering, steering pitman arm and drag link

Manual steering
Power steering

Steering tie rod

DISASSEMBLY OF DRAG LINK

Steps of removal： Steps of installation：

1. split pin 8. Pitman arm
2. nut 7. Nut
3. drag link 6. Power steering
4. universal joint 5. Mechanism mounting nuts and bolts
5. mechanism mounting nuts and bolts 4. Universal joint
6. power steering 3. Drag link
7. nut 2. Nut
8. pitman arm 1. Split pin
Removal
Preparing work：
Removal of oil pipe.
Clean the steering device, joints etc. before removing
the oil pipe; prevent dust and other dirt coming into
the pipe after removing the pipe.

Steps of removal：
Steps of removal are introduced hereinbefore.

Removal of drag link：

Remove the connection between the tie rod and the
pitman arm and the bend arm with special tools.
Reinstallation
Steps of installation：
Steps of installation are introduced at prior

Installation of pitman arm：

Install according to the locating marks.

Position
mark

Tightening torque of pitman arm bolt：Nm

250-280

Tightening torque of fixing bolts and nuts of the

device：

Installation of universal joint：

Install the parts according to the marks made
before removal.

tightening torque of the universal joint bolts：

Installation of drag link：

1. Install the drag link to the pitman arm and
bend arm.
2. Tighten the nuts to specified torque, increase
the torque slightly and adjust the nut slot
opening to align with the cotter pin hole.
Tightening torque of the nuts：

Connection of oil pipe：

Connect the oil pipe; tighten the nuts to specified
torque.
Tightening torque of nuts：
 UNIT MAINTENANCE
Power steering

Steps of removal： 11. O sealing ring

1. dust sealing 12. Bearing
2. lock nut 13. Valve and ball nut assembly
3. side cover and gear segment shaft assembly 14. Valve assembly
4. side cover assembly 15. Ball nut assembly
5. gear segment shaft assembly 16. O seal washer
6. limiting device 17. Sealing ring
7. adjustable screw 18. Sealing ring
8. dust cover 19. O seal ring
9. bottom cover lock nut 20. Gear box assembly
10. bottom cover
Steps of installation：
20—18—19—17—16—15—14—12—11—10—9—7—6—5—4—3—2—8—1
Removal Steps of removal：
Steps of removal are introduced at prior
Removal of the side cover and the gear
segment shaft：
1. Rotate the input shaft to locking position,
then return 2.5 circles and adjust the gear
segment shaft to center position.
2. Rotate the adjustable screw anticlockwise
slightly, and then remove the tightening
bolts of the side cover.
3. Beat the end of the gear segment shaft with
a soft hammer slightly, and then remove
side cover and gear segment shaft.

Removal of gear segment shaft：

Rotate the adjustable screw clockwise, and
remove gear segment shaft from side cover.

Removal of bottom cover lock nut：

Remove with special tools

Removal of bottom cover lock：

Remove with special tools
Removal of valve and ball nut assembly：
Keep the ball nut in horizontal direction and
avoid dropping, or the ball nut will slide out.
Beat the end of the ball nut with a soft hammer
slightly and remove the ball nut.

Removal of limiting device：

Make the two lips of the limiting device rise and
remove the limiting device with relevant tools.
Side cover assembly

Steps of removal： Steps of installation：

1. O seal ring 4. Side cover
2. needle bearing 3. U rubber cup
3. U rubber cup 2. Needle bearing
4. side cover 1. O seal ring
Valve body

Steps of removal： Steps of installation：

1. snap spring 5. Upper cover
2. oil sealing 4. O seal ring
3. needle bearing 3. Needle bearing
4. O sealing ring 2. Oil seal
5. upper cover 1. Snap spring
Gearbox

Steps of removal： Steps of installation：

1. oil seal 4. Housing
2. needle bearing 3. U rubber cup
3. U rubber cup 2. Needle bearing
4. housing 1. Oil sealing
Inspection and repairing Inspection and repairing：
If you find wearing, damage or any other
abnormal situation in inspection, repair or
replace the parts if necessary.
1. Housing
2. Gear segment shaft Visual check：
3. Needle bearing Inspect the parts listed in the left form for
4. Ball nut assembly wearing, damage etc.
5. Oil seal, dust cover, U rubber cup, O ring
and sealing ring
Rotating inspection of the ball nut：
Hold the worm shaft vertically, watching
whether the ball nut can rotate down smoothly.
If the ball nut cannot fall by its weight, you
should inspect whether the worm shaft bends,
whether there are burrs on the ball slot, whether
the ball slot is dented and whether there are
outside objects.
Notes: When inspect the ball nut assembly, pay
attention not to make the ball nut hit the worm
shaft or damage the ball-circulating duct.

Measurement of the outside diameter of gear

segment shaft：
Model Standard Limit

Measurement of the clearance between gear

segment shaft and needle bearing：
Limit 0.2
Measurement of the axial clearance of the ball
nut：
Limit 0.12

Measurement of the clearance between the ball

nut plug and the rotor：
Standard Limit
0.04~0.09 0.15

Inspection of ball nut assembly：

Ball nut assembly and control valve assembly
etc. are precession components, if damage,
they should be replaced together.
Keep the ball nut in horizontal direction and
prevent it from falling, or it will slide out. Beat
the end of the ball nut with a soft hammer
slightly to remove it.
Reinstallation of power steering device Steps of installation：
Steps of installation are introduced at prior

Installation of O ring and sealing ring：

When install O-ring and sealing ring, collocate
them with an assembler.

Installation of the ball, duct, duct clamp,

screw and washer：
1. Lay the valve assembly in horizontal
direction, and then rotate the pivot shaft with
putting the balls into the circulating duct hole.

2. Apply sufficient lubricating grease on the

circulating duct inside surface, on which
adhere the balls, then put the other duct on
the circulating duct.

3. Tighten it to specified tightening torque

tightening torque：
Tightening torque of the valve bolt：

Installation of bottom cover：

Tighten the bottom cover with special tools till that
the start running torque of the input shaft is in the
specified coverage.

Starting torque：

Installation of bottom cover lock nut：

Tighten bottom cover lock nut to specified torque
with special tools. Inspect the start running torque
of the input shaft after tightening. If the starting
torque is not in the specified coverage, readjust
the bottom cover tightening.
Torque of bottom cover lock nut：

Installation of limiting device：

Desert the used limiting device and adopt new
one. Install and tighten the limiting device
completely, then return 180°; retighten it to N.m
and return 20°. Check whether the adjusting
screw turns smoothly. At last, return two lips of the
limiting device.

Installation of side cover：

Turn the adjusting screw anti-clockwise till the end
of gear segment shaft touches the side cover, and
then return it for a whole circle.
Installation of side cover and gear segment shaft
assembly：
Align the center gears of the ball nut and the gear
segment shaft, and then install the ball nut and the
gear segment shaft.
tightening torque of side cover bolt：

installation of lock nut：

Adjusting of side clearance of the segment gear
and the ball nut：
1. Install the pitman arm
2. Make the pitman arm straight ahead
3. Use the adjustable screw, and adjust the side
clearance to specified value.
Side clearance（at the end of the pitman arm） ：
0.33 or less
4. Lock the adjustable screw with lock nut

tightening torque of lock nut：

5. Inspect the start running torque of the input

shaft
Starting torque：
TIE ROD

Disassembly sequence: Assembly sequence:

1. cotter pin 6. tie rod connector
2. nut 5. tie rod
3. cotter pin 4. nut
4. nut 3. cotter pin
5. tie rod 2. nut
6. tie rod connector 1. cotter pin
Disassembly

Disassembly sequence:
As the description hereinbefore

Disassembly of tie rod

Use special tool
Check and repair
Check and repair:
When you check , if there are some wear、tear
or something wrong , you can revise or change
the accessory .
Ball joint check:
Check the ball joint dust cover、thread、conic
surface and lubrication.
If you find something wrong, just change the
joint assembly. Because the ball joint can not
be dismantled.

Tie rod check ：

Check the bend of tie rod or the damage of the
thread. If you find something wrong, change the
tie rod. If the bend of the tie rod is little, you can
correct.
Assembly:
Assembly sequence:
Assembly sequence accordingly.
Length of tie rod (L):

Assembly of tie rod nut and cotter pin:

Fasten the tie rod nut to the stated torque, if the
nut hatch is not aim at the pinhole, you can
correct it by increasing torque little.

Tightening torque of the tie rod nut:

Tightening torque of the lock nut:

Note ：
Before tightening the lock nut, you should
adjust toe-in of front wheel.
The way of adjusting refers to the chapter of the
front axle’
s maintenance.
Steering drag link

Steering linkage mechanism

Disassembly sequence: (disassemble the cotter Assembly sequence:

pin first)
1. adjusting plug 13. steering drag link
2. ball valve seat 10. mud cover
3. ball valve seat 9. ball valve seat
4. coil spring 8. ball valve seat
5. mud cover 7. coil spring
6. adjusting plug 6. adjusting plug
7. coil spring 5. mud cover
8. ball valve seat 4. coil spring
9. ball valve seat 3. ball valve seat
10. mud cover 2. ball valve seat
11. grease inlet 1. adjusting plug
12. grease inlet 12. grease inlet
13. steering drag link 11. grease inlet
Disassembly Disassembly sequence:
Do as foregoing content

Thin end Wide end Disassemble the pitman arm ball joint:
You can loosen adjusting nut, move the pitman
arm ball joint to de wide end, and pull it out from
the drag rod.

Check and repair

Check and repair：
When you check , if there are some wear、tear
or something wrong , you can revise or change
the accessory .
Check aspect：
Checking the left accessories, to find that
whether there are some wear 、 tear or
something wrong

Drag link spring’

s free length and set load:

standard limit
free Set free Set
length length/set length length/set
（mm） load （mm） load
mm/kg mm/kg
80 72/42 78 72/35

Ball joint diameter’

s mensuration:
If ball joint diameter is off-rating, you should
change a new one.
model
standard limit
number
27 26.5
Assembly Assembly sequence:
Do as foregoing content

Grease filling：
Fill grease in the coil spring

grease
Pitman arm

Adjusting plug’s assembly：

Tighten the adjusting plug, so as to compress
cotter the adjusting plug completely, then revolute the
adjusting plug 60°, keep on revoluting , until
drag rod drag link hole aims at the adjusting plug groove
(adjusting when revoluting between 60°and
adjusting 90°).
plug
Note: insert the cotter pin from the top down.
 BRAKE AND CONTROL SYSTEM
GENERAL

MAIN DATA AND SPECIFICATIONS OF BRAKE

TIGHTENING TORQUE OF MAIN BOLTS AND NUTS

DISASSEMBLY

INSPECTION AND REPAIR

REASSEMBLY
 GENERAL
The structure of air brake:

MAIN DATA AND SPECIFICATIONS OF BRAKE

Item Front brake C10QZ
Rear brake C10QZGJ
Type
Front brake：leading trailing shoes
Rear brake：leading trailing shoes
Inner diameter of brake drum (mm)
：Front 400
：Rear 400
Width of brake shoe slice (mm) Front：130； Rear：155
Clearance of the brake shoe (mm) 0.25-0.4
Free play of brake pedal (mm)
Principle diagram of air brake pipe

Assembly diagram of air brake pipe

1. Brake pedal 2. Brake valve 3. Quick-release valve 4. Unloading valve 5. Air tank

6. Safe valve 7. Air tank 8. Check valve 9. Quick-release valve

TIGHTENING TORQUE OF MAIN BOLTS AND NUTS
DISASSEMBLY

Disassembly sequence
1. Brake shoe return spring 2. Screw 3. Dust cover 4. Shoe shaft
5.Brake shoe assembly ６. Snap ring 7. idller wheel shaft 8 . idller wheel
9.cotter pin，slim，shaft 10 .brake air chamber 11 . cotter pin 12 . washer
13. slack adjuster 14. camshaft 15. air chamber bracket 16. brake base board
 Important work
Dismantle the brake shoe return spring.

Check and repair

Brake drum
If diameter of brake drum increases resulting from
abrasion or rubbing, friction disc with larger diameter
should be used.
Standard(mm) limit
Inner diameter 400
Nonconcentricity ≤0.1

Check if the friction disk has abnormal abrasion.

Rivet hole depth limit 0.5mm

Dismantle the used friction lining

Rivet new friction lining.

Rivet the brake shoe and lining together on a rivet
machine.
Meaure the clearance between the brake shoe lining
and the brake shoe pin.
limit 0.25mm

Measure the clearance between the brake camshaft

and brake back plate bushing.
limit 0.6mm

Measure the clearance between the brake slack

adjuster pin and the hole
limit 0.6mm

Adjust the brake clearance

Press the lock sleeve on the slack adjuster first, then
adjust the brake clearance through screwing the
adjusting bolt.
Reduce the clearance by clockwise screw, increase it by
anticlockwise screw. The right clearance is 0.25-0.4mm
 Adjust the brake pedal
Adjust the brake pedal overall travel between mm
by adjusting the brake light switch, then adjust the pedal
free travel between 5-8mm by adjusting the brake valve
push rod.
Finally screw the two lock nut.

Air chamber
Disassembly

Disassembly sequence
1. push rod yoke 2. lock nut 3. hoop 4. fixed plate 5. rear cover 6. diaphragm film
7. piston disk 8. spring 9. front cover 10. dust proof
 Important work
Mark on the front and rear cover and hoop
of the chamber before disassembly, note
the mark when reassemble
 CABIN

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

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

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

Front windshield glass

Disassembling and assembling

Disassembling sequence Assembling sequence

▲ 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

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

Rear windshield glass

Disassembling and assembling

Disassembling sequence Assembling sequence

▲ 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

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

Instrument desk

Disassembling Reassembling

Disassembling sequence Assembling sequence

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

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

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.

Important operation ---assembling

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

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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
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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
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Ceiling inner trim

Disassembling and assembling

Disassembling sequence Assembling sequence

2. Ceiling inner trim buckle 1. Ceiling inner trim

1. Ceiling inner trim 2. Ceiling inner trim buckle

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Ceiling ventilation

Disassembling and assembling

Disassembling sequence Assembling sequence

1. Inner cover assembly ▲ 3. Outer cover & control assembly

▲ 2. Hex nut ▲ 2. Hex nut

▲ 3. Outer cover & control assembly 1. Inner cover assembly

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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.

Important operation ---assembling

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
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1. Inner cover assembly

Top cover

Control Clip

Inner cover
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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
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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
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Important operation ---assembling

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
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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.
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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.
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Seat

Disassembling and assembling

Disassembling sequence Assembling sequence

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
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Seat safety belt

Disassembling and assembling

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

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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
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Cab tilting and locking mechanism

Tilting mechanism
Disassembling and assembling sequences

Disassembling sequence Assembling sequence

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
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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
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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

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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
5. Tilting lock mechanism assembly
4. Lock mechanism left assembly
3. Lock mechanism right assembly
2. Long slide rod assembly
1. Short slide rod assembly
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Important operation--- assembling

5. Tilting lock mechanism assembly

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

2. Long slide rod assembly

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