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Service Manual for Wuling Electric Pickup Truck

1. Body 8 7 8 2 Front Windshield Use special glass cement for automotive windshields to install the front windshield l e Through one component polyurethane seal S ZA Front windshield external matches with primer directly adhere the trim rubber strips 2 Front windshield internal windshield onto vehicle body metal plates i irimmubberistins When replacing the front windshield 3 Front Windshield glass f 4 Front windshield rubber strong adhesion adhesives should be used according to the following correct methods Attention e Usually adhesive One component polyurethane seal and two primers or some only use a kind of common used primer are used for replacing the windshield Whichever to use should comply with its user manual Non comply or misuse other adhesive may reduce adhesive performance Therefore please read the adhesive manual or instruction provided by manufacturer carefully before using And strictly comply with defined steps and methods while repairing Additionally repair and paint the scratched or buffed surface to avoid worse corrosion The applied adhesive must meet the following requirements eShear strength 40kg cm 569Ib in or above eThe adhesive and tools used to remove front windshield are One component polyurethane seal and primers The materials and volume used for installing front
2. 8 9 8 13 8 13 8 14 8 15 8 18 8 18 8 18 8 19 8 20 8 21 8 21 8 22 8 22 8 24 8 24 8 25 Body 8 1 Body 8 2 8 1 Front Door Assembly 1 Front door hinge 12 Front door weather rubber strip 23 Front door window regulator 2 Front door check unit 13 Front door middle inner rubber strip 24 Lock core insert 3 Pin roll 14 Front door waterproof film 25 Front lower guide rail of front door 4 Front door middle rubber strip 15 Interior trimming panel of front door 26 Front door lock core 5 Front door welding assembly 16 Angle trimming panel of front door 2T Inner lock button 6 Cushioning rubber plug 17 Right switch on automatic regulator 28 Front door buckle T Front door glass 18 Left switch on automatic regulator 29 Front door lock mains Rubber strip of front door glass 19 Interior panel of front door 30 Front door inner handle t Plastic nut 20 Rubber strip of front door rim 31 Front door lock outer handle 10 Glass channel 21 Automatic window regulator of front door 11 Rear lower quide rail of front door 272 Front door regulator handle 8 1 1 Disassembly and Assembly of Front Door Lock Disassembly 1 Lift up window glass to limit 2 Take off the regulator handle of front door window Remove the door inner handle cover Remove the door handle Remove the door decorative subassemblies and clamps Take off the waterproof film Take off th
3. 5 8 5 4 3 Mai te ance GUIdE Me 5 9 5 5 PFONT VWVNGGCl BRAK C me M Q 5 10 5 5 1 SDECINIC ALON S esrrsieseieetecnesetecestecscetiees tiered dereetneee AE Aa 5 10 5 5 2 BUS a eA 155m iiem een eae eee ect ews a acess a S CM 5 10 5 5 3 Maintenance GUIG E cH 5 10 5 6 Rear WHEE B aKO Me 5 17 5 6 1 DPECIIC ALI ONS oeoeir ieee te TR 5 17 5 6 2 Rear Brake with Clearance Self adjusting Device 5 17 5 6 3 Maintenance ClP o M 5 17 5691 Brake FUN iR 5 17 5 6 3 2 Brake Shoe Parking Brake Lever and Clearance Self adjusting Device 5 19 5 6 3 3 Rear wheel Brake Cylinder Assembly 1 eLeeeee eee eese eene e nennen nnns 5 20 5 6 3 4 Rear brake Soleplate Welding Assembly c cceeeeee e rreeeeee re 5 22 5 6 3 5 Rear brake Clearance Adjustment e lleeeee eee Leeee erre eeeee nennen nnn nnt 5 22 5 7 Parking Brake Control Device 1 ecce Leere eee rennes 5 23 5 8 x lli APIEC Weri fe c 5 25 5 8 1 Inspection Table for Brake System e cieeeee eee eeeeee nne e nennen nnn n nhan nnn 5 25 5 8 2 Failure Diagnosis Table of Brake System ccce esee 5
4. Left right seat belt outer cover Left right seat belt subassembly Seat belt buckle 9 1 2 Maintenance Guide Attention A full set of seat belt should be replaced if its belt retractor or lock buckle subassembly is damaged even a little by which ensure the safety performance of seat belts Replace seat belt The seat belt must be replaced when crashed violently or damaged a component Please play attention to the following 1 2 3 4 5 6 7 Ensure that the seat belt retractors tongues and buckles are in working order Keep the fabric belt in good condition do not use a gapped or damaged one Keep away from sharp edge or things which may damage the seat belt Keep off chemicals or other medicaments which may contaminate fabric belts Use a torque spanner to screw down the set bolts of seat belt as per specified torque of 36 40N m Do not have seat fabric belt twisted or tied Always keep fabric belts dry and clean Chapter 10 Complete Vehicle Electrical 10 1 Chapter 10 Complete Vehicle Electrical Contents 10 1 Automotive Power System vissecasestiscesicdecstcawudetinceciemsvoreusnabicensteees 10 2 10 1 1 Power Battery PacK aioevEesersic EU a e ceed d PRIN IE Dea DE REI IU DEDE CuEE 10 2 10 1 2 DIOFAGE BAtlely ee E 10 5 10 1 3 DC DC CONVENT CN dH e 10 6 10 1 4 Charging GEnGralol isscessesecensarcvasassacensabsusdiwidecunsancnessued teaxewnrdsstadsedceeateed 10 9 10 2 reign 10 11 10
5. C OA Roco n2 170 220 Nm 24 29 Nm 35 40 Nm 65 70 Nm Power Train 4 10 4 3 5 Maintenance Guide Disassembly 1 Let out the gear oil from rear axle assembly 2 Remove the drive shaft from the position used to connect the flange 8 Pull out the half rear axle of right side and left side about 70mm as per the methods of half rear axle disassembly 4 Remove the reducer from rear axle housing Check before disassembly Check that every gear have defects of gear broken cracks surface flaking off and serious deep pockmarks etc were this to happen replace them The driving bevel gear and driven bevel gear should be replaced in pairs Check the bearing and bearing hole that used to install bearing Replace them if they are damaged or abraded seriously Check on reduction gear pair side play Make the contact of dial indicator contact the proper position of the convex surface of driven bevel gear big end Fix the driving bevel gear and then make a reciprocating rotation on driven bevel gear to measure the gear pair side play Check on the end surface run out of driven bevel gear Lay the contact of dial indicator on the back of driven bevel gear and rotate the gear to measure the run out around the whole gear Check on the side play of differential gear pair A wooden chock is wedged between one planetary gear and one half rear axle gear so as to fix the gear pair not to rotate Put the c
6. F C Temperature S n x Frequency OAny condition Road DAt any time aSometimes times day month aJust 1 time oln special conditions oCity area Da Out of city poExpressway Mountain areas nupslope o Down slope oBituminous macadam oOMacadam oOthers Vehicle conditions Vehicle oRunning o Constant speed oWhen accelerating GDecelerating conditions o Turning right moment oTurning left moment oParking moment oDriving speed km h miles h when trouble arises Others Troubleshooting code First check oNo code pnNormal code oFault code Second check oNo code pnNormal code n Fault code Note The above form is for reference only which may be revised according to the special conditions in different areas if necessary Basic Information 1 3 1 1 2 Vehicle Identification Number VIN VIN is stamped on the frame under the right seat of 1 2 Brake Fluid Lubricating Oil and Fluid Sealant Items Recommended specifications Volume L Gearbox oL General area D 4 75W90 Northeast or northwest China Pearaxia m 80W90 Northeast or Lubricating northwest China 5 Oil 85W90 North China driving cab TEEC HZY3 automobile brake fluid Brake fluid HZY3 degree or DOT 3 degree One vehicle identification plate is riveted on the above Brake Cylinder grease surface of dashboard on the left VIN is indicated Chongqing Yiping 7503 on it Chongqing Yiping 7022 2 viscosity Q SHYPO2 017Z 2000
7. Specifications Rated power 400 500W Functional Description Control the operation of warming machine through defog defrost switch on instrument panel to realize the function of defogging and defrosting Inspection and Repair Power battery 72v qx ATE Td hitachine OC contactor Heater of Waning machine I of Start bate ny 124 ABE s GE d e Ignition switch Defrost Detog ACC Gear Surtch Complete Vehicle Electrical 10 19 1 Measure the resistance of two units of outlet terminals of warming machine one unit is fan and the other unit is heater with multimeter and judge the damage of warming machine 2 Inspect whether the fuse on circuit is damaged if damage please replace 3 Inspect the contactor and relay if damage please replace 4 Inspect whether the circuit has failure such as broken line short circuit etc 10 6 Direction Select Switch Direction select switch is three way rotary switch for the selection of vehicle driving direction In which F represents the direction of advance R represents the backing direction and N represents neutral gear NI E Warning Before the vehicle start the direction select switch should be placed on N gear otherwise result in no start of vehicle Warning During the course of vehicle run do not change the gear of direction select switch you should change after the vehicle stops stably Inspection
8. 1 Anaerobic adhesive GY340 2 Baideadhesive 3 Glue1201 4 HZ 1RTv sealant oil and grease resistant 5 1406 screw fastening adhesive Chassis grease Servicing materials Attention Do not mix two kinds of brake fluid 1 3 Tire pressure 1 1 3 Nameplate Tire pressure cold conditions Nameplate is riveted on the center pillar on the left of driving cab The information contained in the nameplate varies with different vehicle type PSI kPa 29 200 29 200 Attention After the tire being inflated take the four holes of assembly bolt as location centre to test the balance on a dynamic balancer The unbalance degree should not exceed 10g Otherwise always attach adequate counterbalance onto the two sides of wheel rims Basic Information 1 4 Oil seal 1 4 Notices to Vehicle maintenance and Liner Repair ce preso 1 4 1 Notices before Inspection and Repair Locking washer Security Split pin Lock nut Before maintaining the high tension parts of the motor motor controller power battery and DC DC Guard belt and retaining ring conversion the cable of the power battery must be Have to replace with new parts disconnected Before checking and repairing the high tension circuit the cable of the power battery must be disconnected Protecting Components Concerned Since some parts may be damaged or stained during the check and repair always take relevant measures for p
9. 2 Disassemble brake shoe parking brake lever and clearance self adjusting device according to the above mentioned steps 3 Loosen the brake oil pipe joint and plug up oil outlet 4 Disassemble the bolt of brake cylinder and take off wheel cylinder 5 Disassemble the bleed screw 6 Take off the dust guard 7 Draw out piston from cylinder block 8 Take off cup ring from piston Checking 1 Measure the clearance between piston and cylinder block when the clearance exceeds the limit value which will result in bad seal of wheel cylinder and arouse leakage so always replace it limit value lt 0 15mm 2 Hairlike grinding crack is allowed on piston and cylinder block but obvious nick will enlarge the abrasion of cup ring of brake cylinder or directly scratch the cup ring which will result in leakage of wheel cylinder so always replace it in time 3 Inspect whether the dust guard is good or not and replace it if any crackle 4 Always replace the cup ring of brake cylinder once disassembled Brake System 5 20 Rear brake soleplate welding assembly D oo Cil pipe connection B Tightening bolt of cylinder A A 13 17N m B 8 I2N m Rear brake soleplate bolt Torque 45 60N m Tightening bolt of cylinder Oil pipe connection Attention e Leakage of any brake fluid badly influences the performance of brake so always repair it at once e Do not dip any brake fluid and other liquid or sund
10. 2 3 cycles on the purpose of locating the bearing well Loose the nut until the finger can dial it slightly and then fasten it again to a torque of 5 N m 5 Assemble the brake caliper assembly and fasten the brake caliper fastening bolt by the specified torque Fastening torque value b brake caliper fastening bolt 75 95 N m 6 After fastening the nut insert the split pin for the purpose of locking 7 Assemble the inner cover of front wheel hub 8 Assemble the wheel well and remove the jack Suspension Wheel and Tire 3 11 Assemble bearing outer ring m oil seal and brake puck T 55 5N m OS rom ON Front suspension components assembly 13 Front shock absorber and coil spring disassembly 3 2 3 2 Front Shock Absorber and Coil Spring Assembly Disassembly 1 Jack up the vehicle from the earth reliably 2 Take off the front wheel steering tie rod and lower swing arm 3 Separate the brake hose and shock absorber by taking off the Jump ring of hose joint as shown in the figure 4 Take off the bolt for wiring hardness nip of wheel rotating speed sensor from the shock absorber if it is provided 5 Take off the bolt on the connecting between the steering knuckle and front shock absorber as shown in the figure Suspension Wheel and Tire 3 12 Dust guard Nut M12x1 25 8g Washer 12 Front suspension support assembly Plane bearing Fr
11. 50 60 N m Lock nut steering Ball joint rack A 20080514 11 Assemble the expansion sleeve 12 Assemble a new tightening hoop tape 13 Assemble a new spring hoop 14 Assemble a new plinth assembly opecified torque 32 48 N m Attention v Connect the tie rod end to the steering rack as Alignment mark per alignment mark 20080514 Steering System 2 15 20080514 1 Rubber boot of steering gear 2 Mounting bracket of steering gear 3 Plinth assembly of tie rod 4 Lower driving shaft assembly 5 Flexible connection assembly 6 Steering bevel pinion assembly 7 Spline joint 8 Rubber sleeve assembly 2 4 Front Wheels Alignment Parameters 2 4 1 Front wheels Alignment Parameters of D150 Equipped with B12 Engine Camber angle 30 30 Caster angle 2 45 3 mm 2mmH15 10 Kingpin inclination angle 14 20 1 Steering System 2 16 2 4 2 D150 Equipped with Engine Manufactured by Liuzhou Wuling Liuji PowerCo Ltd Camber angle Caster angle 2 42 1 Kingpin inclination angle 14 20 1 2 4 3 Tire Pressure Tire Model Type le Cees Full Load kpa 175R13LT Check on wheel radial and lateral run out Radial run out Not more than 0 8mm Lateral run out Not more than 1 0mm 2 4 4 Check on Clearance 1 Jack up the vehicle and push or pull each wheel alternately so as to make sure tires installation and clearance are mounted in the defined scale 2 If the wheel clearance is o
12. Attention e When removing the brake pads always observe the brake caliper to check if the brake fluid leaks If leaking always repair it Guide Bar Locating Rod Check that locating rod moves flatly and smoothly as shown in the figure If finding any damage repair and replacement should be carried out Apply grease on the outer surface of guide bar and locating rod Dust Guard C I5 CII Apply grease on A Check if there are quality problems such as crack Brake Disc Check the scratches of the surface of brake disc and the friction parts Check the brake disc periodically it is normal phenomenon when there are slight scratches on the brake disc However if the scratches are too deep or high the brake disc should be replaced If scratches are only at one side of the brake disc always repair this position by polishing Thickness of brake disc Standard value 13 0mm Ultimate value 11 0mm Fix the brake disc with wheel nuts and then install a dial indicator measure the oscillating quantity of the brake disc as shown in the figure Choose two points at the circle and centre of the brake disc and then rotate the brake disc measure the oscillating quantity of the brake disc with the dial indicator Ultimate value for oscillating quantity of brake disc 0 10 mm Attention e Before measuring always check that the hub become loose Installation 1 Install the noise reduction panel in the brake pads and
13. Front suspension components assembly 11 Bolt Disassembly 1 Jack up the vehicle reliably 2 Take off the front wheel 3 Loosen off nut 5 on the connecting between swing arm assembly and knighthead bracket welded assembly and take off the cushion 4 and front bumper block 2 4 loosen off bolt 11 and nut 12 on the connecting between swing arm and knuckle 5 loosen off bolt 9 and washer 8 on the connecting between swing arm and front axle assembly 6 Take off the swing arm and rear bumper block 2 7 Take off axle sleeve assembly of swing arm 8 loosen off bolt 3 4 pcs on the connecting between knighthead bracket welded assembly and frame 9 Take off knighthead bracket Take off the axle sleeve assembly of swing arm with a special tool as shown in the figure Special Tool A Dismounting device Assembly 1 assemble the axle sleeve assembly of swing arm by using a dismounting device Attention Before assembling coat the suds onto axle sleeve assembly of swing arm for lubrication Refer to the figure of Front Suspension Components Assembly Swing Arm Components Suspension Wheel and Tire 3 16 Disassembly when assembling 2 Assemble knighthead bracket welded assembly onto the front frame Tightening torque value of bolt 3 68 6 78 4 N m 3 Assemble bumper block 2 onto the knighthead of swing arm assembly firstly assemble another bumper block 2 and cushion 4 secondly and tighte
14. Input voltage v 90 260 AC Charger AC DC Max input electric current A 12 Max charging time h 12 The rated electric current of fuse 300 Safety control system Cutout A The rated electric current of contactor A 100 Basic Information 1 14 1 6 Regular Check Service and Maintenance Regular check service and maintenances refer to the check service and maintenances you should perform at a regular interval of time or driving mileage To maintain a proper functioning of your vehicle and to ensure the passengers safetyand comfort it is highly recommended that you should perform the regular maintenance as per the following schedule 1 6 1 Regular Check Service and Maintenances Please refer to the Form below X Under hostile conditions such as in the dusty area replace all parts at a shorter interval or clean all parts more frequent 2000 5000 10000 20000 30000 40000 E es Propeller shaft check Propeller shaft check check Wheel nut tightness As per the specified torque Check on Front wheel hub NET pre tightening lubricate ee ee ee Rubber cushion for the connections of steering axle and steering gear ball joint of tie rod and link rod the wear or rubber aging of steering swing arm engaging clearance of steering rack and pinion Check adjust and replace Check the braking line Check adjust and lubricate the parking brake and brake pedal check and adjust the free travel of brake pe
15. V and W phases of motor is not rotate normally examine current correct or not meter current value is supranormal Inspect whether the coded disc connection is good or not examine controller without failure Problem on vehicle driving system information Release hand brake if not releasing hand brake If motor bearing seizure replace motor bearing 3 Difficult rotation after starting motor If the bearing seizure of retarder replace the bearing of retarder If the coded disc signal is disturbed change the wiring direction of coded disc wire If overload drive reduce load If the accelerator damages replace accelerator 10 4 Multi function Display SEBE H 1 1 eS a A Ii n LJ Panel Description 1 Display screen The display screen shows the power battery s capacity current discharge power and 12V start battery voltage D Capacity Show residual capacity of power battery with two digits such as 01 02 03 10 in which 01 means 1096 residual capacity 02 means 20 residual capacity 03 means 30 residual Capacity and 10 means 100 residual capacity i e full load 2 Power Show power battery as accumulation value unit Kwh with 6 integral digits show page after page set digit and reset digit by serial interface 3 Current Show the discharge current value of power battery unit A with 4 digits including 3 integrals and 1 decimal 4 Voltage Show 12V
16. damage If there are any problems of dust guard always replace it in time Seal Ring Both heavy and uneven abrasions to brake pads are likely to reflect uneven piston return Under the circumstances seal rings should be replaced Attention e Once seal rings are removed new ones must be replaced Brake System 5 13 Jump ring of dust guard 1 Cotton yarn 1 Seal ring 2 Dust guard Assembly Reassemble the brake caliper according to the sequence contrary to the disassembly The following points should be adverted Caution e Before installation clean each of parts with brake fluid e Do not allow to use other fluid or diluent e Before installing piston and seal rings in the brake caliper apply brake fluid on the piston and the seal rings e After assembling the brake hoses again bleeding should be carried out 1 Install the seal ring into the seal groove of brake caliper take care never to make it twist 2 Before insetting the brake caliper into the piston install the dust guard in the piston as shown in the figure 3 Install the dust guard press the dust guard into the groove of brake caliper with hands 4 Inset the piston into the brake caliper with hands install the dust guard in the groove of the piston dust guard 5 In order to make sure the dust guard can be installed in the groove of brake caliper correctly the piston should be pulled out a little from the inne
17. tooth surface 2 Bending Excessive clearance of ball joints Breakage or Pinion 1 Abrasion or breakage of tooth surface 2 Crack on tooth end Tooth point end tooth Guiding sleeve 9M9 abrasion Crack breakage and aging 1 Mount the steering gear onto the jaw vice Avoid damaging of steering housing 20080514 2 Alignment mark on the joint ends of tie rod and steering 2 nmnu m1 J Distinguish between the left and right end f Alignment mark 20080514 Steering System 2 8 Lock nut Ball joint Remove the rubber bushing Steering rack Disassemble the tie rod plinth assembly Disassemble the self tightening spring Disassemble tightening hoop tape Remove expansion rubber sleeve Disassemble the tie rod ball joint assembly COND OF BW 20080514 9 Install the tie rod ball joint assembly in jaw vice to take off lock nut Lock nut 20080514 10 Adjust the plug screw lock nut Lock nut 20080514 Steering System 2 9 11 Unscrew adjusting plug screw 1 Unscrew adjusting plug screw 2 Take off adjusting spring and block 12 Take off steering rack Pull the rack out of housing from side as shown in the figure to avoid damaging rack guide bushing Do not rotate the rack and keep it flat and straight when pulling it out 20080514 13 Dismantle oil seal with a screwdriver Particular attention should be paid not to damaging steering housing
18. windshield are Adhesive 400ml Glass primer 10ml Vehicle body primer 10ml Awl Steel wire Brushes for brushing primer two Knife Rubber sucking disc Glue gun injected with adhesive Putty scraper Scrape off viscous liquid Body 8 8 8 2 1 Disassembly 1 Clean the edge internal and external sides of windshield 2 Remove the wiper hose 3 Cover the surface of vehicle body around the windshield with adhesive tape to avoid any damage 4 Remove rearview mirror sun shield and front pillar decorative subassembly and then take off windshield strips from R L front pillars 5 Cut off all strips around the windshield to show windshield edges 6 Scrape off all adhesive around the windshield for example if scrape off all adhesive with steel wires refer to the step 8 and 9 7 Have steel wire thread through the hole on adhesive drilled by a awl 8 Scrape off the adhesives on the glass Attention e When using steel wire approach the glass as much as possible to avoid damaging the vehicle body 1 Steel wire 2 Windshield 3 Rubber strips 4 Adhesive 08AD1103004 9 Smoothly scrape off remained adhesive on the vehicle body next to windshield The inserting depth of knife shall be 1 2mm Attention e Before scraping clean the knife with ethanol or use similar method to eliminate grease dirt 10 Before reuse the removed windshield remove all the strips and adhesive on
19. 10 9 1 Fuse Total fuse Inspect whether there is blowout with multimeter If blowout which shows that the circuit has problem Before changing total fuse make sure to find reasons and repair Warning If you change total fuse make sure to use the total fuse with the same specifications for preventing the damage of vehicle or fire Fuse block Inspect whether the fuse socket is loosened or the fuse in the fuse holder is firm Inspect whether the capacity of fuse piece on each circuit is correct Inspect whether the fuse piece is burnt out If burnt out firstly find out reason for repairing and then replace Make sure to use the fuse piece with stipulated capacity when changing fuse piece Fuse Box S tom Complete Vehicle Electrical 10 23 Under the driving seat 15A 12V per Piece for Fuse Specifications Wiper intermittent Flash apparatus relay 1 Combination instrument 2 Blank 3 Blank 4 Cigar lighter Radio amp cassette player Warming machine control 12V battery charging relay 5 Blank 6 Rain blade Turn signal 7 Lamplet Residential light Horn 8 Dangerous power supply Complete Vehicle Electrical 10 24 10 9 2 Combination Instrument 61 Sr DN p j Jf i 1 Tapping bolt ST4 8 19 7 99 2 Assembly of Combination Instrument 10 9 3 Lightening System Lightening system includes head lamp front blinker rear co
20. 3 MOTOL mc R 10 14 10 4 Multi function Display ues 10 16 10 5 Warming Brem c A ERNE ox 10 18 10 6 Direction Select Switch euseeeseenueeIIS 10 19 10 7 Emergency Cut off Switch eeeeeee eese 10 19 10 8 Safety Device of Power for Vehicles 10 20 10 8 1 Large Fork bolE FUSe idee tea esu euet cuo te di uude eoi ee weise iss DM a 10 20 10 8 2 rael 10 20 10 9 Lighting Device and Auxiliary Equipment of Meter Switch 10 22 10 9 1 gif 10 23 10 9 2 Combination InsIFUmehl xx seeeriteluhivbs tex M un ERU EUER DM EEIEFEPeSSiMR RS RR Ke 10 24 10 9 3 T fe jati nfo SYSTEM arreir EDD LCD 10 24 10 9 4 IGNITION SWING eee ern 10 29 10 9 5 Combination SWIHCD is orust e e Cesena ondes n aaa 10 29 10 9 6 Windshield Wiper and Syringe esee eee ee ene 10 31 10 9 7 Steering Wheel and POET o corii ce o trait n Date i abe Vd neg avec Ea eee athens des bas 10 31 10 9 8 Radio amp Cassette PIayGE ise ote ou eenpis at ux uu n Qurtive uentus se A ode SDN KE EED MN D DOE USE 10 32 10 10 Circuit DIagramiuesi o uesie vede s Usus ev a ENS Mie OE USaPE2do Hd 10 33 10 10 1 Structural Arrangement Diagram for Complete Vehicle Wiring 10 35 10 10 2 Schematic Diagram for Complete
21. 4 Rear suspension plate 6 Bolt assembly M10x1 25x25 55 60 ne 8 NtM8 25 30 a emm bracket welded assembly 10 Suspension soft pad assembly P Forward mounting welded a 11 assembly of electric motor Rear support glued laminated 12 member d 6 2 3 Maintenance Guide When periodic maintenance always check the parts for suspension system assembly of electric motor and transmission according to the following methods Check the forward mounting welded assembly of electric motor and the electric motor mounting bracket if they are cracks and contortions do not use them and replace them with new ones Check each connecting piece for bolts tighten them if they become loose Besides replace them with new ones if they are incapable of tightening Dynamical System 6 3 Suspension System of Electric Motor and Transmission Accelerator Assembly and Transmission Assembly 7 1 Chapter 7 Accelerator Assembly and Transmission Assembly Contents 7 1 Accelerator Assembly eee esee eere eee 7 2 7 2 GEA X COM UO le ORDER DEL 7 3 Accelerator Assembly and Transmission Assembly 7 2 7 1 Accelerator Assembly 1 Accelerator pedal module 5 Return spring 2 Bolt assembly MB x 1b p Acceleration transducer assembly 3 Accelerator cable assembly 7 Bolt Assembly hi x 45 4 Jump ring Maintenance Guide e Check that the wire ropes if they are
22. 8 18 8 5 Front Bumper 8 5 1 Disassembly Disassemble as sequence numbers as shown in the following figure 08AD1107001 8 5 2 Tips Tips for disassembling front bumper Front decorative panel ocrew off the four claspers inside the cab to disassemble and then may remove the front decorative sheet Front decorative panel 08AD1107002 Body 8 19 8 5 3 Assembly Assemble as sequence numbers as shown in the figure Body 8 20 8 6 Instrument Panel Components of Instrument Panel 1 Meters Shield subassembly 2 Combined meters 3 Medium decorative sheet subassembly 4 Glove box 5 IP holes cover 6 Instrument panel 7 Tuyere subassembly of mid amp side IP 8 Oil can cover 8 6 1 Disassembly 1 Disassemble electrode of storage battery 2 Disassemble steering wheel 3 Disassemble as per sequence numbers shown above 8 6 2 Assembly Assemble all components according sequence numbers shown as below 1 Oil can cover 2 Tuyere subassembly of mid amp side IP 3 Instrument Panel 4 P holes cover 5 Glove box 6 Medium decorative sheet subassembly 7 Combined meters 8 Meters Shield subassembly Body 8 21 Body 8 22 8 7 Fuel Filler Gate Subassembly 1 Fuel filler cap welded assembly 2 Bolts assembly 3 Fuel tank locker 4 Rubber buffer 8 8 Front Wall Angle Cover Disassemble as per sequence numbers as shown below ii i l 1 i 4 T AE i i i 1 i I i i a Front turn
23. This Manual 1 This Manual s catalogue consists of general catalogue and chapter catalogue The chapter catalogue is listed in the first page of various chapters And the chapter name and chapter page are marked in the header for each page 2 Please read basic information of Chapter 1 firstly when reading and using this Manual 3 For avoidance of improper operation Warning is used for special prompt of danger to vehicles and personal safety and Attention for prompt of light hazard and harm Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Chapter 9 Chapter 10 General Catalogue Basic INTORMAUON e 1 1 Steering S VSTE Miiri a 2 1 Suspension Wheel and Tire 3 1 POWO E Vi e m 4 1 Brake SySIUeI rines tse escec eim aa ioco iecore t escolar ree 5 1 Dynamical SySIelnia uiii ipei Er Re Eee EE IR EDI sioe crest E EeRis E ERES 6 1 Accelerator Assembly and Transmission Assembly 7 1 jsp jm 8 1 PrOtECUON UNIS sssri 9 1 Complete Vehicle Electrical 10 1 1 1 1 1 2 1 1 3 1 2 1 3 1 4 1 4 1 1 4 2 1 4 3 1 4 4 1 4 4 1 1 4 4 2 1 4 4 3 1 4 4 4 1 5 1 5 1 1 5 2 1 5 3 1 6 1 6 1 Chapter 1 Basic Information Contents General INfOrMatION 0c0ccecceccenccnccnncenceuscesnenene
24. Vehicle Electrical Arrangement 10 35 10 1 Automotive Power System Automotive power system consists of power battery pack auxiliary battery DC DC converter and charger Power battery pack provides power for vehicle operation DC DC converter provides power for in vehicle 12V apparatus and auxiliary battery during vehicle operation and DC DC converter charges auxiliary battery during vehicle stop to charge When DC DC converter stops output because of failure or the output of DC DC converter can not meet the demand of in vehicle 12V apparatus auxiliary battery will provide power for in vehicle 12V apparatus Charger charges power battery pack 10 1 1 Power Battery Pack Specifications Model Valve regulated sealed lead acid battery Capacity C 115A h Single battery voltage 12V Voltage for battery pack 72V Operational Safety and Precautions e Operators should be trained or work under the guidance of professionals e During charging prohibit any naked flame near battery for preventing self igniting combustible gas in the air e The charging workshop of battery should keep good ventilation in favor of the diffusion of combustible gas Chapter 10 Complete Vehicle Electrical 10 2 Attention The tightening torque for battery interconnecting cables is 20 1Nm At the beginning of use the battery s open circuit voltage difference is big but with the use of battery the voltage between monom
25. and Repair Main contactor pulls in multi function display shows E 09 code place the ignition switch to OFF gear unplug plug in connections of the direction select switch start again if the wrong code continues appearing inspect amp repair or replace the service brake switch if wrong code disappears replace the direction select switch 10 7 Emergency Cut off Switch Y m Emergency Power Off Complete Vehicle Electrical 10 20 Emergency cut off switch is the main power switch of power circuit if emergency status happens or there is need to cut off the main power press the switch according to the direction of the above drawing see the electric schematic diagram for details cut off the power supply of power circuit 10 8 Safety Device of Power for Vehicles The safety device of power for vehicle includes large fork bolt fuse and main contactor for electricity protection of high voltage power circuit 10 8 1 Large Fork bolt Fuse Specifications Rated Current 300A Warning Functional Description T Power circuit may have the high For over current protection of high voltage power voltage which can harm people creuit you should cut off the connection of power battery when inspecting Inspection and Repair and changing large fork bolt fuse After the vehicle is started low voltage circuit of for avoiding personal harm vehicle is normal but high voltage power circuit has no reflectio
26. by battery passes controller and then is translated to three phase AC power suply which will be supplied to motor and then translated to mechanical energy drive the vehicle directly or through transmission case Complete Vehicle Electrical 10 14 Warning Motor circuit possibly has the high voltage which can harm people please firstly cut off the battery connection wire before disassembling and assembling motor Prohibit immersing motor with water Prohibit washing motor with water Complete Vehicle Electrical 10 15 The frequency of power supply output by controller can be continuously changed so the rotating speed of motor also can be stepless adjustment and the highest rotating speed can not exceed 5800rpm Motor Maintenance For guaranteeing heat dissipation effect of motor regularly clear away the dust and pollutants of the exterior of controller Motor Inspection and Maintenance Failure Content Analysis for Reason amp Corrective amp Preventive Measures 1 Insulation resistance of motor less 1 Remove motor from vehicle and examine than2 MQ Dry motor and inspect insulation resistance Motor damp If the change of insulation resistance of motor is not big Internal insulation material ageing of after drying it s possible that the internal insulation material motor of motor is aged replace motor Wrong motor connection 2 Motor twitters near zero speed and can Inspect whether the order of U
27. concerns can be showed per free run out value of tire wheel measure It is necessary to find out the three reasons that cause vehicle swing per tire problem check device TPD such as run out when loaded If tire problem check device can not be available just replace with good tire assembly but that may waste so much time to finish it Suspension move run out when loaded Reasons a oe t wami PU Smooth road Suspension Wheel and Tire 3 2 Limitation Radius run out 2 5mm Lateral run out 2 5mm ere Sree bd ee oe m Tire out of round Poor wheel stiffness Rim bend or out of round 4 Suspension Wheel and Tire 3 25 3 5 Failure Diagnosis 3 5 1 Check Table of Breakdown Maintenance Methods Tires are not matching Replacement Adjust the tire pressure to the Improper tire pressure vA specified value Spring broken or shorten due to plastic deformation The uniformity change of lateral stiffness of radial tire exceeds its limitation One tire moves with braking Repair the brake The suspension components of front or rear get Fasten or replace the suspension loosing bending and broken components Spring broken or shorten due to plastic Bedlacemefl deformation p Tires imbalance exceeds their limitation Adjustment Slip value of tire exceeds the tolerance limit Check and adjust the
28. door with a piece of cloth as shown in the figure 4 Take off the front door handle 1 Cloth strip 2 Rocking handle 08AD1101006 5 Unscrew the bolts and then take off the inner handle cover by sliding dead ahead on the interior trimming panel 6 Remove the front door decorative panel subassembly and clamps 7 Remove the waterproof film of door 08AD1101007 8 Screw off the setscrew of front glass channel 9 Take off the front window glass 10 Take off the glass channel 1 Front window glass KO 2 Front window 4 rubber strips 3 Front door channel lower rear 4 Window regulator 08AD1101008 11 Screw off the five setscrews on glass regulator and then take off the glass regulator through hole A 1 Mounting screws 2 Front window regulator assembly Body 8 5 Checking e Check the lubrication status of sliding and rotating parts of glass regulation e Check if the glass regulator pinion is abraded or damaged Installation Install the front window glass and regulator according to a reverse step of the disassembly but notice that e Whether the top of glass touches the inner of guide rail in front door window glass evenly and Lubricating point of window the glass fluently slides up and down when requlator installing the grass And then fix it with screws e Whether the glass regulator handle is at a 30 degree angle when the window glass is lifted up completely t
29. drum If it is hard to disassemble the brake drum screw a bolt M8x1 25 into the spare bolt hole to push out the brake drum Remove the tightening bolt of brake Pull out the half rear axle assembly If it is hard to do that use a special tool of sliding hammer Check before half rear axle assembly disassembly Check the half rear axle if bending happens to half rear axle proceed a cold pressing by a press machine to adjust it Its ultimate value allowance of the flexural Power Train 4 8 modulus is not more than 0 8mm Check that the half rear axle splines are serious abrasion or cracks or the cracks occur on other places just replace them Check the installation site of oil seal on the adapter sleeve external diameter if it appears a obvious groove or serious abrasion that may affect the performance of seal If so replace the adapter sleeve and oil seal Replace the rear axle housing if it gets bending deformed and broken after checking Half rear axle assembly disassembly Use a grinder to polish the adapter sleeve of bearing to a thickness of 1 1 5mm and cut it down by a chisel Pull out the bearing with a special tool Install the bearing cover half rear axle gaskets bearings and adapter sleeve in the half rear axle as shown in the figure Use a press machine with a initial pressure 29 kN or 29 kN above and a final pressure 58 kN or 58 kN above to press the adapter sleeve to
30. dust caps on the air bleed screws 4 Fill with brake fluid up to the specified position 5 Carry out brake test check that the installation parts leak Brake System 5 9 Attention e Apply recommendable Zhangjiagang Teec Brake Fluid if different brake fluid mix brake fluid will appear delamination and low boiling point so that its braking ability is influenced e Storage of brake fluid should be sealed and covered tightly e Always replenish brake fluid with the same specifications 1 Jump ring Correct Wrong 2 Retainer ring 3 Hose Brake System 5 10 5 5 Front Wheel Brake 5 5 1 Specifications Type Disc brake External diameter of brake disc mm 237 Internal diameter of brake disc mm 138 Thickness of brake disc mm 13 Thickness of friction block mm 15 Internal diameter of front brake wheel cylinder mm 50 8 1 Left brake caliper M assembly Sh em A g Dust guard l 2 Front wheel brake id y YY piston 3 Seal ring Supporting frame Locating rod 4 Dust guard of Front Ho t AH 4 L Az wheel brake piston N S AV ver RT NE Whe Gasket of brake pad I 5 Jump ring of dust 7 o VY LB uui NS Gasket of brake pad II guard X L Zt UIR holt 6 Noise reduction Bolt piece 7 Brake pad Es 5 N 8 Guide bar k X Be Sy n Dr dh A 21 Brake disc Washer 12 9 Dust guard Il X 3 Hl 2 22 Dust excluding plate 10
31. it 8 2 2 Assembly 1 At the position that adheres to the windshield remove and clean remained adhesive on the adhesive interfaced area of vehicle body or on the edge of windshield Expose it at least10 minutes 2 Fully clean the old adhered surface paint and bare metal Carefully brush the primer on the surface of paint or bare metal surface Never brush the primer on the adhesive remained on the vehicle body Attention e Comply to correct steps on instructions provided by primer manufacturer And have them dried in required time e Do not have primer touched with old adhesive surface to which the vehicle body and glass will adhere Body 8 9 1 Adhesive 2 Primer 08D 1103006 1 Knife 2 Adhesive 3 Vehicle Body 08AD1103005 Coat primer Primer S Old adhesive Uncoated of primer _ B ia ADT Body 8 10 3 Embed the glass into new trim strips which must be preheated for half an hour under 35 C 95 T 4 Clean all adhesive on the glass with a piece of clean cloth if cleaning solution is used have it exposed in the air for more than 10 minutes 5 Insert windshield internal strips into front windshield frame 1 Windshield external trim strips 2 Front windshield glass 3 Windshield internal trim strips 08AD1103008 6 Use a new brush to brush sufficient primer along the adhesive edge of glass Attention e Must comply to
32. meet the bearing Make sure the bearing has been pressed to the right position and met the bearing tightly around the edge of the adapter sleeve Replace the removed and used oil seal of half rear Power Train 4 9 axle in the inner of rear axle housing with a new one Apply appropriate amount of high performance lithium base lubrication on the mouth and the inner of groove of the oil seal The oil seal mouth should face inwards Apply semi dry seal gum on the end face of axle tube of half rear axle for rear axle housing and the contact face of brake base plate After installing the half rear axle assembly in the rear axle housing gradually fasten the nuts of set bolts for bearing cover up to the specified torque according to a diagonal order by divided into several times Tightening Torque 40 60 N m Install the braking oil pipe connection of brake If the rear axle has been disassembled assemble it as per the reverse order of disassembly 4 3 4 Speed Reducer Assembly Left bearing cower Adjusting shims Right bearing cover Sleeve gasket Adjusting shirt Bearing support Differential bearing Rear bearing Driven bevel gear Adjusting shimz Differential housing Driving bevel gear Cwindrical pin Planetary shaft Planetary gear 1 Spherical surface washer 11 Half rear axle gear 12 Adjusting shim 13 Washer 14 Connecting flange assy 15 Oil seal 15 Front bearing CD cO
33. of system if no failure information determine the fatigue damage of main contactor and replace main contactor Complete Vehicle Electrical 10 22 10 9 Lighting Device and Auxiliary Equipment of Meter Switch Specifications Horn Effective working voltage 9 14 5V Power consumption Less than 3 5A Voice voltage 100 115 dB Basic frequency 350 20 HZ Total Fuse Fuse section 1 25 mm Allowed continuous working current 33A Residential lamp 5W Instrument mark lamp 3 4W Flash Apparatus Flash time in each minute Turn signal 85x12 desidia Cassette Player Dangerous signal 85x12 xb crei SR Fuse Frequency modulation Capacity 15A FM 88 108MHZ Head lamp 60W 55 W Amplitude modulation Rear fog lamp 21 W AM 535 160KHZ Antenna Type Rod antenna Windshield Wiper Wiper motor Permanent Magnet Front Lamps Type Head lamp 60 55W Rotation speed without load Turn signal lamp 21 W High gear 70x10 r min Front position lamp 5 W Low gear 45 5 r min Side turn signal lamp 5W Clearance gear about 13 Length of wiping piece 400mm Loudhailer Rated power 4W Dimensional specification mm 100x100 Installation position Internal plate at left and right front door or instrument panel Rear Lamps Turn signal lamp 21W Service brake lamp tail lamp 21 W 5 W Backup light 21w License plate lamp 5W Syringe Electric power consumption Less than 3A Hydraulic pressure 88 kPa Kettle capacity 1 2 L
34. off the brake cylinder and remove the cotter pin and axis pin that connect with the brake pedal assembly and the rod fork and then screw off the nuts on the master cylinder mounting bracket welded assembly to take off the master cylinder mounting bracket welded assembly from the brake bracket 2 Disassemble the brake pedal according to the following sequence Nut 3 Washer Axis pin of pedal rod Brake pedal rod welded assembly Torsion spring of brake pedal rod Bushing Pedal slipcover Buffer rubber mat 3 Check and replace damaged parts 4 Apply appropriate amount of grease according to the position again as shown in the figure 5 Assemble the bracket assembly according to the sequence contrary to disassembly sequence Check 1 Check the height of brake pedal its standard value is 155 165mm if the requirements can not be met refer to Section 5 1 1 to adjust them 1 Check the free stroke of brake pedal the free stroke of brake pedal is 2 7 mm Refer to Section 5 1 2 to adjust exceeding the requirement prescribed them when Brake System 5 4 5 3 Brake Master Cylinder Assembly 5 3 1 Specifications Type Double series wound chambers Internal diameter 20 64mm 5 3 2 Master Cylinder Assembly Brake fluid reservoir is under the cover plate of the left side of the instrument board pay attention to filling the bottle with the brake fluid and keeping it between the graduations from top to bottom T The
35. signal assembly Bolt Front wall angle cover Rubber strips of front wall angle cover Body 8 23 Tips of Disasembly Take off the front turn signal assembly at first and then remove Bolt 1 and turn signal assembly 2 08AD1106006 Assemble as per sequence numbers as shown below Rubber strips of front wall angle cover Front wall angle cover Bolt Front turn signal assembly Attention Be careful not to clamp windshield rubber trips while installing Body 8 24 8 9 Seat 8 9 1 Front seat T Tightening torque Unit N m kgf m T 4 6 0 4 0 6 0 D Body 8 25 8 10 Cargo Cabin Tightening torque A J 8 dk CN A IN UP P A 13 1 Left right plate 6 Spacer 10 Rubber buffer 2 Rear plate Don 11 Support bracket 3 Platform floor 7 Latch hook 12 Support assembly 4 Rear floor cover 8 Handle 13 Guard board plate 9 Rubber plug 5 Tacher assembly Protection Units 9 1 Chapter 9 Protection Units Contents Ot SOA DOM celiciictccrseceeasaccaddacuninavawdadeitactacueawcauesguteadloadessuecuaucauagateadiadiwavetaus 9 2 9 71 41 Seal Bell ASSembIy eios a aches HeececanteceaaneeeeteccenSsirects aaa aaa riaa 9 2 9 1 2 Maintenance G lde 5 niis oi veu oes ce Evene eec even open a Du Ua coo co Cas See o Ee ooee v eee cope aaaea 9 2 Protection Units 9 2 9 1 Seat belt 9 1 Front seat belt 2 3 4 1 Seat Belt Assembly Dust box subassembly
36. the input shaft If there are defects in any parts of the above mentioned input shaft always replace them in time Check that the transmission extension housing and the bushing pressed into the extension housing are damaged measure the diametral clearance between the bushing and the universal joint splined shaft yoke of transmission shaft its normal clearance is 0 02 0 06 mm and its serviceability limit is 0 1mm If the clearance exceeds its serviceability limit it can make the splined shaft yoke rock in the bushing so that vibration of the transmission shaft is caused at that time not only the bushing must be replaced but also the extension housing pressed assembly Check that each bearing is worn were this to happen always replace it in time Installation The installation procedures of the transmission are contrary to its disassembly procedures All parts used in the installation of transmission must be cleaned Before installation apply machine oil of transmission on the parts with slide and friction surface inside the transmission Before the input shaft module and the output shaft module are installed in the lower box of transmission locating jump ring of bearing and dowel pin for box should be installed in the lower box of transmission firstly When assembling each shell of the transmission clean junction surface of each box at first apply a layer of sealant on the junction surface evenly after a few minutes fit e
37. then fit the gaskets of brake pads mount the brake pads on the supporting frame 2 Install the brake caliper tighten the guide bar according to the specified torque Attention e Dust guard should be installed in the designated position 3 Install the brake hoses in the supporting frame 4 Install the tires Brake System 5 12 1 Gasket of brake pad 2 Noise reduction piece 3 Brake disc 4 Supporting frame 1 Guide bar a 45N m Brake Caliper Assembly Disassembly 1 Disassembly the brake hoses and the brake caliper 2 Remove the jump ring of dust guard with a flat card tool 3 Take off the dust guard from the front wheel brake piston 4 Inject compressed air into the cavity of brake caliper through the bolt hole which is used for installing the brake hoses The piston is pushed out of the cavity under the air pressure Attention e Do not inject compressed air with very high pressure otherwise it can result in separation between the piston and the brake caliper Extrude the piston by blowing the medium pressure of compressed air slowly When using compressed air do not put your hand in the front of the piston 5 Remove the seal rings with thin cutter blade tools such as thickness gauge etc Caution e Take care never to damage the inner wall of the brake caliper cylinder Checking Dust Guard Check that the dust guard has breaches cracks and
38. time insert the cross axle to the inside of bearing pedestal rings to avoid roller pins dropping out of the bearing pedestal rings 2 Insert the bearing pedestal ring on the other side to the inner of tube yoke and knock it with a hammer until it flushes to the inner side face of Jump ring groove in tube yoke 3 Insert the bearing pedestal rings to the inner of flange yoke as per the methods in the process of 1 and 2 Attention Put a plate onto the bearing seat ring so as to avoid breaking the universal joint of axle yoke when insert the bearing seat ring 4 Fix a proper thick snap ring onto the yoke hole of the axle yoke and the flange yoke clearance is 0 0 06 mm 5 Fit the sliding yoke on the axle yoke of drive shaft with the above mentioned same method Assembly Assemble the drive shaft as per a reverse order of disassembly Tightening torque value for connecting Flange yoke as following Tightening Torque 35 40 N m Power Train 4 6 Attention The connecting flange yoke should be aligned with the matching marks when it is fixed on the rear axle Otherwise it can result in vibration when running Power Train 4 7 4 3 Rear Axle 4 3 1 Specifications Type of rear axle housing Integral press welding type Supporting mode of half rear axle semi floating type Size of half rear axle internal dia x external dia xwidth mm 3207A 2RS 35x72x27 Speed reducer Type of gear hypoid gear Gl
39. toe in Front shock absorber failure Replacement e Running Replace the spring deviation of the tire Replace the tire Overload of the vehicle MESS S c S No transposition of the tire Transposition Wheel bearing is so over abraded that becomes loosi Replacement oosing Insufficient or over high tire pressure Adjust the tire pressure to the specified value Wheel wobble lateral or radial Replacement Wheel bearing has been abraded Replace the wheel bearing Spring broken or shorten due to plastic Beulaosdiontec SUE deformation p pring Abnormal Insufficient tire inflation e Inflate the tire to a required pressure Abrasion of thetire e Spring broken or shorten due to plastic Replace the spring deformation e Wheel overloaded or the load on R amp L sides are e Check the load not in balance e X R amp L springs are not in a group Replace the spring Overloaded or load of one side is over Cheese ied burdened e Spring holder of front shock absorber is welded Redince the front chock aucorber unstably P Spring broken or shorten due to plastic i B dhbedbesod deformation p PIUS Fasten the bolt and nut of stabilizer Lateral stabilizer bar gets loosing bar or replace the bushing or joint Spring broken or shorten due to plastic Beolcsdhdsonm deformation p pring e Checkthe load
40. when dismaniling Do not reuse the dismantled oil seal 20080514 Steering System 2 10 14 Remove retainer ring with a circlip pliers Do not reuse the removed retainer ring 20080514 15 Disassemble steering rack and bearing 16 Remove bearing retainer ring with a circlip pliers Bearing retainer ring Do not reuse the removed retainer ring ET 20080514 17 Disassemble ball bearing with a puller SST Do not reuse the removed ball bearing 20080514 Steering System 2 11 2 3 2 Assembling Sequence Chart Oil seal breakage Excessive clearance of ball knuckle abrasion breakage aging of dust shield Excessive clearance of ball knuckle l Bearings abrasion Adjustment block Steering rack 1 Abrasion or breakage of tooth surface 2 Bending Excessive clearance of ball joints Crack breakage and aging Pinion Breakage 1 Abrasion or breakage of Guiding sleeve S S tooth surface abrasion 2 Crack on tooth end Tooth point end tooth Worn out breakage and aging 20080514 1 Assemble new ball bearing onto steering gear wheel 5 N 20080514 2 Assemble the gear ring onto steering gear wheel with a circlip pliers Bearing retainer ring 20080514 Steering System 2 12 3 Assemble the steering gear wheel onto steering gear housing with a rubber hammer Po Attention Always knock gently when mounting the steering gear wheel 2008
41. 0514 4 Assemble new retainer ring with a circlip pliers Hole retainer ring 20080514 o Assemble the oil seal into the steering gear housing 20080514 Steering System 2 13 6 Assemble the steering rack onto the steering gear housing Apply grease lubricant on the whole outer surface and teeth surface of grease steering rack Do not damage steering rack bushing when assembling 20080514 7 Assemble the adjusting plug block 8 Assemble the adjusting spring Adjusting plug block 9 Starting torque adjusting system 1 Screw down the steering rack with a spanner to adjust the plug screw according to the specified torque Tightening torque is 11 15N m 2 After step 1 return the plug screw to 45 55 back 3 Measure the staring torque with a tension wrench Repeat the process from step 1 to step 3 if unqualified Steering System 2 14 Specified torque is defined as 1 5 1 6 N m 4 gt Keep adjusting plug screw immovable still and screw it down as per specified torque of 35 45N m 5 Remeasure starting torque of 1 5 1 6N m 20080514 10 Assemble the tie rod ball joint assembly 1 Screw the lock nut down to thread bottom of tie rod ball joint assembly The big end of lock nut faces to tie rod ball joint assembly 2 Assemble the tie rod ball joint on the steering rack under status 1 3 Tighten the steering rack and lock nut as per the specified torque Specified torque
42. 12 Knock the axis pin out on the brake shoe Checking 1 The brake shoe lining can not have any oil stain otherwise the performance of brake will be influenced seriously 2 The thickness of lining should not be less than 1 mm otherwise the brake shoe will be replaced 3 The brake shoe lining should be replaced if any deformation or desquamation 4 The spring should be replaced if any failure or partial failure 5 The split washer should be replaced after disassembled 6 The clearance self adjusting device should be replaced if it can not work Attention e if some brake shoe needs to be replaced the brake shoes of left and right brakes should be replaced in pair at the same time Brake System 5 19 1 Split washer 5 4 Split washer 7 Axis pin 9 10 Compression spring Compression spring Pincheack Parking brake cable Installation 1 Before installation carefully inspect all parts and ensure no any defects for use 2 Install brake shoe parking brake lever and clearance self adjusting device in the order reverse to the disassembly steps of brake shoe parking brake lever and clearance self adjusting device 3 Install brake drum install it according to the above mentioned installation steps of brake drum and adjust rear brake clearance See the followings for method 5 6 3 3 Rear wheel Brake Cylinder Assembly Disassembly 1 Disassemble brake drum according to the above mentioned steps
43. 2 16 2 4 9 Dre PressllB uccccenseotetc pusccRa EIDEM AA 2 16 2 4 4 Cneckon Clearance o cies cose a Eod ee cust OU als sed wee eh eee Yoel 2 16 2 4 5 CHECK ANG AdIUusumebi iure oo e deoco a uisx FE OU Su Oo prO UME ebSnDEDER I Ber UE P DE Ere UENIRE DE 2 16 Steering System 2 2 Attention All fasteners of steering system may influence key function of important fastener If any parts must be replaced be sure to use the same parts with same part number If reassembling always tighten all the parts as per the specified torque to ensure they are re fixed well 2 1 Check and Adjustment of Steering System 2 1 1 Check on the free stroke of steering wheel Leave the steering wheel in straight driving position and turn it left and right The arc distance of the outer diameter swing is defined as free stroke which is limited by 30mm If the actual distance exceeds the limit please check the connection of the steering tie rod ball stud the backlash of steering pinion racks and the universal joint clearance of the cross axle of steering shaft Sectional inspection could be used Normally the clearance of the joints should be zero or slight whose total clearance reflects as the free stroke of steering wheel Overlong of free stroke may cause slowness of the manipulation or swing of the SURSe 15 front wheel 2 1 2 Check on the steering column axial clearance There should be no clearance when pushing or pulling the steering wheel up
44. 26 583 SPECIAL TOIS 5 27 5 1 Check and Adjustment of Brake 5 1 1 Check and Adjustment of Brake Pedal Measure the height of brake pedal its standard value should be 160 5mm If failing to meet requirements the methods for adjustment are as below 1 Unscrew the service braking light until it does not connect with the brake pedal rod 2 Loosen the stop nut on push rod rotate the push rod to change the position of rod fork and then adjust the height of brake pedal after the requirements are met screw the stop nut Adjust the service braking light switch again its clearance is 0 5 1 5 mm at the same time screw the stop nut of braking light switch tightly 5 1 2 Adjustment of Brake Pedal in Free Stroke Depress down the brake pedal until an obvious resistance is felt At that time the stroke of brake pedal is the free stroke its standard value is 2 7mm If the free stroke is too long that is because the clearance between the push rod and the brake master cylinder piston is too large If the free stroke is too short it is possible that there is no clearance between the push rod and the brake master cylinder piston or adjustment of the service braking light switch does not meet the requirements were this to happen make the adjustment according to the above mentioned methods 5 1 3 Adjustment of the Height for Brake Pedal Step on the brake pedal with 300 N force measure the stroke of brak
45. 6304N C3 Axis of rolling 6204 Axis of rolling 6204 Structural Diagram of Transmission Maintenance Guide Disassembly Disassemble the connecting bolts of the transmission extension housing and the rear housing upper box on the upper box and then remove the extension housing assembly Disassemble the connecting bolts on the extension housing to remove the extension housing assembly Disassemble the connecting bolts of the upper and lower box to remove the upper and lower box assembly and then remove the input shaft module and output shaft module assembly Remove the reverse check plate disassemble the sealing ring assembly at the front end of the countershaft and dismantle 47 bearing retainer ring Strike the housing washer of countershaft front bearing from front to back with a copper rod and a hammer to make the front and rear bearings rush out from the inner of the dead eye on the lower box Remove the rear bearings with a shaft bearing replacer and take off the countershaft unit Accelerator Assembly and Transmission Assembly 7 4 Take off the sealing ring assembly on the input shaft remove the retainer ring on the input shaft with a circlip pliers and then disassemble the input shaft module When disassembling always pay attention not to damaging each gear of the input shaft due to collision and take notice of assembly relationship between each adjacent component When installing do not allow to ins
46. 8 3 1 Disassembly 1 Replace rear window when it was cracked or broken 1 Remove the broken glass pieces 2 Remove the backboard guardrail with a spanner 3 Take off the strips from rear window frame 4 Clean up the broken glass pieces in strip channel Screw driver Attention When cleaning up protect vehicle body from scratched by broken glass pieces 2 Replace rear window when it was scratched Tip up the bordure in the rear window rubber strips with a slotted screwdriver meanwhile disjoin the glass hereof by pushing up slowly upwards Make the bordure in the rubber strips turned out along the window frame slowly until all the edge of rubber strips turn out of the edge of window frame Take off the glass rubber strip assembly and take apart adhesive from the glass 08AD1106002 Disassembly of back door windowpane and rubber strip Attention This operation should be operated carefully be careful not to scratch vehicle body when using screwdriver 08 401 106003 Body 8 14 8 3 2 Assembly 1 Invaginate the rear window into rubber strip appropriately 2 Insert a flexible rope with 4 5mm diameter and 3 5m long into the whole bordure of glass rubber strip assembly and have the two ends of the rope crossed at the middle of rubber strip assembly s longer side 3 Putthe glass rubber strip assembly with the rope onto the rear window frame and adjust it a little to make the glass rubber strip assembly align
47. Checking Check that the parts that are disassembled are worn or damaged Replay them if necessary Attention e Clean disassembled parts with clean brake fluid e The original accessories in repair kits must be used to replace parts Check that there are scratches or corrosion in the master cylinder better replace corroded cylinder If the cylinder block has mechanical pitting or too rough it shows the cylinder has corroded Attention Never use any grinding material for polishing the cylinder with cast aluminium pedestal After rinsing the master cylinder always shake off the brake fluid on the master cylinder but do not wipe it with a piece of cloth because fine hairs on the cloth can adhere to the surface of the cylinder block Assembly Attention e When cleaning and assembling the parts do not use any mineral oil such as kerosene and gasoline e Check and ensure there are no impurities such as dust and dunghill in the inside wall piston and packing leather always be careful when of cylinder sealing parts assembling with tools or damage will be resulted in e No parts are allowed to fall off never use a fall of any parts 1 Apply brake fluid on the inside of the master cylinder and the contact surface of the piston assembly Insert the secondary piston assembly into master cylinder Make sure the direction of installation for piston packing leather is correct and the piston packing le
48. Dust guard ust gu 23 Right brake calipe 11 Bleed screw assembly 12 Joint in oil pipe 13 Left brake caliper 24 Right brake caliper body body 5 5 2 Disc Brake 5 5 3 Maintenance Guide Disassembly 1 Use a jack to jack up the wheels from the ground remove the wheels 2 Disconnect the U jump ring used for fixing brake hoses and take off the hoses from the supporting frame 3 Remove the guide bar of the brake caliper 4 Remove the brake caliper from the 1 Brake 2 Guide bar supporting frame 3 Brake disc Brake System 5 11 5 Remove the brake pads damage and so on If any repair them Attention e Remove the brake caliper with a wooden cushion pad prevent the brake hoses from bending twisting and dragging too much e After removing the brake pads the brake pedal is not allowed to step on Checking Brake Pads 1 Brake caliper body 2 Wood brick 3 Brake pads Check the attrition rate of lining on the brake pads when they are worn excessively new ones should be replaced Attention e No sand papers are allowed to use to polish the brake pads otherwise hard particles of the sand papers can seep into the linings and it is possible to damage the brake disc When the brake pads need to be replaced brake pads in the left and right wheel should be replaced together Thickness of brake pads Lining Steel backing of brake pads Standard value 15mm Ultimate value 7mm
49. E type Retainer Ring 6 Bolt 7 E type retainer ring 8 Erection bolt 9 Erection bolt 10 Bushing 11 Bushing 12 Steering shaft welded assembly Note Steering column will be easily damaged once it is disassembled from vehicle The end of steering column assembly may damage or loosen the steering shaft due to collision if it slides off Plastic shear lock pin for keeping length of steering column 2 2 5 Disassembling Sequence 1 Disassemble steering wheel module 2 Disassemble protective shell module of combination switch and X combination switch assembly 20080514 Key points of installation 1 Application of grease lubricant Apply grease lubricant as shown in the figure Bushing 20080514 Steering System 2 6 2 2 6 Bushing Use rubber hammer to install bushing in the column When installing a new bushing do not make it excessive distortion or crack Bushing should match well with the column 2 3 Location Map of Steering Gear Assembly 20080514 Note It is necessary to take off clutch release cable when disassembling front axle welded assembly and adjust it after installing front axle welded assembly well Steering System 2 7 2 3 1 Exploded View of Steering Gear Excessive clearance of ball knuckle Oil seal breakage j uu d abrasion breakage aging of dust shield Excessive clearance of ball knuckle Adjustment block Bearings abrasion Spring Steering rack 1 Worn out or breakage of
50. Mc 6 3 Tightening Torque Required for Suspension System Assembly of Electric Motor and 6 2 2 Transmission PR 6 3 623 MaINIGNANCE CIUDo E 6 3 6 1 Connection Assembly of Electric Motor and Transmission Dynamical System 6 2 Washer 10 mmm Motor baffle plate MM 6 Dowel pin of cylinder head 6 1 1 Specifications 7 Bolt assembly M10x1 25x30 48 68 Connection assembly of electric motor and 8 Connecting plate transmission is composed mainly of the parts as 9 Bolt M10x1 25x120 a below Bolt assembly 10 M10X1 25x45 45 65 T TET EP1102 001 ransmission assembly Locknut M10x1 25 45 65 Coupling plate II p 138 Washer 16 MEN EP1102 10001 Coupling plate EP1102 10002 Connecting plate V1102 10001 Coupling plate II Washer 16 pp Hex nut M16X1 5 20140 Coupling plate 6 1 2 Tightening Torque Required for Connection Assembly of Electric Motor and Transmission z pars and tightening torque in the bald uds nT N m x ST s Transmission assembly P Nut M10x1 25 3 Washer10 Bolt for coupling plate s 6 1 3 Maintenance Guide During periodic maintenance service always check the parts for connection assembly of electric motor and transmission according to the following methods Check that the bolts and the nuts on the joints become loose were this to happen tighten them according the specified torque Check that the spline in the coupling
51. Service Manual for Wuling Electric Pickup Truck Preface Wuling electric pickup truck is researched and developed by Technical Center of Liuzhou Wuling Automobile Industry Co Ltd and manufactured by Liuzhou Wuling Special purpose Vehicle Manufacturing Co Ltd This product is used for freight in factories residential areas gardens farms and other areas This economical environment friendly and practical product is your good assistant in your work and life The preparation of this Manual provides references for correct repair and maintenance of Wuling electric pickup truck by maintenance man This Manual is precise in layout and convenient in lookup The content in this Manual is consistent with the latest product structure and technical state when this Manual is published The technology of our product is improved continuously so the structure of the product manufactured later may change Please pay more attention to these differences when maintenance If you have any questions please show solicitude for the updated edition of this Manual or directly consult to Technical Center of our Company This Manual also can be used as the references for engineering technicians Because the time for preparation of this Manual is so short please understand and correct if any insufficiency and error and welcome to make your valuable comments and suggestions Liuzhou Wuling Automobile Industry Co Ltd January 2009 How to Read and Use
52. Turning speed is too fast Decrease the turning speed Suspension Wheel and Tire 3 26 3 5 2 Special Tools Spring Compressor Replacer of Swing arm Axle Sleeve Assembly Deep Socket Wrench Power Train 4 1 Chapter 4 Power Train Contents 4 1 Check and Adjustment of Power Train 4 2 4 1 1 Check f r ROTATIONAL NoiSe 5 uuo rap o de eoe s e E CH aapa aaO pest vd RP D gag ee CUR Pda EI 4 2 4 1 2 Check for Abnormal Noise of Rear Axle eeeeeeee eee eee eene nennen 4 2 4 1 3 Check for Calorification of Outer Housing of Rear Axle and Speed Reducer 4 2 4 1 4 Check and Replacement for Lubrication Oil of Speed Reducer 4 2 4 2 Drive SM AN sistas c ceetitutawetancenwacden seated cuusantentauaetatsieueenaeemnencaeoeta ke wences 4 4 4 2 1 SDSCIIC AMON eee a a aa 4 4 4 2 2 Drive Shaft ASSEMDIV ivcsssatccecesssccswecteswitececcsantuccesinsaeuetesdarcceesesuedewassssveswcdasegteadene sevice 4 4 423 Maintenance GUI oe poi a ede ah cat eeaeeee cadens 4 4 4 3 PROC AN yj fI P 4 7 4 3 1 SpecMC AOI Mee 4 7 4 3 2 Half Rear Axle and Rear Axle Housing Assembly 4 7 4 3 9 Maintenance GUIde iori E eR Loc oo atas oon tea ceo o cheer Use aaa coca aaa Eaa 4 8 43 4 Speed heducer ASSemb ly 52 125 5 322521 coca aeuo eere eba
53. When disassemble and installation of rear brake its clearance has been enlarged convenient to install and the rear brake clearance should be adjusted again Pull the parking binding handle with 400N force at this time the stroke of the handle should be more than 9 teeth otherwise the stroke of the handle should be enlarged and then release the handle at this time the adjusting device should make a noise of adjustment otherwise the self adjusting device will be out of service and should be replaced repeat doing like this step on the brake pedal for many times during this period for full pullback of brake shoe until the adjusting device make no noise again then the adjustment is completed During general use of vehicle rear brake clearance can pass hand brake automatic adjustment and manual adjustment has no need Brake System 5 22 Attention e Adjust hand brake stroke after the rear brake clearance completion of adjustment Brake System 5 23 5 7 Parking Brake Control Device Parking brake lever T Tightening force FY Prohibit using the disassembled 20080514 1 Binding handle 3 Parking brake cable assembly 4 Nut 5 Nut 6 Auxiliary instrument decoration plate assembly 9 Hand brake cable end joint Moment at 10 15 N m Moment at 3 7 N m Brake System 5 24 Adjustment of Parking Brake After the assembly completion of rear brake assembly clearance self adjusting device and hand
54. a se ers os fee Pe esssua ere SORA aiaia 4 10 4 3 5 Maintenalhice Guide sisi ci DER eto co Eie xis ok aL Lev o cesa eisan ceci e iia vete P mo R S Eon PERS 4 11 BBO PECAN rer op tcc cane a teace caeiecscancecerveneeeeaeers 4 18 4 1 Check and Adjustment of Power Train 4 1 1 Check for Rotational Noise If there is a noise when drive in a high speed or the whole vehicle gives a feeling of swinging in general that means the dynamic balance of the propeller shaft assembly exceeds its specified value or has been bent and deformed In that case it must be adjusted by a professional workshop and proceed with a dynamic balance adjustment as well or just replaced If the noise occurs when drive in a low speed or speed change in general that probably because of part gets loosing due to abrasion Replace the whole drive shaft when sliding yoke splines cross axle and needle bearing is abraded badly 4 1 2 Check for Abnormal Noise of Rear Axle This noise may happen when the drive gear wheel and driven gear of speed reducer are broken or the mesh mark can not meet the requirements due to serious abrasion of gears and bearings or bearings are abraded seriously and are damaged If the noise occurs on driving stop the car check and carry out trouble clearing D Push the gear shift lever of gearbox to the neutral position pull up the parking brake handle 2 Rotate the drive shaft to the end with a clockwise direction mark with a match
55. ach box together After aligning the boxes tighten each fastening bolt evenly in proper order pay attention to using even force to tighten them 8 1 8 1 1 8 1 2 8 1 3 8 2 8 2 1 8 2 2 8 3 8 3 1 8 3 2 8 4 8 5 8 5 1 8 5 2 8 5 3 8 6 8 6 1 8 6 2 8 7 8 8 8 9 8 9 1 8 10 Chapter 8 Body Contents Front DOOF ASSEMDIY s ocdesuaceosuoxs sexv dus ae Disassembly and Assembly of Front Door Lock Front Door Glass and Window Regulator esse Disassembly Assembly and Adjustment of Front Door Front windshield and Rear Window eese DISASSCIMDIY e PASSOMDIY et skein a a a Rear WINDOW re BIECLII Q eM ASSEMDIV et FEONUI DOO MIMS ET o mm Front BUITIDGF ocarina TVERRRA eSI EDXHOE NUR RUE IMBRE NR DR RE dS DISASSEINDIY ec Key point OF disassembly 5 2 ease ck a a RUP Dea EEasDREcD OR E UOOEA E edi ASSEMDIY e Inistrummiernt Dariel ic 25 ieoxo oie ios ice Uoens ecc POE epa On DN CORE BMECCrIJHPeuee C ASSeMDIy Oil filler Gate Subassembly seus Front Wall Angle COWVGL oioo ioo eee oa eo inrer Rana uu a novnr a e men OS A eee ER PRONE SCA CNN ER er oie m
56. ake 5 6 3 Maintenance Guide 5 6 3 1 Brake Drum Disassembly 1 Guarantee that the vehicle can reliably stop when disassembling brake 2 Jack up hoist the vehicle and disassemble rear wheels 3 Disassemble rear brake drum If it is difficult to disassemble rear brake drum extrude the drum by screwing M8 bolt in the screw of brake drum Brake System 5 17 Tightening torque Hrm T 9 B 8 12 C 45 60 Position for grease Poston for daubing waterproof putty powder erproof Waterproof putty powder Screw in M8 bolt Extrude brake drum Checking 1 Cleaning Ensure cleanness but no sundries of brake drum after being disassembled and any oil stain can not be left on the working face of brake drum 2 Internal diameter 220mm as standard value 222mm as ultimate value and you should replace brake drum if more than the ultimate value 3 Other defects Replace the brake drum in time if any crack or damage aggravate the damage of brake lining if the brake drum has any serious scrape or scratch under the circumstances do not continue using the brake drum and they must be replaced Installation 1 Clean out the dunghill and oil stain in the brake drum 2 Adjust external diameter of rear brake shoe uplift the adjusting paddle shift to make it deviate the adjusting solenoid and then turn the adjusting solenoid upwards external diameter shortens or downwards external diameter enlarges an
57. al Arrangement Diagram for Complete Vehicle Wiring Instrument Panel Wiring Harness Spar powe rz spply dwar lig amp aid price Earth wer za aW l n calc ator are auallabks Wiper motor posits The pex thon Tor socket E Residential instrument panel shown a the Et ame ee Jo pore rm E T NES 4 TOG REIHE DAD ee rds e NN A M oU ESQ SCA e e 10 10 2 Schematic Diagram for Complete Vehicle Electrical Arrangement Schematic diagram for complete vehicle electrical arrangement mark the drawing according to different vehicles attached to the book lookup the above diagrams to exclude specific electric failure according to the mode of failure occurred
58. alizing charge for long time correct as much as possible e Too short working time of battery l Corrective amp Preventive Possible Causes Measures 1 Insufficient charge for 1 Inspect the charging battery time prohibit over discharge work of 2 Variable ambient battery environment 2 Confirm and change Inspect brake and tire lubricate Inspect motor and Mechanical failure other power circuits Adjust the driving route or adjust load Failure of circuit oo bad road according to 3 Internal short circuit of situations battery 3 Inspect and correct 4 Battery service life end 4 Make volume test soon 10 1 2 Storage Battery Specifications Type 6QA36 Capacity C 36Ah Voltage 12V Electrolyte Density standard value 1 28 g cm at 20 C Inspection and Repair Clean the surface and wiring terminal of battery and Complete Vehicle Electrical 10 5 Warning Because the battery will produce combustible hydrogen avoid treating the battery near the place where there is kindling otherwise there is the possibility of explosion The battery liquid can not touch the eyes and skins ln case of touching skin wash the skin with clean water for more than 5 min and cure in time Complete Vehicle Electrical 10 6 apply lubricating grease to wiring terminal every half a month in winter and every 7 10 days in summer Inspect electrolyte surface keep the surface
59. ance eeerrnne IH 9 720 Daa PECIA TOOLS ERE T I Ue 3 26 3 1 Check and Adjustment of Suspension System 3 1 1 Preparation before Check on Front Wheel Alignment It is necessary to carry through all check up and maintenance works below before starting to check and adjust the auto front wheel alignment so as to ensure the correctness of alignment parameter when measuring and adjusting 1 Check all wheel tires replace the one hose abrasion level is not equal on the right and the left either that of seriously and partially abraded with new one 2 Check wheel air pressure Empty load Fentwheel 200KPa 200KPa 3 Check tire s radial and lateral run out quantity Requirements Radial run out lt 3mm Lateral run out lt 3mm 4 Check all components of suspension replace the one that appears to be deformed and damaged 5 Check all fasteners among the components of suspension tighten the loosing one as per relative specifications requirements 6 Check the steering tie rod end modify the loosing one before adjusting 7 Check and make sure the measurement apparatus is under a good condition operate it according to the instructions provided by the factory Suspension Wheel and Tire 3 2 3 1 2 Check and Adjustment of Front Wheel Alignment 1 Wheel Alignment Parameter Rotation 37 10 2 2 Check and Adjustment of Toe In 1 Toe In Measure Push an empty loaded vehicle 5m on a sm
60. and reinstall it once according to the above mentioned methods Attention e Do not spray with high press water e Do not blow the coated area for airing with 1 Rubber disc compressed air directly when airing e Do not bake it with Far Infrared Ray or similar methods Body 8 12 Attention Pay attention to the following while installing e It may cause the glass unstable or fall off if you close the door suddenly before the adhesive solidified completely So before solidified ensure to open all glass on the doors with careful operation In case of trim strips are not fixed in the specified place firmly fix them with adhesive tape tightly until the adhesive completely adheres to them Drying time for different adhesives is varied Always refer to the Service Instructions provided by manufactory before adhering and find out the solidifying time of adhesive Always comply to its notices when operating In order to have it attached firmly do not start the car before it dried completely 12 Install the rearview mirror roof strips front pillar strips and trimmings sun shield other trimmings and wiper Body 8 13 8 3 Rear window 1 Rear window rubber strips 2 Rear window glass 3 Rear guard brackets 4 Rear panel welding assembly Comply with the following instructions to replace rear window Attention Please wear safety glove to operate to process the following operation
61. ars the ignition switch returns to OFF position and the system will not run again until the system resets When IPM protection repeats appearing which should be regarded as failure the reason for failure is IPM damage or short circuit at load end IPM failure Replace IPM or inspect whether motor and the connecting cable connects earth or not When it is detected on control circuit that the output current of controller is more than the set value controller will blank off its output and alarm and T disconnect main contactor at the same time After over current protection V E 03 M appears the ignition switch returns to OFF position and the system will u not run again until the system resets When over current repeats appearing which should be regarded as failure inspect whether motor and the connecting cable connects earth or not When the vehicle is started if the direction select switch is placed on R Neutral gear or L gear the electric control system has no output but outputs this failure code Place the ignition switch on OFF gear and place the direction select switch on N position and then start this vehicle again this failure will disappear position detection of Power on The controller detects the temperature of radiator if the temperature is Radiator more than 75 C the controller will alarm but not blank off its output 215C You should reduce the load of this vehicle af
62. assembly Replace the return spring Repair according to need Repair according to need Repair or replace the brake master cylinder Charge the tire appropriately Replace brake shoe Replace brake shoe Replace brake drum or brake disc Repair or replace the brake wheel cylinder pressure of Replace brake shoe Repair or replace the self adjusting device Replace brake drum or brake disc Even air pressure in tire Repair or replace the brake wheel cylinder Repair or replace the brake shoe Replace the brake shoe Replace the brake caliper Repair according to need Set down the parking binding handle Replace or repair according to need Add corresponding brake fluid according to the scale merit of brake fluid reservoir Brake System 5 27 5 8 3 Special Tools 1 Installation tools for the piston cup ring of rear wheel brake Cylinder ie ea The operation method is shown as the figure T Dynamical System 6 1 Chapter6 Dynamical System Contents 6 1 Connection Assembly of Electric Motor and Transmission 6 2 Bact SPEC CAORS aeui eee E rade nesacseceuan E E TA OERE EEEE 6 2 Tightening Torque Required for Connection Assembly of Electric Motor and 6 1 2 E CETTE RM 6 2 613 Malintenalce GUIOG o nixcauccaxupr eic eode siu Ux UNUM RUE MEDI aa ia Eu NE ARUM AD Ud EE UE 6 2 6 2 Suspension System Assembly of Electric Motor and Transmission 3 3 621 SDCCIICAUOINGS EIC
63. at 10 15mm above the surface for insufficiency add distilled water but not oil of vitriol When the concentration of electrolyte is not enough deliver the storage battery to professional service shop Inspect the blowhole on the battery cover and keep smooth At 20 C the standard value of electrolyte density is 1 28 g cm the reduction of density indicates the insufficient power of battery and charge immediately During the course of using vehicles the battery is in the status of half charge and half discharge and for a long time the plate will be vulcanized Take the battery away from vehicle every 3 months and make the course of full charge and full discharge and recovery charge of re charge 10 1 3 DC DC Converter DC DC converter converts 72V DC high voltage input by power battery pack to 12V DC low voltage for the use of on vehicle 12V low voltage apparatus If auxiliary battery loses power DC DC converter will charge it Specifications Input voltage 50 90VDC Output voltage 12 14V Max output current 20A Attention User should adjust the specific gravity of electrolyte to 1 29 1 30 for preventing gelation at the cold area below 5C Attention The failure of DC DC converter will result in over low voltage of auxiliary battery and even will damage auxiliary battery for a long time therefore the vehicle will not be used Use of DC DC Converter When the power batter
64. ather does not seize up and Brake System 5 6 stop when inserting it into the cylinder straightly 2 Install the primary piston and the guide sleeve into 1 Pull rod 2 Retainer ring 1 Locating bolt the cylinder 3 Push the retainer ring in and install it 4 Push the whole piston and then install the locating bolt for piston Tighten them according to the specified torque Tightening torque Ca 6 10N m 5 Apply a thin layer of brake fluid around two new seal rings and install them in the cylinder block and then fit the brake fluid reservoir 6 Install a new pin into the hole in the connection and screw it in At the same time make the length of the surface of the pin end equal to that of the connection spare end Installation Attention e The specified torque value is applicable to dry and non lubrication fasteners e Check the clearance between the booster piston rod and the master cylinder piston e Adjust the length of the booster piston rod with special tools 1 Install the master cylinder as shown in the figure tighten the nuts according to the specified torque Tightening torque a 10 16N m 2 Install tighten the tubing connecting nuts according to the specified torque the hydraulic tube Tightening torque b 15 22N m 3 Connect the hoses for brake fluid reservoir L1 4 2 mm L2 Less than 5mm 4 Fill the brake fluid reservoir with the prescribed brake fluid Refer to the figure sh
65. brake cable connect the hand brake control device with hand brake cable according to the hand brake connection status adjust the stoke of the handle to the scope of 7 10 tooth pull the hand brake time after time until that the clearance adjustment of left right rear brake assembly is over namely the clearance self adjusting device does not make a noise again the operating force of the handle is 400 500N Brake System 5 25 5 8 Failure Diagnosis 5 8 1 Inspection Table for Brake System Normal Results Abnormal Results Check the fluid level The fuid level height of brake fluid The fluid level height of brake fluid height of brake fluid in is normal IS too low brake fluid reservoir 1 The brake pedal stably moves to Step on the brake pedal floor 1 The brake pedal moves unstably to the maximum extent 2 The brake pedal stops and 2 The brake pedal is too soft withstands pressure The brake pedal returns to original The brake pedal does not return to Loosen brake pedal poston original position Brake action is produced bois when stepping on the 1 The brake action will lag after brake pedal stepping on the brake 2 The operation of brake is stable 2 When stepping on the brake and normal without clamping pedal lightly the brake operates phenomenon and the brake pedal roughly does not librate 3 When stepping on the brake 3 Steering wheel and brake pedal pedal the live brake pedal of
66. ccseceeeeseeeeeeueeeeueeeeessesesessssesessssee OTE Ss Front SUSE SIO osse oediptocte gaude Lote PE cm bete ue eU aN NENAS 3 7 3 2 1 Specifications ccccecccssecccsucucceccececceccuccenseceueenceausesssssecsscscccccsasenseneseeseeses OTE 3 2 2 Front Suspension Assembly Drawing nennen nennen en nnns 3 8 3 2 3 Maintenance Guide c sccesccscccccenueceeceaeeaeeueaceaeeaueneaceasacssesseenseessessssseeens SI 3 3 Rear Suspension 0 cecsececeececeeeecueeeeuseeaecueeeesssteessssetssssetssstensssseees O71 P 3 3 1 Specifications suucesens cum EE ROO FEE DU MIU EEER ITIN ENCUE IMMER M E ENIN EIN FU Ur iN UMS 3 17 3 3 2 Rear Suspension Assembly Drawing nennen ennemis STIT 3 3 3 Rear Shock Absorber Assembly eene nnnnnnmnmnrrrrennnnnnnrnss S719 3 3 4 Notices to the Maintenance of Rear Suspension seeeen ees 9720 3 4 Wheel and Tire eeeseeeeeeeeee nennen nnne nnne nenne nnne nnne ne nnns 3 21 3 4 1 Specifications cccccecccececceuceeceaeeaeeceaceauuaeessssssssssssssstssesstrsvesvestsssisissses S721 3 4 2 Wheel Assembly Graph cccccecsecccseccueeuenuecuenuanuaneanuaneunuaauanuasassessesesesess 3 21 3 4 3 Wheel Transposition ccccceeceeeescesceceeaceanuaessensssssssseseststssssssvesseee 3721 3 4 4 Maintenance Guide eese nennen nennen nennen manente nra tense ananas 3 21 39 Falur DIAGNOSIS cr 3 25 3 5 1 Check Table of Breakdown Mainten
67. cessary Tightening Torque Wheel Nut a 88 117N m 3 Check the Abrasion Condition of Wheel Bearing Front Wheel Jack up the front axle to make the wheel away form the earth take off the decorative cover of wheel and the inner cover of front hub After that measure the thrust clearance of wheel hub bearing by using a dial indicator on hub Ultimate value of thrust clearance a 0 1 mm Replace the hub assembly once the measure value exceeds the ultimate value Rear Wheel Jack up the rear axle to make the wheel away form the earth take away the decorative cover of wheel After that measure the thrust clearance of bearing by using a dial indicator on the semi axis center of rear axles Ultimate Value of thrust clearance a 0 8mm Replace the bearing once the measure value exceeds the ultimate value 4 Make wheel running to check whether there is any noise on wheel bearing or smooth in running If yes replace the wheel hub assembly or bearing Suspension Wheel and Tire 3 5 3 1 4 Check on Front and Rear Shock Absorber in Failure Check that the vehicle runs smoothly first If there is abnormal shock feeling when driving or noises such as dong dong in cab when driving on non smooth road stop the car and press one side of the car forcibly to check whether the car sways three or four times if yes that means the performance of shock absorber has got poor Then check if there is a leakage of oil in the
68. ck service and maintenance Regular check service and maintenances eeeeeeeeeee eere Basic Information 1 2 Chapter 1 Basic Information 1 1 General Information 1 1 1 Diagnosis Form Diagnosis form records the vehicle trouble users shall properly fill in this Form which is the original record for the Service Station to analyze the vehicle s failures before maintenance and write in Maintenance Record Checklist for Trouble Sample Vehicle Model VIN Purchase Date LF Date in Trouble Mileage Trouble oAbnormal noises of drive shaft oAbnormal noises of rear axle oOthers nSteering loose oFront wheel vibrating nTire uneven abrasion oDriving deflection nBrake delay oBrake deflection nBrake pedal loose oBrake fluid leaking n Others aBattery charging in failure OAbnormal light OAbnormal horn ORadio and cassette player not working olnstruments working abnormally oOthers oPower battery fault opoles of battery ablated otransmogrification of power battery oPower battery charging in failure oElectromotor and Electromotor controller failure oRecord the information of the failure oOthers aDoor lock fault OSeats bad aWindow regulator fault oOthers The vehicle conditions environmental aspects when problems arise Vehicle Environmental Conditions in Trouble Environmental Conditions aSunny aCloudy aRainy OSnowy OAny weather p Others vean I iiot aw 4Cool aCold
69. clearance between 1 Brake fluid reservoir altes master cylinder and piston 2 Shield sleeve n 3 Inlet sebific duct 4 Pipe clamp 5 01 inlet connection Detent T Seal ring Master cylinder block S Front piston assembly 10 Rear piston assembly 11 Guide sleeve j JS 12 Retainer ring i Limit 0 5mm 13 0 seal ring E The position for applying brake fluid E 6 Li ENT Brake System 5 5 5 3 3 Maintenance Guide Checking Master Cylinder Check if there are cracks in the master cylinder casting or brake fluid around the master cylinder If a little fluid is available it shows leakages exist It is also not normal phenomenon when moist regain Disassembly 1 Use a special tool to unscrew the detent that is used for fixing the connection 2 Remove the connection and two seal rings 3 Remove the retainer ring 4 Take off the guide sleeve and the primary piston Remove the locating bolt for piston and then blow in compressed air through the locating bolt on the piston take off the secondary piston When disassembling the secondary piston special care must be taken because it is possible to spring out Attention Operate on a clean working table without mineral machine oil e No compressed air with lubrication oil is allowed to use Special tool JA WA f 1 Detent 2 Oil inlet connection 3 Seal ring 1 Retainer ring 2 Master cylinder 1 Locating bolt 2 Compressed air
70. correct steps on instructions provided by primer manufacturer And have them dried in required time Do not brush primary coat onto the surface of finishing coat Do not touch primer coated surface Width a is about 20mm 0 78in b is about 15mm 0 59in c is about 18mm 0 70in 08AD1103009 Body 8 11 7 Coat adhesive referring to the figure on the right Attention e Brush the glass from the side of bottom e Be careful not to damage primer e The underside of adhesive shall be higher then that of the other three sides e Top right and left side e Width e about 8mm 0 31in e Height f about 14mm 0 55in e After adhesive brushing press glass into body at once e After adhesive brushing take the glass with a rubber sucking disc e Complete steps 7 9 within 10 minutes to ensure the adhesive has sufficient viscous e Processing methods and time for airing must comply with Instruction Manual provided by adhesive manufacturer trim strips 2 Adhesive 3 Front windshield 1 External 8 Press the glass into vehicle body with rubber sucking disc and pat the glass surface and strips around to firm it 1 Rubber sucking disc Attention e Be careful not to damage glass surface or vehicle body 9 Check the leakage by spraying water from the outside of the window If it leaks dry the glass in the air and cover the leakage with adhesive If it still leaks take off the glass
71. d horizontal line be 22mm and then change to dipped headlight at this time the beam of dipped headlight should meet the anti dazzle requirement of headlight Lamp center Vertical line E oJ ior RE te Harl zontal line 3 metres IS Far llglitlilgli cirengti rea center Far llglithigh crengti area Description on Adjusting the Finished Axle of Headlight e Adjust the calibration of headlight through the adjustment of screw On the screen which is 3m in front of lamp adjust the luminescence centre on the screen which is 3m in front of lamp with adjustment instrument and adjust the luminescence centre with the adjustment instrument Up and down calibrating spots Central point of head lamp eee Up amp dewn and left amp right calibrating spot 10 9 4 Ignition Switch Wiring Position Ignition switch with lock Wiring Position Following Diagram OFFiLCSCE calli wii look Fo dion r key Complete Vehicle Electrical 10 29 Calibrate up and down through the adjustment of screw Calibrate up and down left and right through the adjustment of screw Common ignition switch Complete Vehicle Electrical 10 30 10 9 5 Combination Switch Dimmer Dipped light Far light Connection Position of Various Switch Motion Shown as the Following Tables Turn Signal Danger Warning Light Lamp Dimmer Switch Wiper and Syringe Switch Switch l l e Motion and connection position of lamp and Motio
72. d pin 3 Slotted nut 4 Bott 5 Brake dist Checking Refer to the above mentioned contents regarding the check of brake disc Installation 1 Install the brake disc in the hub 2 Install the brake caliper assembly in the steering knuckle 3 Tighten the bolts on the supporting frame according to the specified torque 5 6 Rear Wheel Brake 5 6 1 Specifications Type Drum type leading and trailing shoe Internal diameter of brake drum mm 220 Dimension of brake shoe mm chord length x width x thickness 176x40x5 Internal diameter of rear wheel brake cylinder mm 20 64 Clearance adjusting method Hand brake drive automatic adjustment 5 6 2 Rear Brake with Clearance Self adjusting Device The structure decomposition of rear brake and clearance self adjusting device is shown as the right figure 1 Bleed Screw 2 Dust Guard of Rear wheel Cylinder 3 Rear wheel Cylinder Piston 4 Rear wheel Cylinder Cup Ring 5 Rear wheel Cylinder 6 Soleplate of Rear Brake 7 Spring Seat Post 8 Pinchcock 9 Leading Shoe of Rear Brake 10 Return Spring of Brake Shoe 11 Clearance Adjustable Bolt and Solenoid 12 Seatback Spring of Brake Shoe 13 Small Spring of Rear brake Shoe 14 Hand brake Lever 15 Rear Brake Drum 16 Rubber Plug 17 Rear Brake Trailing Shoe 18 Paddle Shift 19 Compression Spring 20 Split Washer Attention e Daub waterproof putty powder at the graphic position when installing all spare parts of br
73. d until light contact when assembling brake drum and brake shoe and turn the adjusting solenoid for 1 2 circles upwards 3 Install the brake drum place M8 screw at two sides with larger half shaft flange in order to screw in M8 bolt for extruding the brake drum 4 Install rear wheel tightening torque of wheel nut 88 108N m 5 Adjust the clearance of rear brake See the adjustment on clearance of rear brake 6 Adjust the parking brake travel see the adjustment of parking brake travel Brake System 5 18 Internal diameter can not exceed limit value Turn the adjusting solenoid for 1 2 circles upwards 5 6 3 2 Brake Shoe Parking Brake Lever and Clearance Self adjusting Device Disassembly 1 Disassemble the brake drum according to the disassembly step of brake drum 2 Disassemble one end of return spring from brake shoe hole 3 Take off pinchcock 4 Depress down the spring seat with forceps and then take it out after circumvolving 90 degree 5 Take the brake shoe out from piston ring groove of wheel cylinder 6 Take off small spring at the bottom connecting two brake shoes 7 Take off the parking brake cable and take down the brake shoe 8 Take out split washer 5 small with forceps 9 Take the paddle shift out from axis pin and take off the compression spring 10 Take off split washer big with forceps enlarge the split firstly 11 Take off the parking brake lever from axis pin
74. dal Check the brake fluid replenish change if necessary Mater cylinder and wheel cylinder rubber cup replace Check the friction plate for the disc or drum brake Connecting bolt fastening Power Train Basic Information 1 15 Check the performance of front and rear shock absorber Check lower arm bush and ball pin check strut bar bushing check the leaf spring hanger inner board U bolts and rubber lining check the rubber cushion assembly check the wear of rubber cushion flat bearing and dust guard etc on the front suspension check the breakage and aging of rubber elements Check and lubricate the leaf springs check the coil spring Connecting bolt fastening Frame and cab calibrate and weld Check and charge battery grease the pillar as necessary Check the venthole Check the cable connectors Check the lighting equipment check all signal lamps check the indicator instrument cluster and switch e ae ol Oe I Note J Check J T Check or adjust replace if necessary J B Check and replenish liquid level N Tighten specified torque R Lubricate G Replace Q Clean H Weld Service the power battery motor controller DC DC Converter and charger according in chapter 10 Steering System 2 1 Chapter 2 Steering System Contents 2 1 Check and Adjustment of Steering System 2 2 2 1 1 Check on the Free S
75. damaged and cracked replace them in time Adjustable nut Rotate the adjustable nut and push the wiring hardness Lack nut shell until the turnplate of the acceleration transducer assembly is about to rotate according to the direction of the arrow shown in the figure Then screw the adjustable Acceleration transducer nut one circle back screw one circle in a clockwise direction according to the position shown in the figure and lock the adjustable nut tightly with the lock nut Accelerator Assembly and Transmission Assembly 7 3 7 2 Transmission Assembly Assembling transmission is mechanical fixed speed ratio its total transmission ratio is 2 1091 whose structure is shown in the figure as below 1 Lower box 2 Countershaft unit 3 Input shaft sealing ring assembly 4 Input shaft 5 Upper box 6 Plug of reversing lamp 7 Output shaft module 8 Extension housing 9 Shifting box cover 10 Rear overhang 11 Output shaft sealing ring assembly 12 Closing ring The transmission has no gear position and connects to ED150 motor reducing the output speed of the motor is equivalent to a deceleration mechanism Axis of rolling 6204N Axis of rolling
76. do not librate when stepping on steering wheel wobbles brake pedal 4 If the vehicle pulls to one side Test brake system 4 If the vehicle does not pull to one when the brakes are applied side when the brakes are applied 5 Front brake or rear brake does 5 Rear and front brakes work at the not operate evenly same time 6 There is noise when the brakes 6 There is no too large noise when are applied the brakes work 7 The brake drags when 7 The brakes do not drag when loosening the brake pedal loosening the brake pedal 1 For checking correct test result if possible compare the test result with that of the same type of vehicle system being operated 2 Please refer to relevant failure diagnosis table for the operation results 5 8 2 Failure Diagnosis Table of Brake System Failure Phenomenon Solution Method The brake pedal is too low or too soft Brake drags Insufficient brake force Uneven brake force The brake pedal is hard but the brake effect Parking brake warning light is on during drive Brake fluid level warning light is on Friction wafer wears Oil of brake system leaks There is failure on brake master cylinder Air is mixed into brake hydraulic system There is failure on brake wheel cylinder There is failure on rear wheel brake self adjusting device The parking brake is misadjusted Length of handspike assembly is misadjusted The return spring of rear brake i
77. e N 1304 186 Length mm 912 3x997 3x276 Contraction Resistance N 353478 Spring Stiffness N mm 53 943 7 Bronce a Cycle Number 6 78 Toe In 0 3mm Camber Angle 1 x30 Caster Angle 2 42 1 Kingpin Inclination 14 20 1 Suspension Wheel and Tire 3 8 3 2 2 Front Suspension Assembly Drawing Cet Oo sw Inner cover of front wheel hub Pin 2 5x4 0 Hexagonal slotted nut Inner ear washer Bearing 30204 P6 Bolt Washer Front Wheel hub Spoke bolt Brake Conical roller bearing Bearing oil sealing assembly Dustshield Steering knuckle and shock absorber 5 N 1 b Washer Bolt l 7 2 3 E 1 Front suspension components assembly 2 Swing arm and knighthead assembly 3 Front Axle 4 Tire and wheel assembly 5 Knighthead support Front suspension components assembly hub and brake disassemble Suspension Wheel and Tire 3 9 3 2 3 1 Front Wheel Hub Assembly Disassembly 1 Jack up the vehicle from the earth reliably 2 Remove the front wheel 3 Remove the inner cover of front wheel hub Knock three points around the inner cover of front wheel hub slightly with a screw driver as shown in the figure Be careful not to damage the edge of inner cover due to collision 1 Inner cover of front wheel hub 4 After removing the split pin loose and remove the locknut Attention No reuse of the split pin is allowed after it is removed 5 Loose
78. e driving 3evel gear far away from lt he center of driven bevel gear A the seme time make driven bevel gear close to ihe center of driving bevel C Am AY Ory N PC 4 Power Train 4 13 Power Train 4 14 Rush out the cylindrical pin that used for loosen proof with a punch Take off the planetary bearing planetary gear spherical surface washer half rear axle gear and adjusting washer Clip the connecting flange with a special tool Remove locknut from connecting flange No locknuts that have been disassembled are allowed to reuse except the new ones Take off the connecting flange after marking a position mark on the driving bevel gear and connecting flange Remove the driving bevel gear together with inner race of rear axle sleeve gasket adjusting shim allow to knock with a wooden hammer Check the roller and ball track on the inner races and outer rings of rear and front bearing If they get broken remove the inner races and outer rings with a special tool If there is no need to replace them just adjust the position of driving bevel gear and may remove the inner races of front bearing only Installation and adjustment Driving bevel gear assembly Press the outer rings of front and rear bearing into the correct position of the bearing support well with a special tool Make sure the thickness of adjusting shim for driving bevel gear installation distance according the following
79. e following figure Handle snap rings Regulator handle subassembly Front door handle Front door internal handle subassembly Front door decorative sheet assembly Front door waterproof film 08AD1104001 Body 8 16 Tips Disassembling sequence Use a piece of cloth to disassemble shaft cotter pin at first and then disassemble regulator handle and front door decorative sheet Take off front door decorative sheet waterproof film with a slotted screwdriver Take off front door waterproof film 1 Cloth strip 2 Rocking handle Attention Take off waterproof film and butyl tape together at 08AD1101006 the same time in order to protect waterproof film from tearing Assembly Assemble as sequence numbers as shown in the following figure Used Front door waterproof film Front door decorative sheet assembly Front door internal handle subassembly Front door handle Regulator handle subassembly Handle snap rings Assembling steps Front door waterproof film Refer to the figure at the right 1 Fix butyl tape along the panel groove but not too tight 2 Press waterproof film onto butyl tape and fix it 3 Water leakage may occur if the film has defects such as torn wrinkled etc Window regulator handle 1 Install regulator handle together with handle snap ring onto front door Attention Install regulator handle subassembly after closing all front doors and windows Body 8 17 Body
80. e front door inner handle 3 Take off all joints of control levers and then remove the outer handle and lock assembly Assembly Install the front lock according to the steps below 1 Install the lock subassembly and the outer handle and then connect all joints of control lever 2 Install the inner handle and fix the lever 3 Attach the waterproof film 4 Install decorative panel subassembly and clamps 5 Install the door handle and the inner lock handle cover 6 Install the window regulator handle Pay attention to Install the lock shackle Move the lock buckle up and down to ensure it aligned with center groove A Close the door and adjust it again and again to keep the surface of door and vehicle body level Caution Keep the latch lateral and move it vertically Do not adjust the lock Add or reduce the insert gaskets between body and lock buckle to find appropriate position of lock buckle 1 Lock body 2 Door button stand 3 Door button Body 8 3 I nner door handle i Cutter door handle 3 Inner lock pin 4 Lock core 5 Lock buckle amp Lock bady 1 Door lock 2 Outer handle 3 Clamp reed 4 Lock core 1 Vehicle body 2 Door 3 Door button 4 Front side Body 8 4 8 1 2 Front Door Glass and Window Regulator Disassembly 1 Roll down all the window glasses to limit 2 Take off the inner and outer middle rubber trips of front door 3 Pull out the window regulator handle of front
81. e pedal its standard value is not more than 100mm the total stroke of brake pedal is 152mm if the distance exceeds its standard value the following reasons should be considered in repair and adjustment 1 Air in the brake pipes 2 Leaked in the brake pipes 3 The clearance between the brake push rod and the brake master cylinder piston is too large 4 Brake shoe is badly worn Brake System 5 2 0 5 1 5mm 5 2Brake Pedal and Brake Bracket Assembly 1 Pedal slipcover 5 Bushing 8 Buffer rubber mat 11 Service braking light switch assembly 12 Pin 2 5x20 15 Nut M8 16 Push rod 2 Brake pedal rod welded assembly 6 Torsion spring of brake pedal rod 9 Brake Bracket welded assembly 17 Bolt assembly M8 x 30 Brake System 5 3 Apply appropriate amount of grease on here 3 Nut M8 4 Washer 8 7 Bolt assembly M8x16 8 8 10 Axis pin of pedal rod 13 Axis pin B8x24 14 Rod fork 18 Bolt assembly M8 x 20 19 Master cylinder mounting bracket welded assembly 5 2 1 Maintenance Guide Disassembly Maintenance and Assembling 1 Remove the bracket assembly from the vehicle body Remove the steering column according to the methods for disassembling the steering column jacket pipe in Chapter 2 and put it down Remove the brake pedal and brake bracket assembly together with the brake master cylinder assembly from the vehicle disconnect the nuts used for installing the brake master cylinder to take
82. eason tooth Reduction ratio 41 8 5 125 Type of front axle internal dia xexternal dia xwidth mm 30305X2B 25x62x 18 25 Type of rear axle internal dia xexternal dia xwidth mm 30306X2B 30x72x24 35 Differential mechanism Half rear axle gear type quantity x teeth number Bevel gear of straight teeth 2x14 Planetary gear type quantity x teeth number Bevel gear of straight teeth 2x10 Bearing type internal dia xexternal dia xwidth mm 32008X1WC 40x72x19 4 3 2 Half Rear Axle and Rear Axle Housing Assembly 1 L eft half rear axle assembly 2 Right half rear axle assembly 3 Half rear axle adapter sleeve 4 Bearing 5 Half rear axle washer 6 Bearing cover T Left half rear axle 8 Right half rear axle 5 Half rear axle grease seal 10 Support ring 11 R ear axle housing welded assembly 12 Vent plug 4 3 3 Maintenance Guide Disassembly Disassemble the rear axle 1 Jack up the vehicle body safely and reliably and remove the wheels 2 Use a bracket to Jack up the rear axle 3 Remove the parking brake cable Let out the brake fluid and dismantle the brake hose spring screw of loading sensing pressure proportioning valve and bolts of drive shaft 4 Remove the lower extreme connection of rear shock absorber 5 loosen and draw out the connecting pin with lifting eye that used for leaf spring installing 6 Lower the bracket so as to separate the rear axle and vehicle body Disassemble brake
83. ed the window frame basically The two ends of rope are inside the window frame 4 Pull out the bordure in glass rubber strip by uprightly and adown pulling out the two ends of rope along the edge of window frame with a reserve direction to make sure the bordure in rubber strips is seized into the flanging of window frame 5 Pull out the whole rope and hammer all rubber strip assembly around with a rubber hammer to ensure its rubber strips are jointed on the window frame well 6 Spray the rear window with a water gun of vehicle cleaning for a couple of minutes and then go into the car from the front door to check if there is water permeable 7 If it leaks check the attached surface between glass strip assembly and window frame and repeat step 4 or replace with new windshield rubber strips 8 Assembly will be defined as finish if no leakage Installation of back door windowpane and rubber strip Body 8 15 8 4 Front Door Trimmings Get ready the following materials before installation Applications Butyl tape seal or waterproof Grease lubricant etc Grease Lubricant Lubricative Make lubricate rubber strips slide more Suds smoothly Used for brushing suds Used for door and window regulator Adjusting hook and adjust split ring inside the rear door made up of steel wire etc Used for coat after disassembling installing and adjustino Coatings relevant Disassembly Disassemble as sequence number as shown in th
84. ension Longitudinally mounted symmetry type semiellipse leaf spring with telescopic shock absorber Dual circuit hydraulic braking system front disc and rear drum Service brake brakes Parking brake Mechanical cable type for rear wheel Type of tires Tire specification 175 R13 LT li Two doors with full metal Carriage type frame carriage and frame are connected with bolts The connection type of wire Cathode ground strap connection Rated voltage of circuit Storage battery 12V 36 Ah Low electrical Motor auto return intermittent and two speed no load equipment 45times min 7Otime min Front position lamp 000000000000 w O turn signal lamp 21w for front left front right rear left and rear left 5w for side brake lamp rear position 21w 5w lamp 5w acne icense plate lamp Aw oO o gt o O Cc C D interior lamp instrument panel lamp 4 indicator light Tum signal lamp flashing frequency Alarming signal lamp flashing 85 12times min frequency Basic Information 1 13 Items WLD1200Q1P Rated voltage v 72 Electromotor Rated power kw 6 Electromotor Rated voltage v 72 controller Rated electric current A 85 Auxiliary storage battery 12 V 36 Ah Coo cathode ground strap connection Power storage battery 72V 115 Ah C Input voltage v 72 DC DC Converter Output voltage v 13 5 Max output electric current A 25
85. er abrasion on one side of the tread pattern 2 Improper alignment lack of transposition rib or pattern block 3 Improper alignment tires are not uniform 4 Start by jerk tire pressure is too high 3 4 4 2 Limitation of the Tire Abrasion The tire must be replaced when the depth of tread pattern groove lt 1 6mm 0 063in or there are six indicating patterns on one direction of the tire tread and more than three of them are coming up to the groove Limitation 1 6mm 3 4 4 3 Lateral Sway of the Tire owing means there is a shimmy happens to the vehicle of the front part and rear part which result from the steel wire belted layer in tires out of straight This swing appears obviously when vehicle running at a low speed about 8 48km h 5 30mile h Just carry through road running test to the vehicle to ascertain the trouble tire If the problem happens to the rear wheel the driver may have a feeling that someone is pushing on the side of the car when it swings bilaterally If the problem happens to the front wheel the driver may have a more obvious feeling of swing of the wheel bearing that the metal plate parts move forward and backward 1 Find out which part causes the swing problem wheel of front or rear 2 If the swing side cannot be found after fitting good tire and wheel onto the vehicle replace the wheel of rear 3 Process a road running test again If the swing problem gets weak fit a used tire onto the vehicle until t
86. ers of battery pack will reach unanimity When operating battery workers should wear safety goggles and dress protection suit If electrolyte acid splashes into eyes or skin immediately clean the affected parts with plenty of water and send for a doctor for inspection and therapy The electrolyte on clothes should be soaked with clean water Do not place tools on battery for preventing short circuit of battery Use appropriate slings to hoist battery for preventing the drop of battery or the damage of battery shell After discharge charge as soon as possible The maximum temperature of battery discharge should not exceed 55 C and continuous operating temperature should not exceed 45 C otherwise the life of battery will reduce The surface temperature of battery at the beginning of charging should be less than 40 C If the temperature is more than 45 C the battery should be charged after cooling Discharge should not exceed 80 of standard capacity The usual deep discharge will reduce the service life of battery The battery should be fully charged for once every day because the usual intermittent charge will damage battery Inspection and Maintenance Daily Inspection and Maintenance gt The battery should be charged immediately after each discharge gt Each discharge should not exceed 80 of total capacity of battery Weekly Inspection and Maintenance gt Inspect whether the cable screws among battery un
87. ess Install sleeve gasket adjusting shim for tightness force of driving bevel gear front bearing inner races connecting flange and special nuts into the driving bevel gear in turn not include oil seal 2 Tighten the special nut to a specified torque of 170 220 N m and then check the gear starting torque bearing pre tightening Power Train 4 15 Bearing pre tightening of driving bevel gear Without oil seal 0 40 7H m T occ Wnvlng bevel gear EE m Se Fear dilm af driving be vel gear ort 3 If the bearing pre tightening is not included in the standard range replace its pre tightening adjusting shim If bearing pre tightening is larger than the standard value enhance the thickness of adjusting shim whereas reduce the thickness Disassemble the connecting flange and the driving bevel gear again Assemble oil seal to bearing support and apply the lubrication on the mouth of oil seal Reassemble the driving bevel gear so that the driving bevel gear can be aligned to connecting flange And then screw a new locknut up to the specified torque of 170 220 N m and then rivet the locknut on the notch position of screw thread of the driving bevel gear with a special tool Recheck and verify the bearing pre tightening of driving bevel gear with oil seal 0 6 0 9 N m Attention Loosening the locknut backwards to reduce the bearing pre tightening for the purpose for achieving the standard value is n
88. g Specifications GL 5 90 used in summer in the north and south of China GL 5 80W 90 used in winter in the north and south of China with a condition of 35 C or 35 C below Replacement of lubrication oil 1 Remove the plug screw of oil inlet hole 2 Remove the plug screw of oil drain hole After draining all the oil fit on the plug screw of oil drain hole and tighten it according to specified torque 3 Fill with a kind of gear lubricant oil that fits to the season need on viscosity and brand from the filler inlet to its bottom Fit on the plug screw of oil inlet hole tighten it according to specified torque 4 2 Drive Shaft 4 2 1 Specifications The drive shaft adopts a double universal joint structure which the front end connects with sliding spline and the back end connects with flange bolt Size of universal joint Shape size DxL 24 017x63 99 4 2 2 Drive Shaft Assembly A 35 40 N m Sliding yoke assembly Cross axle assembly Circlip Axle tube and Axle yoke assembly Flange yoke 4 2 3 Maintenance Guide Remove the snap ring with a circlip pliers 2 Use a special tool to pull out the bearing pedestal ring of cross axle from the pedestal ring of the Axle yoke with 3 4mm in length Special Tools 1 Guide Pillar 2 Seating Power Train 4 4 Attention Before pulling out the bearing pedestal rings of cross axle osmotic lubrication should be applied between the bearin
89. g pedestal rings and the pedestal rings of the axle yoke 3 Knock the tube yoke with a hammer to remove the bearing pedestal rings 4 Take off the bearing pedestal ring on the other side according to the methods in the process of 2 and 3 5 Flange yoke disassembly Pull out the bearing pedestal ring of the flange yoke according to the methods in the process of 1 and 2 Then clip the bearing pedestal ring by a jaw vice while knock the flange yoke to take off the pedestal ring Use the same way to remove the bearing pedestal ring on the other side 6 Disassembly of sliding yoke Disassemble the sliding yoke according to the methods in the process of Assembly Attention Make sure all of the roller pins in bearing pedestal ring of cross axle have been located accurately Lubrication oil must be applied on the bearing pedestal rings of cross axle A Lubrication 7022 high performance vehicle lubrication or lithium base lubrication can be adopted for this lubricating Power Train 4 5 Jaw uice 1 Copper hammer 2 Bearing pedestal ring 3 Universal joint yoke 4 Cross axle Attention When reassembly snap ring cross axle and bearing must be used new ones No reuse of the snap ring cross axle and bearing once they have been disassembled 1 Insert the bearing pedestal rings to the inner of tube yoke of drive shaft and knock it with a hammer until it flushes to the yoke surface At the same
90. g shim for the moment 2 Assemble the differential assembly into bearing support Push it to one side include bearing outer ring to measure the clearance between the bearing support and the end face of differential bearing outer ring Remove the bearing inner race from differential housing in order to install the adjusting shim of differential bearing Thickness of the single side adjusting shim for differential bearing a half of measured clearance value 0 05 mm this thickness is provided for the purpose of ensuring bearing pre tightening Choose two adjusting shims according to the thickness of single side adjusting shim as showed above least quantity install them in the two sides of differential housing and then press them into the bearing inner race Assemble the bearing cover of two sides according to position marks Fit on the connecting bolts with a specified torque Tightening Torque 35 40 N m Check the reduction gear pair side play as per the methods above If the side play does not meet requirements adjust it as shown in the figure till it meets the requirements Check the contact area of the teeth surface of reduction gear pair as per the methods above Check the end face run out of driven bevel gear as per the methods above If the run out range has exceeded limiting value find out the reasons and remove the trouble Power Train 4 17 Clearance 0 05mm Thickness of shim ion sing
91. ght of arc in installation status idle load 135mm shown in the following figure 1 Nut M10x1 25 10 2 Grower washer 10 3 U bolt 4 Buffer rubber assembly 5 Shock absorber bottom bracket welded assembly 6 Nut M10x1 25 10 7 Grower washer 10 Nut M10x1 25 10 9 Grower washer 10 0 Shackle plate I D Plate spring shackle assembly Plate spring bushing Il 3 Lock nut M12x1 25 8 9 Front Holding pin of plate spring 3 Plate spring with bushing assembly Suspension Wheel and Tire 3 18 Checking Check the undermentioned parts Bending or damage Damage or abrasion Damage abrasion or aging Damage or abrasion Assembly Install the parts according to the sequence shown in the figure D Plate spring with i 3 Lock nut Plate spring gt M Spring D OE Pale shackle bushing assembly a M12x1 25 8 bushing Il a 6 Shackle plate II Grower Grower pasne 10 ne 29 ds 10 25 i Shock absorber Buffer G rower 3 U bolt tos bracket ao ae awit welded assembly assembly Suspension Wheel and Tire 3 1 3 3 3 Rear Shock Absorber Assembly 3 3 9 1 Disassembly Hex nut Shock absorber Grower washer Inner bearing pad Outer bearing pad Inner bearing pad Hex nut Rear shock absorber bushing Grower washer Rear shock absorber bushing Outer bearing pad 000000 Disassembly Disassemble the parts according to the sequence shown in the figure Checking Check the parts Damage Distort
92. h is Inspect switch damaged Repair according to requirements Wire is damaged Head light tail light or Tail fuse is burnt out Inspect short circuit replace fuse license plate light not bright Easily fusible link is burnt out Replace easily fusible link Side lamp switch is damaged Inspect switch Wire is damaged or earthing is bad Repair according to requirements Turn signal light not bright Switch of turn signal lamp is bad Inspect switch Wire is damaged or earthing is bad Repair according to requirements Turn signal light at two sides Turn fuse is burnt out Inspect circuit replace fuse not bright Turn signal danger switch is bad Inspect switch Turn signal flash relay is damaged Inspect flash apparatus Wire is damaged or earthing is bad Repair according to requirements Brake light not bright Horn fuse is burnt out Inspect short circuit replace fuse Parking lamp switch is damaged Inspect switch Wire is damaged or earthing is bad Repair according to requirements Brake light often light Brake lamp switch is damaged Adjust or replace switch Adjustment of Headlight Beam Park the vehicle on irregular ground In face of the Complete Vehicle Electrical 10 28 screen or wall which is 3m away from headlight charge tyre to the stipulated pressure and discharge the load on vehicle except driver Draw horizontal line and vertical line on screen screw plusminus screw make the distance between high strength center an
93. he problematic one has been found out If the swing problem gets worse replace 4 used tires with new ones and then install one used tire again according to the same method to check the trouble in turn Suspension Wheel and Tire 3 23 3 4 4 4 Running Deviation and Diagnoses Flow Running Deviation means even though there isn t any force acting on the vehicle it may also runs out of the straight line on the plane road surface The reasons for running deviation Improper front wheel alignment Running with applying the brake Tire defects The way of manufacturing may cause the direction deviation of the vehicle Take the tire fixed by belted layer as an example Off centering belt layer may cause a lateral force to the vehicle that make the vehicle sway on the road If the diameter on one side of tire is longer than that of the other one the tire may be easy to swing on one side which may enhance the lateral force to cause deviation running of the vehicle In case of this adopt the following processes in the sheet Diagnoses Flow Chart of Running Deviation to ensure the accuracy of front wheel alignment so as to avoid the direction deviation of the vehicle 1 There are some differences between accurate tire transposition figure in User Manual and Maintenance Guide and the parts of running deviation diagnoses process If one kind of middle or high mileage tire is fixed to one side of the vehicle it must be checked whether it is comfor
94. ing mark SRotate the drive shaft to the end with an anticlockwise direction measure the distance between the matching marks which is the total end play of rear axle of power train Its ultimate value is 5 mm If the end play exceeds the ultimate value remove the speed reducer assembly and adjust it 4 1 3 Check for calorification of Outer Housing of Rear Axle and Speed Reducer The reasons may concern to the over pre tightening of bearing or engagement side play of the gear is too small or insufficient lubrication oil and wrong specifications of lubrication oil Once the problems above occur remove the trouble in time Often clean the vent plug keep the air vent clear 4 1 4 Check and Replacement for Lubrication Oil of Power Train 4 2 Power Train 4 3 Speed Reducer Position 1 Oil inlet hole Torque of plug screw 40 60 N m 2 Oil drain hole Torque of plug screw 40 60 N m Oil level check up D Stop the car on the level ground and tension grip brake 2 Remove the plug screw of oil inlet hole 3 Stretch the finger into the filler inlet to touch the oil 4 Normal oil level level Fit on the plug screw of oil inlet hole Warning After driving the vehicle its oil temperature is extremely high check the oil lever only after decreasing the temperature until the oil outlet plug no longer burn you hand opecifications of the lubrication oil as followin
95. ion damage and oil leak Damage and abrasion 9 Suspension Wheel and Tire 3 20 3 3 3 3 Assembly Install the parts according to the sequence shown in the figure T Tightening torque Unit N m kgf m Rear shock absorber bushing Grower washer Rear shock absorber bushing Hex nut Inner bearing pad Outer bearing pad Inner bearing pad Grower washer Shock absorber Hex nut Outer bearing pad 000000 3 3 4 Notices to the Maintenance of Rear Suspension Check the rubber parts always replace them if any damage crack and aging Check the parts such as back plate and Front pin assembly shackle inner lateral plate welded assembly shackle outer lateral plate left right plate spring plywood assembly U bolts etc and threaded fasteners Always replace them at once if any damage such as abrasion crack or screw thread failure Check the rear shock absorber assembly always replace it if any oil leak abnormal knocking failure and seizure Check the plate spring assembly and replace its spring lamination at once if there are cracks in it Also always replace the clamp and U clamp if any damage When installing apply graphite lithium base grease between each leaf of plate spring When installing class symbols of two plate spring assemblies in the same vehicle should be not different Suspension Wheel and Tire 3 21 3 4 Wheel and Tire 3 4 1 Specifications Wheel type Disc wheel Wheel rim specificat
96. ion switch and light switch before connecting or removing the negative cable Or damages may be resulted in Use a cable clamp to tighten the wiring harness to avoid any looseness The wiring harness Basic Information 1 5 connected to vibrating parts such as the electromotor etc should be loose in a certain scale so that the free oscillations of the vibrating parts will not be restrained by the harness connection When using cable clamps to fix them you should confirm that its relaxation modulus is adequate f there is a assembly mark indicated on the harness color strip on which you should fix the harness properly P Assembly mark a f a harness has to contact with any sharp edge of the other parts be sure to protect the harness byusing ethylene tape etc to twine the parts that the hardness is easy to touch with the sharp edge to avoid any possible damage to electrical wire i WANN an Never allow any wiring or harness be pressed under any parts Basic Information 1 6 Only use the fuse with the specified current Disconnect an adapter by pulling both ends of capacity to replace the fuse blown If using the the adapter Do not disconnect an adapter by fuse with bigger current capacity some parts may pulling the cable connected be blown even accidents such as fire etc may be resulted in Take especially careful about the sensor relay and other electronic pa
97. ions 13x5J Cor 13x5 00B Wheel offset distance 50 Tire Type 175R13LT Inflation pressure of tire Kpa Empty loaded Fully loaded Front wheel tire 200 200 Rear wheel tire 200 200 3 4 2 Wheel Assembly 1 175R13LT Wheel Assembly 2 Wheel 3 lire valve cock Z2 01 3 4 Balancing Block 5 Decorative Cover 3 4 3 Wheel Transposition Transpose the wheels position per 10 thousand kilometers as shown in the figure so that make tires abrasion uniform 3 4 4 Maintenance Guide 3 4 4 1 Irregular or Earlier Abrasion of Tire There are many reasons for the happening of irregular abrasion and earlier abrasion such as improper inflation pressure no tire transposition bad driving habit and location improper If there is something else happen as follow the tire must be transposed Suspension Wheel and Tire 3 22 1 2 3 4 If there are something else happen as follow the Abrasion difference between front and rear tires A betur a i Ltt iH RE Leaning abrasion of tire nne 1 Abrasion difference between front R amp L tires we i A Me Nr Nr 2 P 9 n i a A O m AS n Xa Abrasion difference between rear R amp L tires A eX Ai 4 Palat ots aa wheel alignment should be checked I 1 Abrasion difference between front R amp L tires l 2 2 Serious leaning abrasion of tire 1 Difficulty in steering underinflated 3 Feath
98. irection of driven bevel gear 3 Big end d Gear face on the backward direction of dr ven bevel gear Contact area that the instal ing distance of driving bevel gear is over long Thizken the installirg distance adjusting waster of driving bevel gear An over long distance between driving so as to mase drivirg bevel gear clase ta the center of driven bevel and driven bevel gears gear A the same time move driven bevel gezr out to gain a required gesr side play Contact area that the installing distance of driving bevel gear is over short hn i i mm A lin over shart distance between driving and driven bevel gears gear to gain a required gear side play Disassembly Make a paired matching mark to ensure every part can be re assemble back to its original position after disassembly Disassemble the bearing cover and its connecting bolts Prize the differential assembly by a wooden stick or a hammer Separate the right bearing left bearing and bearing cover when store so that the parts can be assembled to their original positions without mixing Pull out the inner race of differential bearing by using a shaft bearing replacer Mark a position mark on differential housing and driven bevel gear Loosen the connecting bolts on driven bevel gear as per a diagonal line order step by step so as to disassemble the driven bevel gear Thin the installing dislance ad usting washer of driving bevel gear so asto moy
99. its are fixed Monthly Inspection and Maintenance nspect the voltage of all single batteries and make a record after 12 hours at the end of charging gt The difference between the measured value of single battery and the average value of whole battery pack should not be more than 0 049V if over the difference the battery pack wil be equalizing charged gt Keep the battery shell clean Complete Vehicle Electrical 10 3 Warning You should carefully reach relevant operation instructions before operating battery Because the electrolyte has strong corrosion you should operate and maintain battery according to the requirements of operation instructions for avoiding personal injury Warning Do not make up acid or water Do not open or remove exhaust valve Power battery pack contains high voltage which can harm people and you should avoid electric shock accident during its inspection and maintenance Complete Vehicle Electrical 10 4 e Annual Inspection and Maintenance Professionals should inspect the insulation resistance of battery on vehicle for once annually The specified value of insulation resistance of battery is 50O V nspect the charger for once according to relevant instructions for guaranteeing normal charge Storage e Ifthe vehicle is not used for long you should store it Warning in the dry environment without frost If the battery is stored for a long e Fully cha
100. kage invite professionals to replace in refer to Article 11 4 the Reading of time Failure Information for the examination method Warning Controller circuit has high voltage which can harm people cut off the battery connection wire when disassembling or assembling the controller Need electrical and electronic professionals when repairing controller There is high voltage in controller maintenance repair wiring and changing wire should be made after cutting off the power for one minute otherwise an electric shock will happen or the electronic elements will be damaged Prohibit washing the controller with water Complete Vehicle Electrical 10 12 Inspection and Repair Multi function Content of display Showing Corrective amp Preventive Measures Failure Failure Code When the voltage of DC bus bar exceeds the set value of system the controller will blank off its output and alarm and disconnect main contactor at the same time After overvoltage protection appears the Overvoltage ignition switch returns to OFF position and the system will not run again of bus bar until the system resets When overvoltage protection repeats appearing which should be regarded as failure you should repair or replace controller When it is detected that IPM has over current the controller will blank off its output and alarm and disconnect main contactor at the same time After IPM protection appe
101. le side Gear backlash is too small Gear backlashis too large Power Train 4 18 Assembly Assemble the reducer assembly onto rear axle housing assembly Remove the used sealant on the position as shown in the figure before installation and apply the new semi dry sealant on it Tightening Torque 24 29 N m 4 3 6 Special Tools Tools Number and Name Application Methods Bearing puller and bearing installing Disassemble and assemble of tool for universal joint the universal joint bearing of drive shaft 1 Guide Pillar 2 Seating Shaft bearing replacer Disassemble the half rear axle bearing Shaft bearing replacer Disassemble the rear bearing inner race of driving bevel gear B 2 7 us Power Train 4 19 Tools Number and Name Application Methods 1 Torque Spanner Measure the bearing 2 Sleeve pre tightening of driving bevel Installing tool for oil seal of driving Install the oil seal of driving bevel gear bevel gear by pressing Shaft bearing replacer of differential Disassemble the bearing inner race of differential Shaft bearing replacer for outer ring of Disassemble the bearing driving bevel gear outer ring of driving bevel gear Bearing installing tool for outer ring of Install the bearing outer ring driving bevel gear of driving bevel gear by 1 Press bar pressing 2 Briquetting Power Train 4 20 Installing distance measurer assembly Measure the installi
102. mbination lamp side turn signal lamp reversing lamp license plate lamp and residential lamp Complete Vehicle Electrical 10 25 License Plate Lamp E IL Ceiling Lamp Fig 4 Reversing Lamp Complete Vehicle Electrical 10 26 Arrangement and Specifications of Lamp Residential lamp Front position Front turn signal lampzDanger signal lamp Front fog lamp Head lamp License Reversing lamp plate lamp Reversing lamp dr Rear combination lamp Single Row Complete Vehicle Electrical 10 27 Front lamp 60 55 Front turn X signal 21 lamp danger lamp Front position lamp Rear combination 21 5 lamp Reversing lamp Residential lamp Rear fog lamp Guidance for Maintenance 1 Inspect whether the bulb is damaged if damage please replace 2 Inspect whether the combination switch is damaged if damage please replace 3 Inspect whether the power supply circuit has failure such as short circuit broken circuit and fuse damage See electric schematic diagram for details One head light not bright Bulb is burnt out Replace bulb Socket is damaged Wire is damaged or earthing is bad Repair according to requirements Head light not bright Easily fusible link or fuse is burnt Replace easily fusible link or fuse out Inspect switch Lamp switch is damaged Wire is Repair according to requirements damaged or contact is bad Far light or dim light not Wire switch or dimmer switc
103. ments and steering wheel while reassembling Before disassembling disconnect the cathode circuit of battery 1 Pull upward the upper cover along the front edge of steering wheel to remove it 20080514 2 Screw off the four screws 3 Take off the touch pad assembly of horn button 4 Remove the horn button insulation spacer and contact spring from the horn button touch pad o Remove the lower cover subassembly 6 Assemble sequence is opposite to that of disassembling 2 2 3 Installation of steering wheel assembly 1 Apply conductive grease lubricant onto the contact ring surface between steering wheel assembly and combination switch 2 The concave hole on the bottom of steering wheel should match with the dummy club of steering switch when installing the steering wheel The tightening torque of clamp nut shall be 29 39 N m Before mounting steering wheel onto steering upright column keep the vehicle on driving straight position 3 Install horn button and steering wheel upper cover Steering System 2 4 20080514 Apply conductive grease lubricant onto the contact ring surface between the lower cover and the contact of horn Steering System 2 5 2 2 4 Drawing of Site of Steering Column Components 20080514 1 Steering wheel 2 Lower cover of combination instrument panel decorative sheet 3 Upper cover of combination Instrument panel decorative sheet 4 Combination switch assembly 5
104. n please use multimeter to inspect whether large fork bolt fuse is cut Before changing large fork bolt fuse please inspect whether the power circuit connects the ground Warning 10 8 2 Main Contactor Power circuit may have the high Specifications voltage which can harm people you should cut off the connection Rated voltage of coil 12VDC of power battery when inspecting and changing main contactor for avoiding personal harm Rated current of main contact 150A Functional Description Complete Vehicle Electrical 10 21 After closing the vehicle system the main contactor is used for cutting the connection between power battery pack and motor Inspection and Repair After the vehicle is started low voltage circuit of vehicle is normal but high voltage power circuit has no reflection please use multimeter to inspect whether main contactor has failure l Corrective amp Preventive Possible Causes Measures 1 The coil of main 1 Replace main contactor contactor is burnt out Replace main contactor Bad quality of coil with good quality Bad Clean the joint part heat dissipation of between main contactor main contactor and aluminum installation 2 off welding of coil pedestal recoat heat connection wire of conduction silicate and main contactor install reliably 3 Ablation of contact of main contactor 2 Re weld the coil connection of main contactor 3 Inspect the failure information
105. n and connection position of Motion and connection position of turn dimmer switch wiper and syringe switch signal and danger signal switch po dion immer iandle po ddon O40 Qvertking lamp T Cvertikng lamp Capped ght Far light Overtiking lamp Capped ght Far Wight Overhking lamp Oppad ight Far Wight m LL Lp pee nis rara E ve Tem a acad LL LII Complete Vehicle Electrical 10 31 10 9 6 Windshield Wiper and Syringe 1 Wiper motor and_ bracket assembly 2 Wiper connecting rod assembly 3 Wiper assembly 4 Nut M18x1 5 5 Gasket with pad 6 Tarpaulin 7 Wiper arm assembly 8 Wiper assembly 9 Kettle cover 10 Syringe motor 11 Syringe kettle 12 Syringe shower pipe 13 Syringe nozzle discreteness Tightening Torqu N M 6 1 Lower cover of steering 5 Spring of touch board wheel 6 Upper cover of steering 2 Steering wheel wheel 3 Springcup 7 Horn 4 Touch board Complete Vehicle Electrical 10 32 10 9 8 Radio amp Cassette Player il Lr l Ml 1 Bolt M4x14 2 Gasket 4 140HV 3 Antenna assembly of radio amp cassette player 4 Loudhailer assembly 5 Tapping screw ST4 8x13 C H 6 Assembly of radio amp cassette player 7 Installation frame of radio amp cassette player 8 Tapping screw ST4 8x16 Complete Vehicle Electrical 10 33 10 10 Circuit Diagram Specifications Circuit Specifications and Color Description When one circuit uses two colors
106. n nut 5 slightly at last 4 Fasten swing arm assembly onto the front axle 7 with bolt 9 and washer 8 Bolt 9 is tightened slightly 5 Assemble the ball pin of swing arm assembly onto the knuckle to ensure that the ball pin groove is aligned to the bolt hole of knuckle Install bolt 11 and nut 12 as shown in the figure and adjust the torque of nut to the specified value Torque value Nut on the connecting between ball Tightening torque of pin of swing arm and knuckle is 55 65 N m 6 Tighten nut 5 with a tightening torque value of 68 6 88 3 Nem Both nut 5 and 12 are locknuts do not use the locknut that has been disassembled and replace new one when re assembling 7 Assemble the wheel 8 Remove the jack device and weld swing arm and front axle under empty loaded conditionBolt on the connecting of assembly is tightened to a specified torque Torque value 78 4 98 1 N m Suspension Wheel and Tire 3 17 3 3 Rear Suspension 3 3 1 Specifications Suspension mode Longitudinally mounted symmetry Stiffness in installation status type semiellipse leaf spring with telescopic shock Main spring Stiffness 42 67N mm QUSOIDPE Combined stiffness of main and auxiliary spring Number of leaves on leaf spring 4 main spring and 1 86 73N mm auxiliary spring 3 3 2 Rear Suspension Assembly Drawing Flattening length of spring 1000mm Disassembly Spring lamination width 60mm Disassemble according to the sequence Hei
107. n off those two locknuts used for fixing the brake caliper assembly and remove the brake caliper assembly Do not pull out the brake hose from the brake caliper 6 Take off the wheel hub and brake puck 7 Remove the brake puck from the wheel hub Suspension Wheel and Tire 3 10 8 Remove the oil seal and the outer ring of bearing from the wheel hub No reuse of the oil seal is allowed once it is removed Take off the oil seal and the outer ring of bearing 9 Knock down the spoke bolt with a hammer No reuse of the spoke bolt is allowed once it is removed Assemble 1 Spoke bolt assembling Insert a new bolt vertically to the bolt hole of front wheel hub unit by pressure If the front wheel hub unit has been used before be careful to keep the straight grain of bolt root aligning to the straight grain inside of bolt hole Press 2 Bumper block Spoke bolt hese three places 2 The oil seal and bearing outer ring must be coated with grease lubricant as shown in the figure before assembling are coated with grease lubricant 3 Bearing outer ring oil seal and brake puck assembling Tightening torque of fastening bolt on brake puck 55 5 N m 4 Assemble the front wheel hub assembly onto the steering knuckle and fastened it by a new slotted nut according to the requirements Fasten the nut up to a torque of 25 5 31 4N m and make the wheel hub done a reciprocating rotation for
108. nd down for several times Identify the reasons should come first when the difference occurs in data If the problem happens to suspension components that appear to be damaged loosed bended hollowed or abraded replace them If the problem happens to the vehicle body that seems to be deformed maintain it to reach the technical requirements 4 Max Steering Angle Check the toe at first and then measure the steering angle by using steering angle measurement instrument when replacing the steering tie rod or steering tie rod plinth assembly If the steering angle is wrong adjust the length L of the right and left steering tie rod to make the D value of the right and left inside steering angle is not more than 45 The toe in must be re checked if the length of steering tie rod has been changed due to steering angle modification Steering Angle Inside 37 10 2 Outside 32 46 Suspension Wheel and Tire 3 4 1 Steering angle measurement instrument 2 Steering tie rod 3 Steering tie rod plinth assembly 4 Steering tie rod locknut 3 1 3 Check of Wheel Rim Nut and Wheel Hub Bearing 1 Check every wheel rim on each wheel to make sure whether it has been sunken deformed or crackled especially on those four bolt holes If it appears to be crackled damaged and deformed seriously replace it 2 Check that the wheel nuts are tightened well Re tighten it according to the specified tightening torque if ne
109. nd then step on the accelerograph the controller will blank off its service output and alarm loosen the accelerograph lay down hand brake the braking alarm disappears Contactor Inspect the contact of contactor burnish the ablation or replace the E 11 conglutinatio contactor n Inspect the operating coil circuit and fuse of contactor replace contactor the voltage of auxiliary circuit less than 12V also results in the loss of Contactor contactor the inspection and repair method refers to 10 1 3 Inspect loss whether the charging plug is inserted into the charging socket replace the charging stop controller inspect power circuit wiring Coded disc T l E 13 l Inspect circuit replace coded disc sensor failure Pre charging mE E 14 REPE Inspect circuit replace pre charging resistance circuit failure Current E 15 sensor Inspect circuit replace current sensor failure Voltage E 16 sensor Inspect circuit replace voltage sensor failure Phase T stagger Open phase Inspect the connection of phasing line and guarantee reliability otep on the footplate of accelerator for starting touch off this failure Pedal release accelerograph to start this vehicle again the failure will E 20 position of automatically disappear the accelerator cable difficulty or sensor failure accelerator also touches off this failure exclude mechanical failure or replace the sensor of accelerator Before starting moto
110. nding circuit is short circuit or not and replace 30A fuse after repair circuit Inspect and replace relay I Inspect the resistance value of coil with multimeter Inspect contact Inspect whether DC DC converter G end connects N2 end with multimeter if not repair DC DC converter Inspect and replace relay Il Inspect the resistance of coil with multimeter Inspect contact Before and after the operation of DC DC converter inspect the voltage of auxiliary battery with multimeter if there is obvious change the auxiliary battery damages 5 Inspect whether the voltage of P1 and N1 input ends of DC DC converter are close to 72VDC and the voltage of P2 and N2 output ends are more than 12 5V or not if not input inspect the input wire and replace pre charge relay if input but not output replace DC DC converter if input and output inspect No 8 rupture disc output wire and replace output relay Complete Vehicle Electrical 10 8 DC DC oon verer Earthing end lgnlTon cael Fig 1 Charging CEES Wining schemate Dlagram m CSO Power 1 Earthiln converter batery d l pack Gand nition sateh o i I a mx T Sualllary Eartiing battery DID Wining Sehematie Gagram during the Cours of vehlele Fun Complete Vehicle Electrical 10 9 10 1 4 Charging Generator Fig 2 The charging generator for this vehicle is in vehicle charging generator Specificatio
111. ng of driving bevel gear distance of driving bevel gear 1 Stripping attachment of Half rear axle Disassemble the half rear axle 2 Sliding ham Disassemble the oil seal of half rear axle Flange bracket Disassemble the connecting flange Bearing installing tool Install the rear bearing inner race of driving bevel gear by pressing Brake System 5 1 Chapter 5 Brake System Contents 5 1 Check and Adjustment of Brake cccsscccesseeceneeeenseecenseeeeneesenseeseneesones 5 2 5 1 1 Check and Adjustment of Brake Pedal ccsssseccsessseeeeeseeeeeenseecennseeseenseeseessessaoens 5 2 5 1 2 Adjustment of Brake Pedal in Free Stroke eeesssss 5 2 5 1 3 Adjustment of the Height for Brake Pedal esses 5 2 5 2 Brake Pedal and Brake Bracket Assembly 5 3 5 2 1 Maintenance GUId E ese 5 3 5 3 Brake Master Cylinder Assembly es 5 4 5 3 1 e lep reljj ec npo lee X 5 4 5 3 2 Master Cylinder AsSemb IV siii eee eoa ei iae yc ibus uaa Leia nece dota adsit a sab en dcuc ee xdv tee eOL EO Liu aeu bus 5 4 5 3 3 MaintemanCe Guid E s 5 5 5 4 Brake Eine ASSEMDINY ic iss ssitiiteieienciinin anna 5 8 5 4 1 SDECICANONS vrara etic hh wa eee tienes a 5 8 5 4 2 Brake LINE CI
112. nnesceceneucenencenenesneneeennennens DIAGNOSIS FONM etre Vehicle Identification Number VIN Lee eeessee esee rreee eee Nameplate Brake Fluid Lubricating Oil and Fluid Sealant TFE DECS SURG m Notices to Vehicle Maintenance and Repair Notices before Inspection and Repair Notices fo Electrical SEVICE 3s aias o eoe is a aaa aaia diets INTERMENT DOTS Tel ue Preparations before the Disassembly eeeeeeeeeee rennen enne nennen LNO NE Vehicle eet M Hear Axle DisSassembDI Vecauce a aa a e EE a UR are EeuSsf Electr omotor DisasSsembly 25 20 2 Snc eiae oo Sosa soe Pos E E Ee S tesus cres Erusoes eoESS ases e RE e angu E CS GEs jt MQ Basic Information 1 1 1 2 1 2 1 3 1 3 1 4 1 5 1 7 1 10 Table of Performance Structure and Specifications for Entire Vehicle 1 11 Table of Dimension and Mass parameters ecce eee eren nennen Table of Performance Parameters 5 oen coe c ie eot Ina seca cani epa a deae merus ox oou ciere re eno d aedi sees Table of Structure and Specifications e eeeeeeeeeee ee ceeeee rennen nnn Regular che
113. ns Input voltage 110VAC 60Hz Adaptive battery pack voltage 72VDC Max output voltage 9OVDC Te Fuveiuse 250V Fant Acting type on 5A 3ABfusa for 6 3A 8x 20mm for 200 240V input Max output current 12A Floating charging output current Less than 2 5A Max charging time 10h Use of charging generator Connect the charging generator with AC power supply charging generator AC indicator light is on after detection time delay current indicator light is on the charge begins After 100 capacity indicator light illumes and after the charge ends cut off the connection wire between charging generator and AC power supply Maintenance of Charging generator Periodically clear away the exterior of charging generator and the dust and contaminant of radiation fin Inspection and Repair Failure indicator light of charging generator is on Possible Causes 1 Overheating protection When the temperature of the shell of charger exceeds 100 C charger protectively turns off and the charger automatically restores charging when the temperature reduces to about 80 C 2 Short circuit protection 3 High and low voltage protection When the deviation of input power grid voltage from the rated nominal value exceeds 2096 the charger protectively turns off 4 Overtime protection When the charging time exceeds 18h the charger protectively turns off 5 Charger damages Corrective amp Preventi
114. ntact by wires If any abnormity repair or necessary e Check the wires e Check if the wires are completely insulated If any naked section of a wire contacts with the vehicle body or any other conductors it will lead to short circuit eEnsure all wires are in good conditions and may function properly elf a wire consists of several cords check its resistance If abnormal repair or replacement is necessary Basic Information 1 8 1 4 4 Preparations before the Disassembly 1 4 4 1 Lifting the vehicles Lift or jack up your vehicle to a certain height and the hoisting or supporting point should be reliable with reasonable weight distribution The hoisting Supporting height of vehicle should be suitable and convenient for disassembly and assembly When lifting up your vehicle with a jack or a lifting jack you are advised to lift the vehicle according to the specified position to avoid any possible damage to the vehicle body e Using a jack e Using a bracket 1 9 Basic Information e Using a two sided stretch type autolift Basic Information 1 10 1 4 4 2 Rear Axle Disassembly e Jack up the vehicle saftely and reliably remove the wheels e Use a suitable support to jack the rear axle up e Remove the parking brake cable drain the brake fluid and take off the brake hose Loosen the U bolt and disassemble the leaf springs on the two sides at the same time e Rem
115. o the limit 8 1 3 Disassembly Assembly and Adjustment of Front Door Disassembly 1 Remove the door harness joints at first and then take off corrugated pipe from front door 2 Tap out the limit stop pin roll of front door 3 Sustain the front door by placing a wooden block between Jack and door inner panel 4 Unscrew the erection bolt of front door hinge and then disassemble the front door assembly Assembly Install the front door in a reverse step of disassembly such as 3 4 2 and 1 Grease lubricant should be applied on the hinge rotating components e f the rubber seal is hardened otherwise a leakage of water may occur were this to happen replace it with a new one Ensure door to be located appropriately by adjusting the door latch according to Front Door Installation Adjustment Unscrew the four hinge bolts on one body side and the ensure the clearance between door and the edge of door frame are even by pushing the door up and down forward and backward 1 Corrugated pipe N M 2 Harness joint Body 8 6 1 Pin roll 2 Front door limit unit 1 Wooden block 2 Jack
116. ont spring upper support welded assembly Bumper block Shock absorber dust guard Coil spring Front shock absorber assembly Bolt M12X 1 25 x 55 8 8 Nut M12X 1 25 8 Steering knuckle assembly Wheel hub and Brake WS oun 1 Jump ring of hose joint 6 Be careful to protect the front shock absorber and coil spring assembly and avoid any fall off of them when taking off those three locknuts from front suspension support assembly Take off the front shock absorber and coil spring assembly 7 Disassemble the front shock absorber and coil spring assembly Press the coil spring with a special tool until the force between coil spring and spring seat gets to zero Special tool A Spring Compressor Remove the dust guard from the front suspension support and clip the spigot of stop dog hub frame with a fixture Screw off the top nut of shock absorber piston rod Take off the following parts in turn for checking and replace the one that seems in bad situation with a new one 1 Dust guard Nut M12x1 25 8 Washer 12 Suspension support assembly Plane bearing Front spring upper support welded assembly Bumper block Shock absorber dust guard Coil spring 0 Front shock absorber assembly 11 Bolt M12x1 25x55 8 8 12 Nut M12x1 25 8 13 Steering knuckle assembly 14 Wheel hub and brake A O A c RH Suspension Wheel and Tire 3 13 Locknut Suspension Wheel and Tire 3 14 8 Assemble the front shock absorbe
117. ontact of dial indicator onto the middle part of teeth of the other planetary gear rotate the planetary gear to and fro for measuring the gear side play Check on the contact area of reduction gear pair Reduction gear pair side play The end face run out of driven bevel gears Measuring terminal lt lt y E SA SE R LK LES Sie sn Y 93 Ln Limitati an 08mm Power Train 4 11 Apply a thin layer of red lead on the front and back side face of the driven bevel gear teeth with a quantity of ten teeth Inset a copper stick into the space between the bearing support and the differential housing Rotate the connecting flange in forward and reverse direction while apply a load by a copper stick so that the rotation of connecting flange needs a driving moment of 2 5 3mm Check the contact area of gear face which is an important quality index of reduction gear pair and a method to verify whether the installation distance of driving bevel gear and the gear pair side play are proper or not A qualified contact area can be achieved by adjusting installation distance and side play If adjustment is failure to get a qualified contact area that means the gear pair has be abraded so seriously that needs to be replaced Power Train 4 12 Check and Adjustment of Engagement States Regarding the Gear Face of Driving Gear and Driven Gear Contact ways of standard gear 1 Small end 2 Gear face on the forward d
118. ooth and plane surface by keeping its wheels in a straight and forward condition Measure the center distance A and B of the front and rear wheel tread between its two front wheels Attention is allowed when measuring Toe In Value B A 0 3mm 2 Toe In Adjustment Adjust the toe in by modifying the steering linkage in length First of all loose the right side and left side steering tie rod locknut 3 and apply grease on steering tie rod and small end hole of gear rack dust guard to avoid twists when adjusting the toe in Secondly adjust the toe in as per pre setting parameter required by rotating the right and left steering tie rod with an identical torque pay attention to ensuring the distance L between the right side and left side of ball pin and the root segment of tie rod is equal when adjusting After that tighten the steering tie rod locknut as per the specified torque 3 Tighten Torque Steering Tie Rod Locknut a 50 65N m Suspension Wheel and Tire 3 3 1 Steering tie rod 2 Steering tie rod plinth assembly 3 Steering tie rod locknut 4 Gear rack dust guard 3 Check and Adjustment of Camber Angle Caster Angle and Kingpin Inclination Adopt front wheel alignment measurement instrument to measure Camber Angle Caster Angle and Kingpin Inclination Keep the vehicle in a toe in measure condition then take measurement after pressing the front end of the vehicle up a
119. ot allowed Reducer Assembly Assemble the half rear axle gear adjusting shim planetary gear and ball washer into the differential housing Insert the planetary axle not include the loosen proof cylindrical pin for the moment Adjust the differential gear pair side play Use a dial indicator to check the gear side play of planetary gear and half rear axle gear pair You may achieve a proper side play by changing the adjusting shim thickness of half rear axle gear After adjusting well the gear pair will rotate flexibly without any clamping stagnation Here are some type of the thickness of adjusting shim 0 85 0 90 0 95 1 00 1 05 1 10 1 15 and so on Install the loosen proof cylindrical pin Punch two points on the edge of pin hole on differential housing with a dotting punch so as to avoid pin dropping out Install the driven bevel gear in the differential housing and mark by aligning with the position Connect them by connecting bolts which should be coated appropriate amount of anaerobic glue e g Loctite glue 242 on the surface of screw thread to avoid loosening Power Train 4 16 when installing Gradually tighten the connecting bolt up to the specified torque as per an order of diagonal line Tightening Torque 65 70 N m Adjust gear pair side play of reducer as per following process D Tightly press the differential bearing inner race onto the differential mechanis not include adjustin
120. ove the lower connector of the rear shock absorber e Lower the support to separate the rear axle from the vehicle body e When singly disassembling some elements from the rear axle or other assemblies you can lift or jack the vehicle or a part of the vehicle as necessary 1 4 4 3 Electromotor Disassembly e Disconnect power battery Connecting cable e Disconnect connect the connector plug of wiring harness e Remove the flange bolt connecting the rear axle and the drive shaft and then draw out the drive shaft Use a clean stopper to block the output end of gearbox preventing the lubricating oil from flowing off e Pad the bracket under the electromotor and support the electromotor e Remove the hoisting bolt of gearbox at the point where the gearbox is connected with frame e Remove the bolts connecting the electromotor suspension and the R amp L beam then lower the bracket to remove the electromotor from the vehicle e When standing in a trench to install the electromotor make sure to hold the electromotor firmly to avoid any possible injuries 1 4 4 4 Assemble Lift or jack up the vehicle to a certain height Please refer to the information concerning the disassembly for reassembly Attention e During the reassembling the unchanged parts should be all cleaned especially the mating member Apply corresponding lubricant on the surface that needs lubricating e During the reassembling tighten all fasteners to the torq
121. own in 5 3 2 for filling fluid lever in detail Brake System 5 7 5 After finishing the installation check the end play of brake pedal and discharge air in the system Refer to the check on the end play of brake pedal and the exhaust of brake 6 Carry out brake test check that each of installation parts leaks oil 1 Detent 2 Connection 3 Master cylinder 1 Hose for brake fluid reservoir 2 Pipe clamp 3 Connection Brake System 5 8 5 4 Brake Line Assembly 5 4 1 Specifications c4 75x0 71 bundy tube 5 4 2 Brake Line Assembly Two hole pipe clamp Two hole pipe clamp base Master cylinder three way brake pipe assembly A Master cylinder three way brake pipe assembly B Two hole bushing Three way connection assembly Bolt assembly M8x30 Three way right rear wheel oil pipe assembly Three way left rear wheel oil pipe assembly Three way right front wheel brake pipe assembly 10 Jump ring of host coupling 11 Front wheel brake hose assembly 12 Three way left front wheel brake pipe assembly 13 Bolt assembly M6x16 14 Single hole pipe clamp 15 Two hole pipe clamp 16 Two hole pipe clamp base 17 Right rear wheel brake pipe assembly 18 Brake hose assembly 19 Pipe clamp 20 Left rear wheel brake pipe assembly 21 Single hole pipe clamp II g SS Se M a a YS 10 GA KIO g 3 VN Y aun A e 5 4 3 Maintenance Guide Disassembly 1 Lift the automobile and sup
122. plate is badly worn were this to happen replace the coupling plate Carry out general maintenance for the connection assembly of electric motor and transmission according to the following steps Loosen four bolts on the connecting plate remove the electric motor together with the connecting plate Loosen four bolts on the coupling plate remove the coupling plate if difficult to remove do it after vibrating slightly with a wooden hammer Loosen the hex nuts remove the coupling plate II Loosen four bolt assemblies that connect the connecting plate and the electric motor so as to remove the connecting plate Check that the splines and the flat keys in the coupling plate are worn and replace them if necessary When reinstalling tighten the bolts and the nuts according to the specified torque After installation start the electric motor check if there is abnormal knocking 6 2 Suspension System Assembly of Electric Motor and Transmission 6 2 1 Description Suspension system assembly of electric motor and transmission is composed of electric motor mounting bracket forward mounting welded assembly of electric motor suspension soft pad assembly rear suspension plate and rear support glued laminated member etc 6 2 2 Tightening Torque Required for Suspension System Assembly of Electric Motor and Transmission All parts and tightening torque in the figure torque N m Nut M10x1 25 55 60 ae 3 Weser
123. port it reliably remove the tires and wheels When removing the pipelines that connect the master cylinder and two way coupling do not use this operation 2 Clean off the dunghill and impurities from the hoses and installation parts at the end of the hoses Remove the front and rear brake hoses or pipelines Checking Oil pipes and hoses must be in good condition they do not allow being shrunken or fractured due to collision and being rusted if the hoses become swelling ageing etc replace them in time or they influence traffic safety Installation Install the brake hoses as per the reverse process and tighten the oil pipes according to the specified torque Tightening torque Ca 15 22N m Attention e Never reuse the removed retainer ring and jump ring always replace them with new ones e The jump ring and the retainer ring should be correctly installed in the neck of brake hose coupling e When installing the hoses make sure the hoses connect without twist e In any case hoses and brake hoses are not allowed to be in contact with other parts except pipe clamps and bushings Exhaust of Systems 1 Fill the brake fluid reservoir with brake fluid make the fluid lever rise to the specified position 2 Repeatedly carry out bleeding according to the sequence shown in the figure until the fluid no longer contains air bubbles when it flows from the wheel cylinder 3 Tighten the bleed screws and then fix the
124. process Assemble the front and rear bearing and special tools inside the bearing support as shown in the figure Before assembly every matching surface of special tools should be applied a thin layer of lubrication M18 x1 5 6g 2 Tighten the locknut of special tool up to gain a standard bearing pre tightening 3 Measure the bearing pre tightening of driving bevel gear without oil seal with a torque wrench Tighten the nut of special tool gradually while checking the pre tightening 4 Put another special tool inside of differential bearing support Choose a group of adjusting shim whose thickness is equal to the clearance between those two special tools 5 If there is no available special tool to use measure the distance from center line of differential bearing to the end face of rear bearing hole on driving bevel gear as A the height of rear bearing as B the actual installing distance of driving bevel gear as A A should be marked on the small end face of driving bevel gear If it hasn t been marked yet adopt a nominal value as 86 The thickness of adjusting washer D H B A Install the adjusting shim of installing distance whose thickness chosen as above onto the driving bevel gear the least quantity of washer then make sure to press the rear bearing inner race down to the bottom of driving bevel gear Select thickness of front bearing adjusting shim for driving bevel gear according to the following proc
125. r and coil spring assembly Process the assembly with a reverse order of disassembly when assembling Attention The lower point of coil spring should match with the ladder form part of the front spring lower seat 1 Front spring lower seat Attention The plane bearing should be located on the proper position Tightening torque Ca the top nut on the piston rod of shock absorber 40 68 3 N m Assembly 1 Process assembly with a reverse order of disassembly 1 6 and adjust the fastener to the specified torque as shown in the figure Tightening torque Ca Nut on the front suspension support assembly 39 2 49N m Cb Nut on the connecting between the steering knuckle and front shock absorber 85 95N m Both nut 1 and nut 2 are locknuts do not use the locknut that has been disassembled and lace new one when re assembling 3 2 3 3 R L Swing Arm Assembly 2 O C amp x ey SS o RUN ik am A NS ES Wwe a 7 GR R P Uu SONS LN I m KS EN A A a ip N l Y Ki K Front Suspension Components Assembly Swing arm components disassembly Suspension Wheel and Tire 3 15 Hut M12 1 25 8 3 Jump ring ot hose joint 2 Hurt M 10 125 10 4 Brake hose support owing arm assembly Bumper block of knighthead Bolt assembly 4 pcs Cushion Nut Knighthead support welded assembly Front axle assembly 12 Washer 12 M12X1 25X85 Bolt M12X1 25X85 10
126. r of the brake caliper but not all the piston is pulled out Attention e In height face B of the dust guard equals face A of the brake caliper 6 Inset the piston into the inner of brake caliper with hands 7 Install the jump ring of dust guard and fix it firmly Brake System 5 14 2 The shie face of the grecs terards the side face of puree 8 Connect the brake caliper to the brake hoses 9 Apply grease on the guide bar and the locating rod and then mount the brake caliper in the supporting frame 10 Tighten the locating rod according to the specified torque Attention e Make sure to install the dust cover I CIL in the designated position Tightening torque 45Nem 11 Tighten the bolts for brake hoses according to the specified torque Tightening torque 15Nem b 15N m Brake System 5 15 Apply grease on A Brake System 5 16 5 5 3 3 Brake Disc Disassembly 1 Jack up the vehicle remove the wheels 2 Loosen the bolts 2 pieces on the supporting frame take off the brake caliper assembly and hook the caliper body with a iron wire Caution e Take care not to damage brake hoses and never step on brake pedal during the process of disassembly 3 Remove the shield unfix the inserted pin remove the slotted nut loosen the construction bolts 4 pieces for hub to take off the hub 4 Take off the brake disc 1 Shield 2 Inserte
127. r system prohibit the operation mode selection of Wrong forwarding or retrograding Otherwise the system will have no power E 21 starting output and display this failure at the same time release the operation order mode selection place the direction selection switch on N position start this vehicle again the failure disappears 10 3 Motor 2 Se ae Se Se SS SS SS SS SS SS SS SS x ae te ae oe a ae eS SS DITIIIIIIIIIIIIIIIIIIIIII a me me me me ee Hz ILLI a a a Saian man Dan man Dan man pan man pan man pan man pa man oas sa oan man ete cet ae man ee a ae ae oe a ma eas e manian ae san man eae ae ae ane oe ae ee oe man pan an aan man an j man pan mannan man an ma oa man nan man pa sannan man pa anean mes arian ian man an aaa IZTITIIIIILIILIIIIIIIIIIIIIIIIIIIIIIII D LTDIITIITIITIIIIIIIIIIIIII aan aan an aan ean ean aan aan ean a aan ean a aa ean aa aa aan aan a eaa ean e ea aaa ea aa eaa ea a ea ean aa at Fig 3 Specifications Type Three phase asynchronous motor Rated power 6Kw Rated current 84A Rated line voltage 53V Rated rotating speed 2000rpm opeed adjusting scope 0 5800rpm Motor Connection U V and W lines of motor respectively connects with U V and W lines of controller and the motor coded disc line connects with controller Motor Use The battery on electric vehicle instead of engine is used as the power unit of vehicle DC power supply output
128. re code When there is failure on vehicle multi function display continuously gives the alarm of three sounds and partial failure information will be displayed through the display screen the display type is like E XX When more than two kinds of alarm appear at the same time multi function display emits long and intermittent alarm e Charging Cue Light When power battery needs charging this charging cue light is intermittent or often bright for providing warning When current electric capacity of power battery pack reaches 02 multi function display emits short and intermittent alarm at the same time the charging indicator light is intermittently bright which warns user to charge When current electric capacity of power battery pack reaches 01 multi function display emits continual alarm at the same time the charging indicator light is continuously bright which warns user to charge as soon as possible otherwise the battery will be harmed e Multi function display not only shows the electric capacity current and other parameters but also provides the drive signal to speed meter odometer voltmeter and current meter of combination instrument Inspection and Maintenance If the display value is different from actual value or the deviation of combination instrument is bigger or the odometer has no display you should inspect the connection and replace multi function display Complete Vehicle Electrical 10 18 10 5 Warming Machine
129. rge the vehicle for once monthly time and not used its service life will reduce Inspection and Repair e Excess temperature during the use of battery Corrective amp Preventive Possible Causes Measures 1 Overload work of electric 1 Reduce load motor car Lubrication driving Bad lubrication system Uneven damage abrasion Replace tire of tire Inspect brake Brake drag 2 The ambient Excess ambient temperature temperature for battery is required to be 20 45 C which can not be exceeded e Big voltage discrete between battery l Corrective amp Preventive Possible Causes Measures 1 At the beginning of use of 1 Measure after using battery the battery for a long 2 Depth of discharge usually time exceeds 80 2 Avoid the depth of 3 Never equalizing charge discharge more than 4 Too dirty battery cover 80 5 Internal short circuit 3 Equalizing charge for once monthly 4 Clean and blow the battery dry after charging 5 Find the battery with the lowest voltage and replace e Overtemperature of battery during charging l Corrective amp Preventive Possible Causes Measures 1 Failure of charger 1 Inspect the charger s 2 Bad ventilation parameters such as 3 Internal short circuit of time current voltage battery etc 4 Vulcanization of battery 2 Change the operation plates environment or use fan 3 Inspect and replace short circuit battery 4 Equ
130. ries in brake cylinder and its spare parts type of which is different from that of the brake fluid used for the vehicle Installation 1 Install all spare parts in the order reverse to the disassembly steps of rear wheel brake cylinder assembly 2 Exhaust the air in the pipeline and cylinder according to the exhaust method of brake pipeline Attention e Install the cup ring of rear wheel brake cylinder with special cone tools daub brake fluid on the contact surface between special tools and piston and slide the cup ring onto piston slowly evenly and continuously Brake System 5 21 Dust guard Bleed screw A hilewinderblaskaly oo Rear brake cup ring Pistan Lip upwards 5 6 3 4 Rear brake Soleplate Welding Assembly Disassembly 1 Disassemble brake drum according to the above mentioned steps 2 Disassemble brake shoe parking brake lever and clearance self adjusting device according to the above mentioned steps 3 Disassemble rear wheel brake cylinder assembly according to the above mentioned steps 4 Disconnect the connection between the parking brake cable and brake soleplate 5 Disassemble half shaft assembly according to the disassembly method of half shaft assembly 6 Disassembly bolt of rear brake soleplate Installation Install all spare parts in the order reverse to the disassembly steps of rear brake soleplate welding assembly 5 6 3 5 Rear brake Clearance Adjustment
131. rotection You should only use the genuine Wu Ling parts to replace them Vehicle Washing When using a high pressure washing gun to wash your vehicle always maintain the nozzle 300 mm away from each plastic part or each opening such as doors truck and roof opening No washing the automobile chassis of electromotor controller system and power battery directly Properly arrange the parts as per the disassembly sequence Reasonably identify the parts to be replaced and to be reused Always use special tools as much as possible to protect parts from damaging Hose and Other Rubber Parts elo avoid damaging to rubber parts be sure not to stain them by oiled fluids such as machine oil etc ewhen assembling of hoses and hose clamp keep it parts form any other parts to avoid them shaking and abrasing eLubricating Oil It is highly recommended to only use the specified lubricant during the assembly according The parts below have to be replaced with to the methods mentioned in this manual new ones after they are removed Brake Fluid Never spill off the brake fluid or it will damage the finish coating of your vehicle If there is any spill you should wash the stained part immediately by using clean water 1 4 2 Notices to Electrical Service You should disconnect the negative terminal from the power battery before checking the circuit Attention Be sure to disconnect the ignit
132. rts they are extremely Always press the locking device as per the vulnerable do not drop them off arrowhead direction shown below to disconnect an adapter attached with locking device When using a multi meter to check the circuit conductivity or the circuit voltage at the connection of connector only insert the probe into the side of the harness If you need to check a sealed connector insert the probe into the hole on the rubber protecting cover until the connector inside is touched Be sure not to damage the insulation part of wire Sealing jeititer When you connect the adapter attached with a Er locking device plug in the connection until a click is heard Connector 1 4 3 Intermittent Defect The intermittent defect is mostly resulted from the failures of wire connections or wires themselves sometimes it caused by the faults of the stick relay or the magnetic coil Always check the circuit thoroughly if your suspect there is any fault with the circuit Check the mating connectors e he stained contact pin and socket may influence the connection eContact pin or socket is in poor shape or is damaged eIhe adapter is damaged or has a poor contact due to the effect of water oil grease or any other dirties Basic Information 1 7 Check the contact between connection pegs or connector and wires Check every connector of faulty circuits for shaking slightly replace them if poor co
133. s misadjusted Brake hydraulic pipeline blocks up smooth Brake wheel cylinder or brake caliper piston blocks Brake master cylinder has failure Inappropriate pressure in tire There is oil stain or lubricating grease on friction wafer Brake shoe deforms or friction wafer replaces smooth because of abrasion Brake drum or brake disc is out of roundness Brake wheel cylinder has failure There is oil leakage phenomenon in brake system Brake master cylinder has failure There is oil stain or lubricating grease on friction wafer The self adjusting device of rear wheel brake has failure Brake drum or brake disc is out of roundness Uneven air pressure in tire The brake wheel cylinder has failure There is oil stain or lubricating grease on friction wafer Brake shoe deforms or the friction wafer changes smooth because of abrasion Piston of brake caliper and the brake caliper mutually congeals Brake hydraulic pipeline blocks up smooth The parking Binding handle does not fully set down The circuit of parking brake light has failure not not Insufficient brake fluid Brake System 5 26 Replace the brake shoe or brake boot Find out the oil leakage part and maintain Repair or replace the brake master cylinder Exhaust the air from the brake hydraulic system Repair the brake wheel cylinder Repair or replace self adjusting device Adjust the parking brake Adjust the length of handspike
134. shock absorber When removing the shock absorber check whether the piston rod is retardation or there is no resistance when it is pushed or pulled If there were one of that as shown above happen the shock absorber should be replaced Attention There is no repair for shock absorber replace the whole one only 3 1 5 Check on the Rubber Parts of Suspension System Check the components of shock absorber such as damping block and dust guard of piston rod bumper block of up pivot assembly front suspension support rubber on support bar bushing and axle sleeve of lower swing arm bushing of steel plate spring cushion rubber of rear suspension etc If there were something broken and cracking on them replace them immediately Don t mix with any oiliness for it is not a kind of oil resistant cushion rubber It would be better to be lubricated by using soapsuds when disassembling or assembling Ball pin dust guard assembly Suspension Wheel and Tire 3 6 3 1 6 Check on Ball Pin Leaf Spring and Coil Spring of Suspension System Pay more attention to the oil sealing performance of dust guard on the RH amp LH swing arms and the ball pin assembly Once it appears to have an oil leak phenomena replace it with a dust guard filed grease lubricant Besides that check if the swing and rotating of the ball pin are flexible or loose Under the normal temperature the rotating force moment of ball pin on the
135. start battery voltage unit V with 3 digits including 2 integrals and 1 decimal 2 Selector Button Q W A and V respectively show the power battery s residual capacity discharge power current and start battery voltage Install four white light LEDs below the selector button i e red Q blue W green A and yellow V solely lighten LEDs from red blue yellow green to red touch off switch red point is bright which shows the capacity value blue point is bright which shows the power value yellow point is bright which shows the current value and green point is bright which shows the voltage value Complete Vehicle Electrical 10 16 Warning When the vehicle has some failure LED display of multi function display will alternately display current display value and failure code Complete Vehicle Electrical 10 17 3 Charging Cue Light Failure Cue When LED 1 red light at H flickers or intermittent buzz which means the charging remind when LED 1 is often bright or buzzer rings long which means the charging alarm Function Description e After electrifying the default is electric power display e When the ignition switch is at ON gear display switch through touching off button electric capacity discharge power current of power battery start battery voltage electric capacity the display mode will change according to fixed order along with the pressing of button e Display of failu
136. swing arm 0 5 1 5N m To observe whether there is a height difference between the right side and left side of the car under the condition of tires normal pressure and car s empty load If they are not to find whether there is a length difference between the right coil spring and left one of the front suspension or strip break on leaf spring of rear suspension Replace the coil spring or leaf spring once the above situations happen Suspension Wheel and Tire 3 7 3 1 7 Tightening Check of Fastener Tightening torque of front suspension fastener Fastener Torque S Conneaing nut between steering knuckle and ont shockabsorber 85 96Nem Connecting Nut between swing arm ball pin and steering knuckle 097 65N m Connecting nut between swing arm and front axle welded assembly 18 4 98 IN m Bolt assembly on the connecting between Left Right support of knighthead and 68 6 78 4N m front girder Front nut of knighthead welded assembly 68 6 88 3N m Bolt assembly on the connecting between front axle welded assembly and front 68 79N m girder Bolt on the steering gear assembling support 31 48N m 3 2 Front Suspension Shock absorber 3 2 1 Specifications Mode Drum type hydraulic bilateral effect Suspension mode Effective Movement mm 2130 Damping Force 0 3m s Speed V 0 3m s MacPherson strut type independent suspension Coil Spring Steel Wire diameterxOutside diameterxFree Restoring Resistanc
137. table or not on driving 2 Rear tire cannot result in the direction deviation of the vehicle Diagnoses Flow Chart of Running Deviation Charge the tire to a proposed value of pressure Take a bidirectional road test of wehicle on a smooth road Exchange the position of night and left tire to process the road test again Running deviation If the running deviation can Running deviation happens happens in the be comeded by tire in the rewerse direction same direction exchange replace the tire Fix a neu tire to the front mi wheel Fix the tire to ts IF the running deviation can orginal position to be corrected well just check tire replace the tire If the running deviation is alignment still in existence fix a new tire to anaher position of IF tha running deviation can be corrected well just replace the tire IF the running deviation is still in extEteree t means this new tire amp unqualified 3 4 4 5 Tire Swing radial run out That most of the vehicle swing happens on high way driving is due to the imbalance of wheel If the dynamic element has come to balance the swing is still exists the possible reason may be Tire run out Wheel run out Stiffness of tire gets change Wheel run out must not exceed the limitation as shown in the figure Important notice wheel run out should be measured again and carried out a balance test after replacement nly some parts of the
138. tall bearings 6204N on the Input shaft in wrong direction Remove the closing ring on the output shaft with a circlip pliers disassemble rear bearings 6304N C3 of the output shaft with a shaft bearing replacer remove the E type adjustable closing ring on the output shaft with a circlip pliers Because it is a larger magnitude of interference fit between the drive gear on the output shaft and the output shaft always need to use special tools to withdraw drive gear on the output shaft to disassemble the output shaft module When disassembling always pay attention not to damaging each gear of the output shaft due to collision and take notice of assembly relationship between each adjacent component When installing do not allow to install bearings 6304N C3 on the output shaft in wrong direction During the procedure of the above mentioned disassembly mainly pay attention not to damaging each gear wheel due to collision Accelerator Assembly and Transmission Assembly 7 5 Check and Repair Check that the tooth surface of each gear wheel is worn or damaged and ensure to replace them when their tooth surfaces have defects Check that each bearing is worn or damaged Always replace the bearings when they have defects Check that the gear wheels of the countershaft are worn or its teeth are broken off The countershaft must be replaced when the gear wheels lose efficacy Check the tooth surface of splines and gear wheels on
139. ter the alarm signal appears When DC supply voltage is less than the set value of system controller will blank off its output and alarm If the battery under voltage alarm usually appears the battery pack will Undervoltag avoid this alarm after charging e of battery If the reason for alarm excludes the battery factor inspect the connection circuit between controller and power battery if the circuit connection is normal the alarm will be regarded as failure repair or replace the controller The rotating speed of motor reaches or exceeds the limited rotating Overspeed speed blank off the output of controller Complete Vehicle Electrical 10 13 When exceeding the overload capacity of motor the controller output Overload of alarm and the controller reduces the output power thermal relay l l After the alarm signal appears reduce the load of vehicle During vehicle run if R position and F position of the direction select switch because of failure produce an effective signal at the same time the Logic E 09 eodd ae electric control system stops output and outputs this failure code Place gt i P diving the ignition switch on OFF gear inspect the direction select switch and ivi service braking switch as well as its connection circuit and then start this vehicle again the failure disappears Effective When this vehicle is in the status of waiting to service step on the service alarm of brake a
140. the marking for wire is shown as follows ex aUp lee Meo Color Code for Wire Bick B Lm o 0Y 0 Brown orange 0 Note When not giving clear indication of section its section is 0 5 mm Auxiliary stripe color Wire color q 25 Cross section calculated as square millimeter Abbreviation Symbol Description of Circuit Diagram Abbreviation Symbol Express Content Abbreviation Symbol Express Content BEAM Far Light Indicator Turn a Brake Warning Indicator Turn Sa mE Ignition Device Earth Wire Arrangement Diagram and Illustration A A Earthing of battery C A Earthing of tail wiring harness C B Earthing of main Complete Vehicle Electrical 10 34 Connection Beam Arrangement Diagram and Illustration ge Mower stoler 4 1 Assembly of front door wiring harness 2 Assembly of main wiring harness 3 Assembly of ceiling lamp wiring harness Assembly of earth wire 5 Assembly of power positive wire 6 Power wire negative wire T Long wire specialized for Hoppecke battery 8 Power battery connection wire 5 Assembly of charging wiring harness 10 Connection wire of emergency power off switch 11 Connection wire of power battery char ging 12 Assembly of negative controller wiring harness 13 Assembly of contactor and fuse connection wire 14 Assembly of fuse and LED connection wire Motor controller as Complete Vehicle Electrical 10 35 10 10 1 Structur
141. troke of Steering Wheel 9 2 2 1 2 Check on the Steering Column Axial Clearance eese 2 2 21 3 Check on Rubber Pieces JoInt cccccecscnescssccencccseccnncensccesnecsncenenseseeeseees 9 9 2 2 Steenng WINGO E TEE CE TC D DL D TS 2 3 2 9 1 Part Drawing of Steering Wheel isin acs ines n cR RR UR Vi lbs aie Rie ew CE dw det M RR o RN 2 3 22925 Disassembling and Assembling ecce e eene nennen n 2 3 293 Installation of Steering Wheel Assembly ee eee e eene nennt 24 2 2 4 Drawing of Site for Steering Column Components ees 2 5 225 Disassembling Sequence coe usta ote vagos ec dxucUeklsoe ee RUE UR DUE A ad Ku a S VIS w m E 2 5 2 MEE Ilio ee cr S 2 6 2 3 Location Map of Steering Gear Assembly 2 6 2 3 1 Exploded View of Steering Gear Le ecce eee ener e eee ener annnm nnn nun 2 7 23 2 Assembling Sequence ChaLELb icezeeuriic sess exa te EI SURE IR EREDDRRIRIE ERU MUCD eee d do csaees 2 11 2 4 Location Parameter of Front Wheel esee 2 15 2 4 1 Location Parameter Matched with B12 Engine ese 2 15 2 4 2 Location Parameter Matched with WLLJ Liuzhou Wuling Liuji Power Co Ltd
142. ue specified The torque value is indicated on the assembly drawing Basic Information 1 11 1 5 Table of Performance Structure and Specifications for Entire Vehicle 1 5 1 Table of Dimension and Mass parameters Items WLD1200Q1P Type Flat head 4x2 driving with rear wheels seating including the driver s 2 seats Length 4115 Overall size 1560 1840 2080 1350 1335 Dimension parameters mm Inner 2470 dimension of 1490 pacing box The distance between the packing box floor and the 746 ground Type of carriage Carriage with 3 doors Kerb axle mass lb kg Full load axle uc 2 persons 68kg person and 150kg loading 1 5 2 Table of performance parameters WLD1200Q1P Minimum turn radius m Minimum Ground clearance mm Approach angle Departure angle 25 780 Rear overhang mm 710 Maximum turning angle of front wheel Maximum speed Km h Maximum climbing capability Driving Distance Km Trafficability parameters Soe oO eb c iq i iq Q O Cc oO oO 0 Outside wheel 31 parameter Max slope parking capacity No load Basic Information 1 12 1 5 3 Table of Structure and Specifications Items WLD1200Q1P Drive shaft Open single root two universal joints Rear axle Stamping welding Integral shell Semi floating axle shaft l MacPherson strut type telescopic shock absorber independent Front suspension suspension Suspension ys Rear susp
143. ve Measures 1 Corrective amp preventive measures Clear away the contaminant on the surface of charger Guarantee good ventilation at the charging field 2 Inspect the charging circuit electrify again 3 Inspect the input power grid voltage if the regular deviation of power grid voltage from rated nominal value exceeds 20 increase the voltage stabilizing device 4 Inspect the voltage and current value at the end floating charge of charging of charger 5 Exclude the above protection determine the charger is damaged so please replace charger Complete Vehicle Electrical 10 10 Warning Do not wash the charger with water Complete Vehicle Electrical 10 11 10 2 Controller Attention When the controller stops operation ineffective if stepping on accelerator because of various protections like overload Undervoltage etc turn off the ignition switch re start the vehicle after more than 10 seconds and the failure will automatically disappear Controller controls the vehicle run according to exterior input Such as accelerator brake etc Maintenance of Controller e Periodically clear away the dust and grime of Attention exterior controller Before inspecting the failure of e The inspection period of electric capacitor in the controller please examine the failure device is one year if there is expansive deformation code of multi function display and of shell or lea
144. verlarge step on the brake pedal and check if If the clearance between the wheels disappears front wheel braking bearings may be loosened If clearance between the wheels retains the installation face of steering knuckle front shaft or front suspension may be loosened 2 4 5 Check and Adjustment Adjustment of Toe in 1 Loosen the lock nut of tie rod 2 Rotate the tie rod joint and adjust the Toe in Do not distort or damage dust guard when EE adjusting L At HIS Breer Adjust the same length of left and right tie rods when adjusting Toe in The left and right lengths as shown in the figure should be equal otherwise left and right rotating angles may be different when turning Suspension Wheel and Tire 3 1 Chapter 3 Suspension Wheel and Tire Contents 3 1 Check and Adjustment of Suspension System 3 2 3 1 1 Preparation before Check on Front Wheel Alignment se IRRIH0 97 3 1 2 Check and Adjustment of Front Wheel Alignment s ssssssssssssesssesseeserseees 3 2 3 1 3 Check on Wheel Rim Nut and Wheel Hub Bearing ccseneeIeIIeH0 379 3 1 4 Check on Front and Rear Shock Absorber in Failure uuuus 976 3 1 5 Check on the Rubber Parts of Suspension System eene 3 6 3 1 6 Check on Ball Pin Leaf Spring and Coil Spring of Suspension System 3 6 3 1 7 Tightening Check of Fastener ccccccee
145. ward and downward If any it may be caused by worn out rubber mat in steering column tube or shearing defect of plastic shear lock pin which is used for keeping the length of steering column In this case the damaged component or steering column assembly must be replaced 2 1 3 Check on the rubber pieces joint Jack up the vehicle to check whether the dust guard of pinion rack is damaged If so dust and water may immerge into steering gear and tie rod ball stud through worn out dust guard and cause abrasion rust and noise of steering rack amp pinion and tie rod 20080514 ball stud assembly so steering system malfunction is resulted in and replacement is necessary Check if the dust guard of steering tie rod plinth is damaged and replace it with a new one even if a slight breakage was found on it in use Check if there is breakage on lower steering column joint lower steering drive shaft joint and steering shaft such as cracks fractures out of control or excessive clearance etc Steering System 2 3 2 2 Steering Wheel 2 2 1 Part Drawing of Steering Wheel 20080514 1 Steering wheel lower cover 2 Steering wheel body 3 Horn button 4 Horn Button Spring 5 Horn Button Touch Pad 6 washer 7 Screw 8 Screw 9 Lock nut 10 Steering wheel upper cover 2 2 2 Disassembling and Assembling While disassembling steering wheel lock the steering column in straight and forward position to avoid damage to contacted attach
146. y pack charges DC DC converter can charge the auxiliary battery at the same time When the key of vehicle is placed in ACC or ON gear DC DC converter provides power for complete vehicle low voltage apparatus If the voltage display value of multi functional display is less than 12 4V its suggested to reduce low voltage load such as turning off lamps and radiogram etc for making the voltage return to 12 6V above as soon as possible otherwise the service life of auxiliary battery will be influenced Maintenance of DC DC Converter Regularly clear away the exterior of DC DC converter and the dust and contaminant of radiation fin Inspection and Repair Please refer to electric schematic diagram for complete external wiring of DC DC converter When power battery pack fully charges or during vehicle run the voltage value of auxiliary battery is less than 12 5V Complete Vehicle Electrical 10 7 Warning There is high voltage between N1 and P1 input ends of DC DC converter so pay attention to the safety when measuring Possible Causes 1 30A fuse cuts out 2 Relay opens Coil is burnt out Contact ablates The interior of G end connection wire of DC DC converter disconnects Relay Il is burnt Coil is burnt out Contact ablates 4 Auxiliary battery damages 5 Failure of charging circuit of auxiliary battery Corrective amp Preventive Measures 1 Inspect whether correspo

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