Manual Trabajo JAC 5

WORKSHOP MANUAL
维修手册
HFC1121P70K1E1-LG016
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Overview & maintenance
概述与保养分册
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Version No 版本号：JAC-2015050301N5301
江淮汽车部门：[客户服务部]
Overview & maintenance 概述与保养分册
FORWARD 前言 CONTENT 目录
This Manual is helpful for technical maintenance
staff for JAC and provides effective and correct
maintenance and service for JAC vehicle. To ensure
the customer satisfaction of the JAC products, it is
extremely essential that the professional maintenance Engine
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technicians for JAC have the friendly service and the 发动机分册
capability of proper operation; therefore, the
maintenance technicians must fully understand the
Body structure& electrical
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contents in this Manual. This Manual shall be
车身结构与电器分册
accessible for reference at any time.
本手册用于帮助 JAC 授权的专业维修技术人员， Chassis

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对江淮汽车提供有效正确的保养及维修。为确保江淮底盘分册
汽车产品的用户满意，江淮汽车专业维修技术人员的
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热情服务和正确操作是十分必要的，因此，维修技术 Circuit
人员必须充分理解本手册内容。本手册应放在便于使电路分册
用的地方，以便随时用来参考。
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All contents in this Manual, including pictures, technical parameters are the latest. But if product
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modification affects maintenance, JAC will provide technical bulletin or supplementary volume.
Therefore, please obtain the latest information about this Manual. JAC reserves the right to make change
in design, addition or improvement for the product.
本手册的所有内容包括图片、技术参数都是最新的，但是由于产品改进而影响维修时，江淮
汽车将提供技术通报或补充卷。因此，使用本手册应密切注意获取相关信息的最新动态。江淮汽
车保留产品在设计变化、增添或改进方面的权力。
During the process of maintaining JAC vehicle, if genuine parts that are not from JAC or
disqualified oil, the vehicle may be damaged.
在对江淮汽车产品保养及维修过程中，若使用非江淮汽车的纯正配件或不合格油料，有可能
会造成车辆的损坏。
All rights reserved, without the written consent of JAC, it may not be reproduction all or a
part of this manual.
版权所有，未经江淮汽车公司的同意，不得翻印本手册之全部或一部分。
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Tel：0086-551-62296644
Fax：0086-551-62296633
26 JAC 国际公司客户服务部
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JAC International Customer Service Depart.
2015.05
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Contents
Important statements
Adoptable vehicle models
Important Notes
Health and safety notes
Standard operating procedures
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How to use this manual
Preface
Terminology
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Maintenance operation ID
Unit
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Contents
Special tools
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Model identification information

Product model and identification information position
Product model description
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Vehicle identification number description

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Maintenance request
Daily checks
Periodic maintenance
Recommended material filling standard
Recommended tightening torque standard
Recommended special tools list
目录
重要说明
手册适应车型
重要说明
健康与安全注意事项
标准作业程序
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如何使用本手册
序
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术语
维修作业标识
单位
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目录
专用工具
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车辆识别信息
产品型号和车辆识别信息位置
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产品型号说明
车辆识别码说明
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保养要求
日常检查
定期保养
推荐辅料加注标准
推荐紧固扭矩标准
推荐专用工具清单
Chapter I Important statements
第一章重要说明
I. Adoptable vehicle models of this manual 本手册适应车型
Model Series No. Engine model Transmission model
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车型结构号发动机型号变速箱型号
N Series Light Truck
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LG016 ISDe180 43 WLY6G70
N 系列高端轻卡 12
II. Important statements 重要说明
1、 This manual is designed according to the format suitable for the global technical people. The goal of
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this is to use a common format, and list the some contents in all of the manuals.
本手册是以一种适合技术人员需求的格式来设计撰写。其目标是使用一种通用的格式，将相同
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内容列入手册。
2、 Proper maintenance method and the correct repair procedures is the basis of the safe and reliable
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operation of all motor vehicle, as well as the personal security of the operation staff.
适当的保养方法与正确的维修程序，是所有车辆安全、可靠的操作，以及执行工作人员之个人
安全的基础。
3、 This manual cannot be fully predict all of the possible changes and provide individual advice or
warning.
本手册不可能完全预料到所有的可能变化，而分别给予警告。
4、 The one, who will not in compliance with this manual, has to confirm that the chosen method, tool or
part will not be harmful to their personal security and endanger the whole vehicle performance firstly.
不遵照本手册中所提供指示的任何人，都必须先行确定他们所选择的方法、工具或零件，既不
危害到人员的安全也不危害到车辆的整体性能。
III. Health and safety notes 健康与安全注意事项
1、蓄电池
□ Battery is free-maintenance type which is completely sealed except for vent hole on the cover.
Therefore, before installation, it is necessary to inspect whether the housing and upper cover have
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cracks. If yes, please replace them.
蓄电池为免维护蓄电池，除上盖上的通风孔外完全密封，因此应检查壳体及上盖是否有裂纹，
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有裂纹时应予以更换。
□ Always keep battery surface(especially top) clean and dry.

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应始终保持蓄电池表面（尤其是顶部）的清洁和干燥。
□ If vehicle not use for a long time, you must disconnect negative terminal post of battery.
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如果汽车长时间不使用，应该断开蓄电池负极接线柱。
□ Inspect whether battery wire clamp has damage. If yes, replace it. Make sure the clamp and the post
are clamped firmly and have a good connection.
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检查电瓶线夹子有无损伤，有损伤时要更换，对夹子表面进行清理，同时确保夹子与极桩连接
牢固，并接触良好。
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□ When connecting, first connect positive terminal post of battery.
连接时，应先连接蓄电池正极接线柱，同时连接端口应拧紧。
□ It is strictly forbidden to put tool onto the battery. Avoid contacting two pole piles at the same time,
or contacting pole pile and vehicle body, which may cause battery short-circuit and accidents.
禁止将工具放在蓄电池上，避免同时触及两个极桩、或同时触及极桩与车身引起蓄电池短路导
致事故。
□ After installation, it is allowed to apply mineral oil on each terminal post.
安装后，可在各接线柱上涂抹矿物袖。
2、 Acid and alkali 酸与碱
□ Such as the corrosive sodium carbonate and sulfuric acid. For the cleaning of the battery and
materials.
对皮肤、眼睛、嗅觉与喉咙等部位有刺激性与侵蚀性，会造成灼伤。
□ Be irritant and corrosive to the skin, eyes, smell and throat. Will cause burns. Damage the normal
protective clothing.
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会毁坏普通的衣物。
□ Avoid being spilled on the skin, eyes and clothing.
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不可吸入其喷雾。
□ Wear suitable protective aprons, gloves and goggles. Do not inhale the spray.
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佩戴适当的防护围裙、手套与护目镜。
□ It is essential to get ready in the vicinity the eye rinse bottle, rain shower head and soap, so that get
them at any time when there happens the spill accidents.
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务必要在近处准备好眼部冲洗瓶、莲蓬头与肥皂，以便在发生泼溅意外时，随时可以取得。
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3、 Airbags 安全气囊
□ Highly flammable and explosive, and should adhere to anti-smoking regulations.

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高度可燃、爆炸性，应遵守禁烟规定。
□ The expander includes a high energy powder, and it will produce very high gas (2500 °C) when
ignited.
其膨胀器含有一种高能量火药，点燃时会产生极高热气体 (2500°C)。
□ The gas generator in the air bag is sodium azide. This material is sealed in the module, and will fill
the whole bag during the expansion. Do not attempt to open the air bag inflation, because this would
be risky of contact with the hazard. If a gas generator is cracked, you have to handle the overflow
material with a full care and protective clothing.
气囊中所使用的气体发生器，是迭氮化钠。这种材料是密封在模块中，在膨胀时会完全充满气
囊。切勿尝试打开气囊的膨胀器，因为这将会导致与迭氮化钠物接触的危险。如果一气体发生
器发生破裂的情形，在处理溢出的材料时，要穿着全护式防护衣。
□ After the normal expansion, you should wear gloves and safety glasses when you handle it.
正常膨胀后，在处理过程中，应佩戴手套与安全护目镜。
□ For the expanded air bag, it's necessary to place them in a plastic bag and discard the approved
chemical waste disposal site in accordance with local laws and regulations.
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已膨胀过的气囊应依据当地的法规规定，将它置于塑料袋中，丢弃在许可的化学废弃物处理场。
□ What shall one do after the direct contact with any of the gases: clean the affected area thoroughly
with water, or seek medical assistance if it is necessary;
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在直接接触任何气体产生物后。应用水彻底的清洗受到影响的区域。或视需要寻求医疗协助。
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4、 Air Conditioning Refrigerant 空调冷媒
□ One shall comply with the exposure handling with highly flammable, combustible objects.
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高度可燃物，应遵守禁烟规定。
□ The skin can be frostbited if you contact.

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皮肤接触可能会导致冻伤。
□ It is important to comply with the instructions provided by manufacturers. Avoid being exposed in
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lighting, and wear appropriate protective gloves and goggles.
务必遵守制造厂商所提供的说明。佩戴适当的保护手套与护目镜。
□ If the skin or eye contact with the refrigerant, please flush with water affected area immediately. And
flush eyes with the appropriate flushing solvent, but do not frict. Seek the medical assistance if it is
necessary.
如果皮肤或眼睛接触到冷媒，立即用水冲洗受到影响的区域。并应用适当的冲洗溶液冲洗眼睛，
且不可磨擦。视需要寻求医疗援助。
□ Air condition refrigerant - what should be avoided 空调冷媒 –应避免之动作
Do not explore the refrigerant bottle in the sunlight or heat sources.

不可使冷媒瓶暴露于阳光、热源、霜雪。
Do not discharge or exhaust the refrigerant to the atmosphere in any cases.
不可在任何的情况下，将冷媒排放至大气中。
Do not mix different refrigerants, for example R12 (Freon) and R134a
不可将不同的冷媒混合。
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5、 Inspection of Air Conditioning System and Filling of Refrigerant 空调检查及加注制冷剂
□ Installation of refrigerant filling instrument 安装制冷剂加注仪
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Close the manual valves on both ends of refrigerant filling instrument.
关闭制冷剂加注仪两端手动阀门。
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Install the filling pipe of refrigerant filling instrument in the connecting place. Connect the LP
pipe at LP pipe nozzle and the HP pipe at HP pipe nozzle, and then tighten the nuts with hand.
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制冷剂加注仪的加注管安装在连接部位。低压管在低压管口，高压管在高压管口连接后用
手拧紧螺母。
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□ Operation of Refrigerant Discharge 制冷剂排出操作
Connect the refrigerant filling instrument to the

system.
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制冷剂加注仪连接到系统。
Put the cleanly cleaning cloth in the open place of

central hose.
中央软管开放部位放干净的抹布。
Gradually open the HP manual valve and discharge the refrigerant.
逐步开启高压手动阀门并排出制冷剂。
Caution: The compressor refrigeration oil will discharge from the system, if the exhaust velocity is
too fast.
注意:如果排气速度过快，压缩机冷冻油将从系统排出。
Check whether or not the trace of refrigeration oil is present on the cleaning cloth, and slightly
close the manual valve when trace is present.
检查抹布有无冷冻油痕迹，有痕迹时稍微关闭手动阀门。
Slowly open the LP manual valve, after the measuring scale of filling instrument is dropped to
3.5kg/cm2.
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加注仪标尺降到 3.5kg/cm2 之后，慢慢开放低压手动阀门。
It is required to slowly open the HP and LP manual valves, in order to reduce system pressure,
until the measuring scale displays 0 kg/ cm2.
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为了降低系统压力，应慢慢开放高压及低压手动阀门，一直到标尺显示 0 kg/㎠为止。
Evacuation Operation of Refrigeration System 制冷系统真空操作

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□
Caution: The system must be evacuated after refrigerant discharge. It is to remove the air and
moisture through this operation, for 15 minutes after respective parts have been assembled.
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注意：系统排出制冷剂后必须抽真空。此操作是为了除去流入到系统的空气与湿气，时间为各
部件安装后 15 分钟。
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Confirm whether or not engine is under “Close” status.
确认发动机是不是在“关闭”状态。
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Connect the filling instrument to the joint place of compressor, and close the two ends.
把加注仪连接到压缩机接头部位，并关闭两端。
Confirm whether or not refrigerant is discharge from the system.
确认制冷剂从系统是否排出。
Connect the central pipeline to the air suction place of vacuum pump.
中央管路连接到真空泵吸气部位。
Open the HP and LP valves of filling instrument after vacuum pump is operated.
操作真空泵之后开启加注仪的高压及低压阀门。
The measuring scale of LP detector is larger than 0.96kg/ cm2 vacuum after 10 minutes,
otherwise air leak exists with the system, repair as follows.
10 min 之后低压检测仪标尺大于 0.96kg/㎠真空，否则就是系统漏气，应按照以下步骤修理。
Make use of the filling system for the refrigerant container.
利用制冷剂容器加注系统。
Inspect the leak place with leak detector, and repair it if any.
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用检漏仪检查泄漏部位，发现后进行修理。
Discharge the refrigerant and evacuate the system.
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排出制冷剂并对系统抽真空。
Continue evacuation, if no leak evidence is found.

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如果没有发现泄漏的迹象，继续抽真空。
Re-operate vacuum pump.

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重新操作真空泵。
The measuring scales of filling instrument on both ends shall maintain 0.96kg/cm2 vacuum.
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两端加注仪标尺应保持 0.96kg/㎠真空。
Continue evacuation until measuring scale displays 0.96kg/cm2.

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继续抽真空直到标尺显示 0.96kg/㎠。
Stop evacuation after 15 minutes of evacuation and close the pressure valve of filling instrument,
then disconnect pipes from the pump. This allows refrigerant to be filled.
实施 15 分钟左右的真空操作后，关闭加注仪的压力阀门并停止真空泵，从真空泵分开管
路。这样就可以加注制冷剂。
□ Use of Refrigerant Control Valve 使用制冷剂控制阀
Fully turn the Handle in counterclockwise direction, before valve and refrigerant container are
connected.
阀门与制冷剂容器连接前，朝逆时针方向完全转动把手。
Place the disc to the top position in counterclockwise direction.
朝逆时针方向把圆盘放到最高位置。
Turn the disc with hand in clockwise direction, after central pipeline is connected to valve
device.
中央管路连接到阀门装置后，朝顺时针方向用手转动圆盘。
Turn the handle in clockwise direction and drill in the upper part of the seal.
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手把朝顺时针方向转动并在封合的上部钻孔。
Loosen the nut of connecting pipeline for connecting joint of filling instrument.
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松开加注仪中心连接口连接管路的螺母。
Tighten the nut after exhaust for several seconds.

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排气几秒钟之后拧紧螺母。
□ Filling of Refrigerant (in Gaseous State)加注制冷剂（气体状态）

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Caution: It is to fill the gas refrigerant to the system through LP end device, and the refrigerant in
gaseous state will flow into the system, when the refrigerant container is placed in a straight way.
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注意:此操作是通过低压侧装置把气体制冷剂加注到系统的操作，此时把制冷剂容器放直，气
体状态制冷剂流入到系统。
Install the refrigerant container to the regulating valve.

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把制冷剂容器装到调整阀门。
Open the LP valve, and adjust the valve for the LP measuring scale to be controlled below
4.2kg/cm2.
开放低压阀门，调整阀门使低压标尺控制在 4.2kg/㎠以下。
Start the engine and turn on the air conditioning system.
起动发动机并开启空调。
Caution: Place the container in a straight way, in order to prevent the liquid refrigerant from being
filled into compressor through air suction port.
注意：为了防止液体制冷剂通过吸气口加注到压缩机，把容器放直。
Close the LP valve after specified quantity is filled.
加注规定量之后关闭低压阀门。
The container may be put into a water tank of about 40℃, if refrigerant filling speed is too slow.
制冷剂加注速度过慢，可以把容器放到约 40℃左右的水容器。
Caution: It is not allowed to heat water up to higher than 52℃, under whatever circumstances. It is
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not allowed for high-temperature light to get in touch with the container.
注意:无论是什么情况，都不能把水加热到 52℃以上。高温灯光不能碰到容器。
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□ Filling of Refrigerant (in Liquid State)加注制冷剂（液体状态）
Caution: This operation is to be used for filling through HP end. Upend the refrigerant container, and
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the refrigerant will then be able to enter into the system.
注意：此操作是通过高压侧加注时使用。把制冷剂容器倒放，制冷剂就可以进入到系统。
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Close the two ends of HP and LP valves completely, after system is evacuated.
系统抽真空之后，完全关闭高压及低压阀门两端。
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Install the regulating valve for refrigerant container.
安装制冷剂容器调整阀门。
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Fully open the HP valve and then upend the container.
完全开启高压阀门之后倒放容器。
Excessive system filling will increase discharge pressure, and therefore, it is required to fill
refrigerant and close the HP valve with correct capacity at the same time while the weight of
refrigerant is measured.
系统过量加注时会增加排出压力，因此边测定制冷剂重量边用正确容量加注并关闭高压阀
门。
Close the valve of filling instrument after specified refrigerant is filled.
加注规定的制冷剂之后，关闭加注仪阀门。
Check whether or not air leak exists by leak detector.
用检漏仪检查漏气与否。
Caution: Don’t start the engine when HP end is used for filling. It is not allowed to open the LP
valve when liquid refrigerant is used for filling. Performance test must be made before separation of
filling detector.
注意:利用高压侧加注时不起动发动机。利用液体制冷剂加注时不能开放低压阀门。分离加注
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检测仪之前必须做性能测试。
6、 Antifreeze 防冻剂
□ Highly flammable, combustible.
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高度可燃物，应遵守禁烟规定。
□ Cooling water antifreeze (ethylene glycol) may produce steam when heated. Avoid inhaling this
steam.
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冷却水防冻剂在受热时，可能会产生蒸汽。避免吸入这些蒸汽。
□ The antifreeze absorbed through the skin may reach toxic or hazardous dose. Antifreeze can be fatal
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if swallowed, and should be taken to hospital immediately.
经由皮肤吸收的防冻剂可能达到有毒或有害的剂量。防冻剂，如果吞下时，可能会致命，且应
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立即送医。
7、 Brake Fluid 制动液
□ Will have a slight irritation when splashed on skin and eyes. Try to avoid contacting with the skin and
eyes. The inhalation of this in the normal temperature is not so risky, because its steam pressure is
very low.
溅到皮肤与眼睛会有稍许的刺激。尽可能避免接触皮肤与眼睛。在常温下吸入的危险性不高，
因为它的蒸汽压力非常低。
8、 Rust-resisting material 防锈材料
□ Highly flammable and combustible materials, shall comply with the anti-smoking regulations.
高度易燃、易燃物，应遵守禁烟规定。
□ This is a large amount of this material, and should comply with manufacturer's instructions. They
may contain solvents, resin or oil products. Avoid contacting with skin and eyes. They are only be
sprayed in a well-ventilated, open space.
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这种材料有很多，应遵守制造厂商的说明。它们可能含有溶剂、树脂或石油产品。应避免接触
皮肤与眼睛。它们仅可在通风良好且开放空间的情况下，才可以喷洒。
9、 Shock 电击
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□ The misuse of electrical equipment, or abuse the one in good condition, could cause an electric
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shock.
错误的使用电气设备，或滥用状况良好的设备，都可能会造成电击。
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□ Have to maintain the electrical equipment properly and test regularly. Failure equipment should be
indicated, and it would be desirable to be able to move away from the area.
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要定期保养电气设备并经常的测试。故障的设备应予标示，最好能够移离工作区域。
□ Do not let wires, cables, plugs and sockets worn, kinked, cut, broken, or other damages.
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切勿使电线、电缆、插头与插座受到磨损、扭结、切断、破裂或其它的损坏。
□ Do not let the electrical equipment and wires contacted with the water.
切勿使电气设备、电线与水接触。
□ Ensure that electrical equipment is protected by the right fuse.
确保电气设备受到正确保险丝的保护。
□ It is essential to provide the basic first aid training for full-time electrical operating staff.
务必要对电器操作者实施基本的急救训练。
□ When the electric shock occurs.在发生电击时：

Turn off the power before touching the victims.
在触摸受害者之前，先关掉电源。
You have to push or drag the victims away from the power supply by the dry, non-conductive
materials if you are unable to turn off the power.
如果无法关掉电源，则用干燥的非导电材料将受害者推离或拖离电源。
Do the first aid immediately if you have been trained before.
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如果受过训练，立即实施急救。
Seek the medical assistance.
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请求医疗援助。
12
10、 Exhaust Gas 废气
□ Exhaust Gas contains the breathtaking, hazardous and toxic chemical substances, and the materials
20
like carbon dioxide, nitrogen oxides, aldehydes, lead and polycyclic aromatic hydrocarbons. Engine
can only be operated with the appropriate exhaust ventilation equipment or in the open space with
normal ventilation.
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废气中含有令人窒息、有害及有毒的化学物质，诸如碳氧化物、氮氧化物、乙醛、铅与芳香族
碳氢化合物之类的物质。发动机仅可在适当的废气抽风设备或一般的通风设备且开放空间的情
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况下，才可以运转。
11、 Gasoline 汽油
□ Highly flammable - shall comply with the non-smoking regulation.
高度易燃物，应遵禁烟规定。
□ Swallowing may cause mouth and throat irritation, and stomach absorption will cause drowsiness and
obnubilation. A small amount of petrol will be lethal to children. Liquid into the lungs caused by
vomiting is very dangerous.
吞咽会造成嘴部与喉咙的刺激，胃部的吸收则会导致困倦与神志不清。少量的汽油就会使儿童
致命。因呕吐而导致液体进入肺部，是非常危险的事情。
□ Gasoline will dry the skin, a long-time or repeat contact, will lead allergic and skin inflammation.
Liquid enters the eyes will cause severe pain.
汽油会使皮肤干燥，长时间或重复的接触，则会造成过敏与皮肤炎。液体进入眼睛则会造成剧
痛。
□ Gasoline for vehicles may contain large amounts of benzene, and will be poisoned after the inhalation.
So the gasoline vapor concentration must be maintained at a very low level. High concentration of
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petrol vapors will cause eye, nose and throat irritation, nausea, headaches, frustration and drunk
symptoms.
26
汽油可能含有大量的苯，吸入后会中毒。汽油会造成眼睛、鼻子与喉咙的刺激、恶心、头痛、
沮丧与酒醉的征状。
12
□ It necessary to maintain a good ventilation, when dealing with the petrol Special attention must be
paid to avoid the risk of inhaling steam caused by spills in the confined space.
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在处理与使用汽油时，务必要保持良好的通风。
Diesel fuel 柴油
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12、
□ Combustible.
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可燃物。
□ Large shin or long-term connected with the high-boiling point gas oil may cause the serious diseases
of the skin including skin cancer.
皮肤大量的或长期的与柴油接触，可能会导致包括皮肤癌在内的严重皮肤疾病。
13、 Lubricating oil and grease 润滑油与润滑脂
□ Avoid prolonged and repeated contact with mineral oils. All of the lube oil and grease are irritant to
the eye and skin.
避免长时间而重复的接触矿物油脂。所有的润滑油与润滑脂，都对眼睛与皮肤有刺激性。
14、 Waste 废弃物
□ The waste produced during repairing such as waste lube oil, oil filters, braking fluid and the solvent
for cleaning the parts shall be sent to the licensed waste disposal sites, or to the waste oil reclamation
enterprises through officially approved waste disposal contractors. Please contact the local authority,
if you have any question on disposal of waste substances.
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车辆维修过程中产品的废弃物，例如废弃的机油、废弃的机油滤清器、制动液、用于清洗零部
件的溶剂应交给官方批准的废品处理商送到规定的废品处理地点，或送到废油回收企业。如
对处理废物有疑问，请与当地有关部门联系。
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□ It is illegal to pour waste lube oil, oil filters, braking fluid and the solvent for cleaning the parts on to
the ground, down sewers or drain ditches, or into water sources; the laws and regulations concerning
pollution vary between regions.
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废弃的机油、废弃的机油滤清器、制动液、用于清洗零部件的溶剂泼在地面上，倒入下水道或
排水沟中或水源中是违法的；污染的法规因随区域不同而不同。
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15、 Other matters 其他事项

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□ Put wheel chocks or other tire blocks under the wheels

to prevent the vehicle from moving before jacking up
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the vehicle. After jacking up the vehicle, support the

vehicle with safety stands at the designated lifting
points before working on the vehicle. This operation
should be done on a level ground.
举升车辆前，将垫木放在车轮下，防止车辆移动。
车辆顶起后，用安全支架在正确举升点支住车辆。
此项操作应在水平地面上进行
□ Turn off ignition switch and disconnect the negative
battery terminal before doing the repairs which doesn't
need the power and electricity. If the battery terminal is
disconnected, memory in the control module will be
cleared.
在进行不需要电源的修理工作前，关闭点火开关并
断开蓄电池的负极接线
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□ Avoid contacting with the hot metal parts to prevent
burns. Do not remove the radiator cap when the engine
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is hot.
为防止被烫伤，避免接触高温的金属零件。当发动
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机温度高时，不要取下散热器盖
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□ Please make sure that you are use JAC genuine spare parts. Can only use the oils and lubricants
recommended in this manual. Use approved bonding agents, sealants or their equivalents when
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needed.
请务必使用 JAC 纯正备件。只能使用本手册中推荐的油液和润滑剂。需要时，使用认可的粘结

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剂、密封剂或同等产品。
□ When removing the heavy components such as the engine or transmission, please do not waggle it
with excessive force which may disconnect it. Also, do not strike them to adjacent parts, especially
the brake pipes and master cylinder.
当拆卸类似发动机或变速器等沉重零部件时，请不要过于用力来回摇动使其脱开。同时，注意
不要让它们碰到附近的零件。
□ Need to replace oil seals, gaskets, packing, O-rings, locking washers, cotter pins, self-locking nuts,
etc. with new ones when reassembly after the disassembly.
油封、衬垫、填料、“O”形圈、锁止垫圈、开口销、自锁螺母等零件拆卸后重新装配需更换
新的。
□ Needle bearings as well as the inner and outer races of tapered roller bearings shall be replaced
together.
滚锥轴承、滚针轴承等轴承类零部件的内外圈应作为整体一起更换。
□ Clean all removed parts in the designated liquid or solvent before the inspection and assembly.
在检查和组装前，使用规定的液体或溶剂将拆下的零部件清洗干净。
□ Place the removed parts in accordance with their assembled locations and sequence. After
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disconnecting the vacuum or air tubes, attach a tag to indicate the proper connection way.
将拆下的零件按照它们装配时的位置和顺序摆放。脱开真空管等管路时，贴上表示正确连接
26
方法的标签。
□ Please do not touch the ports of electronic components which use microcomputers (such as ECM),
the static may damage the inner electronic components.
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请勿用手触摸使用微电脑（例如 ECU）的电子元件的端口，静电可能会损坏内部的电子元件。
□ In order to repair safely and efficiently, you shall use hand tools, power tools (for disassembly only)
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and special tools correctly.
为了安全高效地进行修理工作，应正确使用手动工具，电动工具仅拆卸用。
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□ When the ongoing repairs related to the fuel, oil, water, vacuum or exhaust systems, check all
affected lines to see are there any leaks.
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当所进行的修理工作涉及燃油、机油、水、真空或排气系统时，检查所有相关管路有无泄漏
情况。
□ Cover fenders, upholstery and carpeting with appropriate cover before repairing the vehicle. Be
careful not to scratch the paintwork with the things like keys and buttons.
修理车辆前，用适当的罩子将翼子板、内饰和地毯盖上。注意不要使钥匙、纽扣之类的东西划
伤漆面。
IV. Standard operating procedures 标准作业程序
1、 When repairing vehicle in the workshop, it is important to determine 在维修车辆时，务必确定：

□ Use the parking brake or block the wheel to avoid vehicle front/rear movement.
使用驻车制动或将车轮确实的挡住，以避免车辆前/后移动。
□ If you need to run the engine, you must have the appropriate ventilation or ventilation tube in order to
exclude emissions from motor vehicles.
如果需要运转发动机，必须要有适当的通风设备或抽风管，以排除废气。
Caution: when the vehicle is arc-welding, you have to take part the generator wiring to avoid current and
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waves, alternator damage to internal components. If you weld on the vehicle, it is necessary to prepare an
appropriate fire-fighting equipment.
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注意：实施电弧焊时，务必要拆开发电机配线和蓄电池负极线，以避免电流之突然增大，造成内部
组件损坏的可能。同时必须要准备适当的灭火设备。 12
2、 Vehicle Towing 车辆拖曳
□ You should use the vehicle tow hook when have to tow. Rope have to be trued to the tow hook, and
20
have to connect to another vehicle with the way that will not tie to the other vehicle parts.
应使用车辆拖钩。绳索必须确保固定在拖钩上，并且必须以不会缠到车身其它部份的方式连接
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于另一辆车上。
□ Or you can deliver the vehicle by the flatbed truck or trailer reel.
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或者将车辆置于平板车上运送。
Warning: When towing the vehicle, the ignition switch must be in position II (steering lock release and
warning lights are on. Only by this, can steer, open turn signals, horn and parking lights. Failure to
comply with these instructions will cause injury.
警告：在拖带车辆时，点火开关必须置于位置 II (转向锁释放且警告灯亮起)。仅有如此才可操作
转向、转向信号灯、喇叭与停车灯。未遵守这些说明，将会造成人员的伤害。
3、 Connect the backup battery by the cross-connection 用跨接线连接备用电瓶
Warning: If the backup battery has emitted gases caused by charging recently, you have to cover the vent
plug with the cross-wiring to reduce the arc explosion hazard when connecting the cross wires. Failure
to comply with the instructions may result in personal injury.
注意：电瓶放电的状况可能是由于短路的造成。如果发生这种情形，即使车上所有的正常回路都已
关闭，仍会有电流流动。这会在连接跨接导线时，造成电弧。
Caution: Battery discharge conditions may be caused by the short circuit. If that happens, even if all
the normal circuit is turned off, there still will be electric current flowing. This is will lead to electrical
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arcing when connecting the across wires.
注意：虽然以跨接的方式起动车辆不值得建议，但是必须承认在某些状况下这是可以将车辆起动的
26
唯一方法。在这种情况下，跨接起动放电后的电瓶必须立即的充电，以避免永久性的损坏。
□ Have to make sure that the cross-wiring wire diameter suits the needs of the work. You must use
12
high-load wires.
务必要确认跨接线的线径适合工作的需要。必须要使用高负荷的导线。
20
□ Have to confirm that voltage of the back-up battery is same with the vehicle battery. Batteries must
be connected in a parallel way.
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要确认备用电瓶的电压与车辆上的电瓶具有相同的电压。电瓶必须要以并联的方式连接。
□ Have to turn off all the electrical circuits, which can be disconnected before connect the cross-wiring.
This can reduce the risk of generating the electric arc during the final connection.
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在连接跨接线前，务必要关闭所有可以切断的电气回路。如此可以降低在最后连接时，产生电
弧的危险。
Warning: The cross-wiring is connected to battery, do not let the cross-wire touch each other or touch the
body ground. A fully charged battery, if is shorted through cross-wire, will discharge with higher than
1000 amps discharge rate and cause electrical arcing and the cross-wiring and terminal temperature rises
quickly, and may even cause the battery explosion. Failure to comply with the instructions may result in
personal injury.Have to connect the battery cable according to the following order
警告：在将跨接线连接至电瓶时，切勿使跨接线彼此接触或碰触到车身接地。一个充满电的电瓶，
如果经由跨接线短路，会以高于 1000 安培的放电率放电，造成电弧并使跨接线与端子的温度快速
上升，甚至可能会造成电瓶的爆炸。未遵守这些说明，可能会造成人员的伤害。务必要以下述的顺
序，连接电瓶线：
□ To connect positive pole of the back-up battery firstly and then vehicle battery's.
先连接备用电瓶正极，然后连接车辆电瓶的正极。
□ Then connect back-up battery negative pole, before the ground connection at the place 300 mm
minimum away from the battery terminals, such as engine ears.
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接着连接备用电瓶负极，然后在距离电瓶端子至少 300 mm 的车辆接地，例如发动机吊耳。
□ Before taking apart the cross-wiring, it is essential to reduce the engine speed to idle.
在拆开跨接线前，务必要使发动机转速降至怠速。
26
□ Be sure to dismantle the cross-wiring according to the reverse order of connecting the cross-wiring,
12
and do not make the wire end short out.
务必依照连接跨接线相反的顺序拆除跨接线，且勿使导线的末端短路。
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4、 Components cleaning 组件清洁

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□ To avoid the entry of contamination, accumulated and loose dirt as well as grease, you should clear
all this before opening and taking parts of the component or assembly.
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为避免污物的进入、积聚的松动污垢及油脂在拆开或分解组件或总成前，应先予清除。
□ You have to clear the components thoroughly before checking the assembly.
在检查组合前，应将组件彻底的清洁。
□ Cleaning method:清洁方法：
Drying clean.
干燥清洁。
To remove the dirt with a soft brush or a steel brush.
用软毛刷或铁刷将污物除去。
To strike off the dirt with a piece of metal or wood chips.
用一片金属或木片将污物刮除。
Wiping with the cloth.
用抹布擦拭。
Remove dirt and debris by compressed air. (You must use eye protection, when using this
method).
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用压缩空气吹去污物。(在使用此方法时，必须要使用眼部保护)。
Caution: Compressed air is "Wet" sometimes, so you have to be very careful when using it, in particular
26
the hydraulic system.
注意：压缩空气有时是“湿的”，因此使用时要小心，特别是液压系统。
12
Remove the dirt by using the vacuum device. This method should only be used to remove
friction to the resin powder (asbestos particles).
20
用真空设备除去污物。这种方法应仅可用于除去摩擦来令原料粉末(石棉颗粒)。
Steam cleaning.
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蒸汽清洁。
Solvant cleaning
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溶剂清洁
Warning: most of the solvent need to be handled carefully, and some are harmful. Failure to comply
with the instructions may result in personal injury.
注意：大多数的溶剂都需要小心的处理，而且有些是有害的。
5、 Necessary measurement equipment calibration 必要测量设备之校正
Failure to comply with the instructions may result in personal injury.
警告：未遵守这些说明，可能会造成人员的伤害或组件的损坏。
□ Some of the necessary equipment, such as torque wrenches, multi-meter, Exhaust Gas Analyzer, it is
very important to do the regular correction in accordance with manufacturer's instructions.
某些的必要设备，例如扭力扳手、多用电表、废气分析仪，依据制造厂商的说明定期的校正，
是非常重要的。
6、 Road Test 道路测试
□ There are many reasons for the road test for the detailed inspection procedures before testing, from
42
the engine starting and stopping, pre-driving inspection, inspection during and after the testing will
be described below.
26
执行道路测试的原因很多，有关测试前的详细检查程序，从起动发动机与停止、行驶前检查、
测试中检查至测试完成后的最终检查，会在下面说明。 12
□ Pre-test inspection 测试前检查
The pre-testing inspection and functional testing on the thing which shall impact on the security
20
and the legitimate operation of the system/circuit, such as brake, lights, and steering shall be
completed before the implementation of the road test.
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影响到安全与车辆合法操作之系统/回路的测试前检查，与功能测试，例如制动、灯光与转
向，都应在执行道路测试前执行完毕。
Warning: If the brake system hydraulic oil shortage, pedal travel is too long or if you find a leak, you
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must not attempt to perform road test, until you find causes and eliminate them.
警告：如果制动系统的液压油不足、踏板行程太长或发现有漏油，则不可尝试执行道路测试，直到
发现制动油不足、踏板行程太长或漏油的原因且排除为止。
Checking after switching off the ignition switch.
在点火开关关闭时，检查：
The height of the engine oil
发动机机油高度
The hight of the engine coolant

发动机冷却液高度
Whether the tire pressure is correct; type and tread are applicable, or have already worn more
than wear limits or not.
轮胎胎压是否正确，型式与胎纹是否适用，及是否超过磨损限制。
Whether there is sufficient fuel for testing in the fuel tank.
油箱中是否有足够测试使用的燃料。
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Are there any leak of oil (oil, hydraulic oil, fuel) and water around the engine, transmission or
under the whole vehicle? Mark the possible leakage place, and clean the around region, so that to
check the leaks easily when the test is complete.
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发动机、变速箱四周与车下，是否漏油(机油、液压油、燃油等)、漏水。记下可能泄漏的
位置，并将附近的区域擦拭干净，以便在测试完成后易于检出泄漏的程度。
12
7、 Start the engine 起动发动机
20
□ Note: Do not operate with high speed or tread the accelerator pedal to the bottom when vehicle is
cold.
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注意：切勿在冷车时，以高速行驶车辆，或将加速踏板踩到底。
□ Checking after switching off the ignition switch.在点火开关关闭时，检查：

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The hand brake is work or not.
手制动是否已作用。
Gear lever is in neutral or not.
排档杆是否在空档。
All of the numbers in the instrument is zero (except fuel gauge).
所有的仪表读数是否均为零(除燃油表外)。
□ Checking when ignition switch is on.在点火开关 ON 时，检查：
The warning light controlled by the ignition switch is on or not.

由点火开关控制的警告灯是否亮起。
Whether the engine temperature gauge indicates similar with engine temperature.
发动机温度表是否指示与发动机温度相当的读数。
Whether the fuel gauge indicates the similar with quantity of fuel.
燃油表是否指示与油箱油量相当的读数。
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8、 Road or roller test check 动态行驶检查
CAUTION: During a road test, before continuing the test, shall check the brake operation when the speed
26
is still at low. If the brake-down to the side, or a failed state, you cannot continue the test before the
troubleshooting.
12
小心：在动态行驶测试中，应在车速仍在低速时，检查制动的操作。如果出现故障，则在故障排除
前，不可继续道路测试。
□ Whether the clutch pedal operation is smooth or in a heavy situation. And there is no clutch towing
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signs.
离合器踏板操作无不顺或沉重状况。且没有离合器拖带的迹象。
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□ The hand brake can be controlled smoothly, and can be released fast and completely.
手制动控制平顺，且手制动可快速而完整的释放。
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□ Clutch can drive vehicles smoothly, and does not slip or vibration.
离合器能平顺的驱动车辆，且不打滑或振动。
□ Gear shifts smoothly, and there is no abnormal noise or vibration in the transmission.
齿轮变换平顺，且变速箱没有不正常的噪音或振动。
□ Engine power output is normal; can reach full power output; speed up smoothly, and pedal operation
is smooth or light; and the engine will go back to idle correctly.
发动机动力输出正常、可达到全马力输出、加速平顺，且踏板操作不会不顺或沉重，且发动机
能正确的回到怠速。
□ The engine will not emit excessive or abnormal color smoke when the engine is in normal running,
heavy-loading or over-speed circumstance.
在发动机正常操作、重负荷或超速运转下，不会排出过多或不正常颜色的烟。
□ Steering operation, including power steering (if equipped) is smooth, accurate, and not too heavy or
too much clearance or vibration.
转向操作，包括动力转向，均平顺、准确、无过重或间隙过大或振动。
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□ Steering wheel does not pull down on the one side and will return to the center position
automatically.
26
方向盘不会拉向一侧且会自动回到中央位置。
□ Speed, engine oil pressure warning light, the cooling water temperature gauge and tachometer
(installer) to indicate the correct reading or correct operation.
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速度表、机油压力警告灯、冷却水温度表与转速表等，指示正确的读数或正确的操作。
□ Switch and the control unit operate smoothly and clearly, warning and indicator light operating
20
properly, and direction indicator light will be automatically canceled when the steering wheel back to
the straight-ahead position.
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开关与操纵装置操作平顺且明确，警告或指示灯操作正确，及方向指示灯在方向盘回到正前方
位置后，会自动的取消。
□ Heating and ventilation system is properly and effectively.

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暖气与通风系统正确且有效的工作。
□ Braking performance properly and effectively.
制动正常且有效。
9、 Brake Test 制动测试
Caution: Avoid doing the test during heavy traffic, and in the road may bring inconvenience or endanger
to other users on it.
注意：避免在交通繁忙，可能对交通造成不便或危及其它道路使用者的道路上，执行制动测试。
Caution: The braking testing, including the brake, cannot be tried on the new shoes/disk or brake drum,
until the components match up. New brake friction components cannot fully perform the effectiveness
before the fully matching up.
注意：包括重踩制动在内的制动测试，不应在新的制动蹄片/碟盘或制动鼓上执行，直到组件配合
好为止。新的制动摩擦组件在完全配合前，无法完全的发挥效率。
□ To test the braking with pedal pressure from light and heavy in the normal operation of all gears with
the multiple speed. Pay attention if there are any tendency of not smoothness, pulling or towing; and
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are there any undue delay during operation and releasing.
以轻及重的踏板压力，在各档位正常操作下的多种车速测试制动。注意是否有任何不顺、拉扯
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或拖带的倾向，及在作用或释放不应有的延迟。
□ Let the vehicle coast, and notice whether there are tendency of pulling to one side, or brake
constraints phenomenon.
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让车辆滑行，注意是否有拉向一侧的倾向，或制动约束的现象。
□ When the vehicle is stopped (immediate stop by non-heavy tread), please check the brake
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temperature carefully. If the brake disk or the brake drum is very hot, or hotter than others, which
means there are some brake constraints phenomenon.
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在车辆停止后(非重踩制动立即的停止)，仔细的检查制动温度。如果制动碟盘或制动鼓很烫，
或比其它的烫得多，则表示制动有约束的现象。
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□ Check the following after the test:在完成测试后，检查：
Whether engine oil, coolant, hydraulic, air and fuel leak or not.
机油、冷却液、液压、空气与燃油是否泄漏。
The abnormal high temperature of any component or assembly, such as wheel hub, transmission,
axle, etc. May be just caused by the lack of lubrication or too tight.
任何移动组件或总成，例如车轮毂、变速箱、车轴等的不正常高温都可能只是过紧或润滑
不足。
Chapter II How to use this manual
第二章如何使用本手册
I. Preface 序
1、 JAC maintenance manual covers <The overview and maintenance fascicule >, <The engine
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fascicule >,<The chassis fascicule >, <The body structure and electric equipment fascicule >, <The circuit
the circuit>
维修手册分《概述与保养分册》、《发动机分册》、《底盘分册》、《车身结构与电器分册》和《电
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路分册》五本。
2、 Engine fascicule, Chassis fascicule, Body structure and electric equipment fascicule are focused on
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the "Brief" and "Location Map and exploded, the "Remove and Install and adjust the troubleshooting, and
processing".
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底盘分册、车身结构与电器分册三本维修手册主要围绕“简述”、“位置图及爆炸图”、“拆装与
调整”、“故障诊断与处理”来讲解。
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II. Terminology 术语
1、 The WARNING and CAUTION parts mainly remind staffs of the steps that must be followed to
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prevent personal injury or damage to some parts of the vehicle.
警告和注意部分，是用来提醒工作人员必须遵守的步骤，以避免造成人身伤害或车辆零部件的损坏。
2、 WARNING indicates that if not follow the instructions, may cause serious injury or significant
property damage.
警告部分表示如果不遵守该说明，可能会造成严重的人身伤害或重大财产损失。
3、 CAUTION indicates that if not follow the instructions, may cause general personal injury, or
damaged components, assembly or engine.
注意部分表示如果不遵循该说明，可能会造成一般的人身伤害，或者损坏零件、总成或发动机。
4、 Besides WARNING and CAUTION, BOLD TYPED STATEMENTS also give you helpful
information.
除了警告和注意外，粗体字部分也会给你有用的信息。
5、 Standard Value: Acceptable during checking and adjustment.
标准值：检查和调整时可接受的。
6、 The limit value: should not be exceeded at inspection and adjustment.
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极限值：在检查和调整时不应超过的最高或最低极限。
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III. Maintenance ID (some manual follow this ID)维修作业标识部分手册执行此标识
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Tightening torque 拧紧扭矩 Adjustment 调整
Special tools 特殊工具 Clean 清洗

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Warning or Caution 警告或注意 Fill the grease 加注润滑脂

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Remove 拆卸 Liquid fill 液体加注
Assembly 装配 Smearing 涂抹
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Break down 分解 Specific assembly 特定装配
Reset 复位 Pairing 配对
Measurement 测量 Check and repair 检查和修理
IV. Unit 单位
The UNITS of measurement used in this manual are primarily expressed as the SI UNIT
(International System of Unit). For instance: Outer Socket Lock Nut: 59 - 78 N M.
本手册中使用的计量单位主要用 SI UNIT 国际单位制来表示。示例：外套管锁紧螺母: 59 - 78
N·m
V. Contents 目录
1、 THE CONTENTS are listed on the first page of each section.
每个分册的首页上都列出了目录。
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2、 THE TITLE is indicated on the upper portion of each page and shows the parts or systems involved
in this page.
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标题位于每页的上部，表明本页所涉及的零部件或系统。
3、 THE SMALL ILLUSTRATIONS show inspection, using of special tools, knacks of work and hidden
or tricky steps which are not shown in the previous large illustrations.
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小插图用来显示检查、专用工具的使用、操作技巧以及前面大插图中没有显示出来的隐含或复杂的
步骤。
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VI. Special tools 专用工具

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Tools marked with JAC special tool numbers are special tools provided by JAC. Tools not marked or
general-purpose tools are commercially available in the mark.
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有注明 JAC 专用工具编号的为 JAC 提供的专用工具，没有注明或通用工具可以在市场上购买。
Chapter III Model identification information
第三章车辆识别信息
I. Product model and the position of identification information 产品型号和车辆识别信息位置
1、 Position 1: the plate at the right side carling of the frame(some countries' products IDs are different )
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位置一：车架右纵梁外侧面产品标牌上（个别国家产品标牌有所区别）
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2、 Position 2: the right side carling of the frame
位置二：车架右纵梁外侧面上
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II. Product model description 产品型号说明
1、 Basic composition 基本组成
□ Vehicle Model Number is composed by the name of enterprise code, vehicle type code, the parameter
name, and serial number of the product and business custom code, as follows:
汽车产品型号由企业名称代号、车辆类型代号、主参数代号、产品序号及企业自定义代号组成，
见下图
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2、 Part 1 第一部分
□ The code name of enterprise is located on the part 1 of the product model. Generally speaking, using
two or three Chinese Pinyin letters to represent the company name, appointed by the competent
department of China automotive industry. JAC enterprise name code is "HFC".
企业名称代号位于产品型号的第一部分，一般用代表企业名称的两个或三个汉语拼音字母表
示，有中国汽车行业主管部门统一给定。JAC 的企业名称代号是“HFC”。
3、 Part 2 第二部分
□ Vehicle Type Code is located in the part 2 on the product model. Using one Arab numbers to indicates
the classification of the vehicle of the vehicle, refer to the table below
车辆类别代号位于产品型号的第二部分，表面车辆所属分类的代号，用一位阿拉伯字母表示，
见下表。
Vehicle Type Vehicle Type

Vehicle Type Vehicle Type Code Vehicle Type Vehicle Type
Code Code
1 Cargo carrier 4 Tractor 7 Sedan
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Special purpose motor ve
2 Cross-country vehicle 5 Semi-trailer and
hicle
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9 special purpose
semi-trailer
3 Dumper 6 Coach
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4、 Part 3 第三部分
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□ The main parameter code is located in the part 3 on the product model. Using two Arab numbers to
indicates the main characteristics of the vehicle.
主参数代号位于产品型号第三部分，是表明车辆主要特性参数的代号，用两位阿拉伯字母表示。
□ The main parameter codes of cargo carrier, off-road vehicles, dumper, tractor, special vehicle and
semi-trailers are their overall quality (T). The total quality of the tractor include the maximum weight
towed on the fifth wheel. When the overall quality exceeds 100t, it is allowed to use 3 numbers.
载货汽车、越野汽车、自卸汽车、牵引汽车、专用车及半挂车的主参数代号为车辆的总质量 t。
牵引汽车的总质量包括牵引座上的最大质量。当总质量在 100t 以上时，允许用三位数字表示。
5、 Part 4 第四部分
□ Serial number of the product is located in the part 4 in the product model number, showed by Arab
numbers. Using the number from 0, 1, 2, 3 ...in order to show the type of vehicle and the sequence
number of the vehicles with the same main parameters.
产品序号位于产品型号的第四部分，用阿拉伯数字表示，其中从 0、1、2、3......依次使用，
表示车辆类别和主参数相同的车辆顺序号。
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6、 Part 5 第五部分
□ JAC custom code in accordance with its own needs, the distinction between the model with slightly
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structural change, such as petrol, diesel engine, long, short wheelbase, double-cab, the left and right
the steering wheel, etc. ), can be expressed by uppercase and Arab numbers. Some JAC-defined code
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in the table below.
JAC 按照需求自行进行规定，用户区别结构略有变化的汽车车型例如汽油、柴油发动机，长、
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短轴距、单双排座驾驶室，左、右置方向盘等，可用大写字母阿拉伯数字表示。部分 JAC 自定
义代码见下表。
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Serial nu Custom code

Code Definition Example Notes
mber position
Use in
1 K Diesel engine 1 HFC1020KRI
combination
Diesel engine+ single cap 1 HFC1061K Use alone
Use in
Gasoline engine 1 HFC1027ER
combination
2 E
Gasoline engine+ single cap 1 HFC1027E Use alone
Use in
Double cap 1、2、3 HFC1045KR
combination
3 R
Gasoline engine+ double cap 1 HFC1045R Use alone
4 N CNG engine 1、2 HFC104ON
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Use in
Single cap with sleeper 1、2、3 HFC1032KR1
combination
5 R1
Single cap with sleeper+ gasoline
1 HFC1032R1 Use alone
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engine
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III. Vehicle identification number description 车辆识别码说明
1、 Basic Components 基本构成

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□ Vehicle identification number (VIN) is composed by 3 parts, 17 characters totally as required and
cannot have some vacancies, as shown in the following figure. Among which, Part 1: the world
manufacturer identification code (WMI); Part 2: Description of vehicles (VDS); Part 3: vehicle
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indications (VIS).
车辆识别代码 VIN 按规定由三部分、共十七位字码组成，不能出现空位，如下图所示。其中，

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第一部分：世界制造厂识别代码 WMI；第二部分：车辆说明部分 VDS；第三部分：车辆指示部

分 VIS。
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2、 Part 1 第一部分
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□ World manufacturer identifier code WMI is consist of three character code, which must through the
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application, approval and keeping record, refer to the following table
世界制造厂识别代码 WMI 由三位字码组成，该代码须经过申请、批准和备案，见下表

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Code Manufacture name

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LJ1 Anhui Jianghuai Automobile Co,.LTD

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3、 Part 2 第二部分
□ VEHICLES DESCRIPTION Code (VDS) consists of the 6-bit characters, refer to the following
figure
车辆说明部分代码 VDS 由六位字码组成，见下图
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4、 Part 3 第三部分
□ Vehicle indication (VIS) consists of an 8-bit character , refer to the following figure
车辆指示部分 VIS 由八位字码组成，见下图
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Chapter IV Service Request
第四章保养要求
I. Daily checks 日常检查
To ensure that vehicles and life safety, and extended life of your vehicle, the vehicle use staff should
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check daily items that listed in the table below . The owners can perform these checks themselves or have
their JAC dealers do them.
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为保证车辆和人生安全，延长车辆使用寿命，车辆使用人员应该每日检查下表所列的项目。车
辆使用人员可以自己进行这些检查或者让JAC专营店帮助检查。
Project项目 Descriptions说明
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Check tire pressure, including spare tire use the necessary tools needed , and then
adjust according to technical data Check tires carefully for damage, cracking or
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Tire
excessive wear.
轮胎
检查轮胎气压，包括备胎。如果需要，使用必要工具，然后根据技术数据进
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行调整。仔细检查轮胎是否有损坏、开裂或过度磨损。
Make sure that the headlights, fog lights, stop lights, taillights, turn signal lights,
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and other lighting are all operating properly and fixed securely. Also check
Lamps
headlight aim.
车灯
确认前大灯、雾灯、制动灯、尾灯、转向信号灯和其他灯光设备都可以正常
使用，固定牢靠。同时，也应检查前大灯对光功能。
Check that buckles, anchor bolts, adjusters and retractors of seat belts operate
properly and smartly and are installed securely; check seat belts for cracking,
Safety belt
fraying, wear or damage.
安全带
检查安全带的搭扣、地脚螺栓、调整器和卷缩器工作是否正常，是否灵活，
安装是否牢靠；检查安全带是否开裂、擦坏、磨损或损坏。
Check the pedal for smooth operation and make sure it has the proper distance
Brake pedal
from the undercover when depressed fully.
制动踏板
检查踏板是否操作顺畅，确认当踩到底时它距下盖板有合适的距离。
Engine coolant
Check the coolant level when the engine is cold.
level
在发动机冷态时，检查冷却液液位。
发动机冷却液液位
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Check the level after parking the vehicle on a level ground with the engine shut
Engine oil level
down.
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发动机机油液位
将车辆停放在水平地面上，关闭发动机后，检查油面高度。
Make sure that the brake fluid level is between the “MAX” and “MIN” lines on
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Brake fluid level
the reservoir.
制动液液位
确保制动液的液面高度在储液罐的“MAX”和“MIN”刻度之间。
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Check under the vehicle for fuel, oil, water or other fluid leaks after the vehicle
has been parked for a while. Water dripping from the air conditioner after use is
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normal. If you should notice any leaks or gasoline fumes are evident, check for
Fluid leaks
the cause and repair it immediately.
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液体泄漏
在汽车停下一段时间后，检查车辆下面有无燃油、机油、水或其他液体泄漏。
使用后的空调器滴水是正常的。如果发现有明显的泄漏或汽油气味，查找原
因并立即修理。
II. Periodic Maintenance 定期保养
The periodic maintenance section lists the minimum maintenance items required to ensure trouble
free operation of the vehicle roughly. Some additional maintenance items may be required depending on
areas and climates. For more detailed information, please refer to your Warranty Manual.
定期保养大致列出了车辆无故障运行所必须进行的最低限度的保养项目。由于地区、气候、使
用状况等因素的不同，需要追加一些保养内容。关于更详细的资料，请参照保修保养手册。
1、 Engine Maintenance 发动机保养
□ Alternator Belt Check 发电机皮带检查
Be sure to perform the following when engine is stopped.

Inspection should be done only when engine is cold, or over
30 minutes after engine is stopped.
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务必在发动机关闭时执行以下操作。同时应该在发动机
冷态时，或已关闭30分钟后再进行检查。
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Check belts for cracks, wear and oil trace. Replace if
necessary.
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检查传动皮带是否有裂纹、飞屑、磨损状况和油迹。必
要时进行更换。
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The belt between the belt at the midpoint check the belt
deflection. When measuring the deflection, apply 100 N at
the marked point. Adjust if the belt deflection exceeds the
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limit.
在皮带轮之间的皮带中点处检查皮带的挠度。测量挠度
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时，在标记点施加100N的力。如果挠度超过极限值，应
进行调整。
□ Alternator Drive Belt Tension adjustment 发电机传动皮带张

紧度调整
Loosen the alternator mounting cap nuts.
拧松发电机支撑螺栓的螺母
Loosen the belt tensioner lock nut
拧松皮带张紧器的锁紧螺母
Turn the adjusting bolt adjusting the belt tension
转动调节螺栓调整皮带的张紧度
Lock nut
拧紧锁紧螺母
Tighten alternator bearing bolt nuts
拧紧发电机支承螺栓的螺母
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Check the drive belt deflection, if there is a need to make
adjustments
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检查传动皮带的挠度，若有需要再进行调整
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□ Engine Coolant 发动机冷却液检查 MA004
Keep the coolant level in this expansion tank between the

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“MIN” and “MAX” lines
膨胀水箱内的冷却剂液位应保持在“MIN”和“MAX”标
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记之间，要在发动机冷却时检查冷却剂液位。
Under normal circumstances the coolant fluid consumption

is very small, the coolant level drops, this may indicate a
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leak problem. If this occurs, immediately drive to a JAC

approved service station for inspection.
正常情况下冷却剂的消耗量非常小，当冷却剂液位下降
时，则表示可能存在泄露问题。如果出现此问题，应立
即到JAC认可的服务站进行检查。
If coolant level lower the coolant expansion tank MIN " "
mark location, please keep adding coolant
如果冷却剂液位下降低于冷却剂膨胀水箱上的“MIN”
标记位置，请及时添加冷却剂。
Precautions注意：
When coolant of other brand is to be used, be sure to drain original coolant and clean. Hybrid use of
coolants of different brands will cause damage to such components as engine and radiator
在使用其它牌号的冷却液时必须把原来的冷却液放完并清洗，不同牌号冷却液的混合使用，
会对发动机、水箱等零部件造成损害。
Note that the expansion tank cap can not be opened during operation when engine is hot. hot
engine cooling system with a certain degree of pressure, if the thermal cooling spray,it will cause
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serious burns.
在操作过程中注意当发动机处于热的状态下时，不要打开膨胀水箱盖。热态发动机的冷却系
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统具有一定的压力，如果热的冷却液喷出，则会造成严重烫伤。
Never open radiator cap before engine cools down completely. Wrap a thick cloth around radiator
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cap. First turn radiator cap 1/4 turn to release built-up pressure in radiator, and then screw off
radiator cap all the way.
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用厚布包裹住散热器盖，先转动1/4 圈释放散热器内的压力，然后将盖完全拧下。
□ Engine Coolant replacement 发动机冷却液更换

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Remove radiator cap. Remove radiator drain valve (from

lower left part of radiator), and drain coolant in radiator and
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engine water jacket
拆下散热器放水螺堵，再拆下散热器盖，将散热器和发动
机水套内的冷却液排出。
Remove the cylinder block drain screw plug and drain

engine coolant
拆下气缸体放水螺堵，放出发动机冷却液。
Remove expansion tank and drain coolant in it completely.
拆下膨胀水壶并放出壶内的冷却液。
Clean engine coolant lines by pouring clear water through radiator inlet until clean water is drained
从散热器的注水口将干净的水加入冷却系统，来清洗发动机的冷却液管路，直至排出清洁水
为止。
Tighten radiator drain valve firmly
牢固地拧紧散热器放水阀和气缸体的放水螺堵。
Pour coolant designated by JAC Motors in radiator slowly until it is topped off. Start engine and then
liquid level in radiator should drop. Wait until radiator is filled with coolant, and then install radiator
cap
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将JAC规定使用的冷却液缓慢注入散热器，直到散热器注满为止，起动发动机，此时散热器
液面会下降，待散热器内部冷却液充满散热器，装上散热器盖。
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Fill expansion tank with coolant until liquid level reaches line “MAX” (full).
往膨胀水箱注入冷却液，直到液面达到“MAX”线为止。
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Install expansion tank cap
装好膨胀水箱盖。
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Start engine and warm it up until thermostat opening
起动发动机并使其加热到节温器开启。
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After thermostat opening, run engine at full speed for several times and then shut it down; wait until
engine cools down, and then fill expansion tank with engine coolant until liquid level reaches line
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“MAX” (full)
当节温器开启后，使发动机全速运转数次，然后停机；待发动机冷却后，往膨胀水箱注入发
动机冷却液面到“MAX”线为止。
The engine coolant contains corrosion inhibitor-ethylene glycol. To prevent these components
from corrosion, be sure to change engine coolant regularly
发动机冷却液中含有乙二醇抗腐蚀剂。为防止气缸盖和水泵等零部件腐蚀，必须定期地更换
发动机冷却液。
The coolant contains corrosion inhibitors, so do not replace it by light water even in summer
由于冷却液中含有抗腐蚀剂，因此，即使在夏季也不要用普通水更换冷却液。
Content of the required coolant varies with ambient temperature used:
所要求的冷却液含量随使用的环境温度而异：
Contrast Table of Coolant Content and Ambient Temperature
Minimum ambient temperature (℃) -10 -20 -35 -45
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Ethylene glycol content (%) 25 30 35 40
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冷却液含量与环境温度对照表
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最低环境温度 ℃ -10 -20 -35 -45
乙二醇含量 % 25 30 35 40
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When the air temperature in the location of your vehicle drops to below 0℃, the coolant in the
engine or radiator may have the risk of freezing causing serious damage to them. To prevent coolant
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from freezing, add sufficient quantity of coolant in it. The engine coolant filled at delivery of the
vehicle has an antifreeze effect even at a low temperature of around -35℃. Before start of each cold
season, check coolant content and add coolant to the system in time when necessary.
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在寒冷的季节如果汽车所在的地区气温下降到0℃以下，则发动机或散热器内的冷却液可能
会发生结冰的危险，而使发动机或散热器受到严重损害。为防止冷却液结冰，应向冷却液内
加入足够数量的冷却液。
□ Checking fuel lines 燃油管路检查
Check fuel lines, filler cap and tank for improper attachment, leaks, cracks, damage, loose
connections, wear or aging. If necessary, please repair or replace damaged parts.
检查燃油管路、燃油加注口盖和油箱有无安装错误、泄漏、裂纹、损坏、连接松动、磨损或
老化。若有必要，请修理或更换损坏的零部件。
□ engine oil 发动机机油
The temperature is high when changing engine oil, be careful to avoid empyrosis.
更换发动机机油的温度很高，小心不要被烫伤。
Warm up the engine, and check for oil leakage from engine room. Stop the engine and wait for 10
minutes. Remove the engine oil filler cap. Remove the engine oil pan on the oil drain plug and
42
drain oil. Replace it with a new oil drain plug gasket and tighten the drain screw plug. The oil filler
cap to the crankcase with fresh oil
26
暖机，检查发动机室内是否有机油泄漏。关闭发动机并等待10 分钟。拆下发动机注油口
盖。拆下发动机油底壳上的放油螺堵，排出机油。换上新放油螺堵垫片，并拧紧放油螺堵。
从注油口盖向曲轴箱注入新机油。
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When filling engine oil, do not pull out oil dipstick

20
加注机油时，不要拔出机油尺。
The refill capacity depends on the engine oil temperature and drain time.
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机油加注量随机油温度和放油时间的不同而异。
From out of the engine oil dipstick to check oil level is in MAX MIN or not
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从发动机拔出机油尺，检查机油液位是否位于MAX 和MIN 刻线之间。
Warm up the engine and check area around drain plug and oil filter for engine oil leakage.
暖机，并检查放油塞和机油滤清器周围是否有机油泄漏。
Stop the engine and wait for 10 minutes. Check if the oil level is within the normal range.
关闭发动机并等待10 分钟，并检查机油液面高度是否处在正常范围内。
□ Oil Filter replacement 机油滤清器更换
Start the engine and let it warm up running until the engine coolant temperature reaches 80 - 90
Degrees C.
起动发动机并让它预热运转直至发动机冷却液温度达到80-90℃。
Remove oil filler cap. Remove the oil pan on the oil drain plug to drain oil.
拆下注油口盖。拆下油底壳上的放油螺堵来排出机油。
Remove the engine oil filter.
拆下发动机机油滤清器。
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Clean oil filter bay side of the mounting surface, put the engine oil filter O-ring with small amount
of oil.
26
清洁机油滤清器托架侧的安装面，在机油滤清器的O型圈上涂少量机油。
When the oil filter O-ring the contact to the pump of the flange， tighten to specified torque.
12
当机油滤清器的O型圈一接触到机油泵的法蓝时，拧紧到规定力矩。
Install oil pan ,and fill oil through oil plug.

20
安装油底壳上的放油螺堵,并从注油口注入机油。
Operate High-speed engine for 2-3 minutes , and then check the filter mounting surface ,it should
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not penetrate oil.
高速运转发动机2-3 次，然后检查滤清器的安装面应不渗透机油。
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□ Air Cleaner Filter check 空气滤清器滤芯检查
Check the air cleaner filter whether it is blocked and there is no damage or not.
检查空气滤清器滤芯是否阻塞和有无损伤。
Gently tap the filter on one side or from the Filter on the inside of compressed air to remove the
sediment filter the dirt.
轻轻的敲打滤芯的一侧或从滤芯的内侧吹压缩空气清除沉积在滤芯上的脏物。
Scrape off the air filter inside the dirt.
刮掉空气滤清器内部的脏物。
If you re-use the old filter element at the time of installation, locate the oiled part in part blow-entry
position (to prevent oil pollution).
若重新使用旧的滤芯，在安装时要使滤芯的油污部分位于窜气入口位置防止油污扩散。
□ Air Cleaner Filter Replacement 空气滤清器滤芯更换
In the process, the air filter, the filter is dirty and stained with dust, so filter effect has declined
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markedly. At this time, you should replace it with a new filter.
在使用过程中，空气滤清器的滤芯变脏并沾满灰尘，从而过滤效果明显下降。此时，应换上
26
新的滤芯。
Loosen air cleaner cover snaps. Remove the air cleaner filter, and replace the new filter. when
fill the air cleaner cover, be sure that it is fully closed.
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松开空气滤清器盖卡扣。拆下空气滤清器滤芯，装上新的滤芯。在扣住空气滤清器盖时务必
使它完全闭合。
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□ Check crankcase breather hose (if any)检查曲轴箱通气软管(如有)

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If necessary, use mirror to check the hose of the entire perimeter and length.
必要时可用反射镜检查各软管的整个外围和长度。
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Check all the folders are clamped,if leaks joints .
检查所有卡夹是否夹紧，接头处是否渗漏。
If hose is significantly worse, or damage the signs should be replaced immediately.
若软管有明显劣化或损伤的迹象应立即更换。
2、 Chassis and body maintenance 车身和底盘保养
□ Checking exhaust system 检查排气系统
Verify that exhaust tube should not be in interference. with any component.
确认排气管应不跟车上的任何构件产生干扰。
Check to see if the exhaust pipe is affected by gravel, and the shock and damage.
检查排气管是否受到碎石等的撞击而损坏。
Start the engine and check to see if the exhaust pipe joints leaks.
起动发动机，检查排气管的接头处是否漏气。
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□ Transmission Lube 变速器润滑油
Lube oil quality, good or bad, oil too much or too little will affect the transmission of the normal
26
work and life, the oil level check in the following ways:
润滑油品质的好坏、油量过多或过少都会影响到变速器的正常工作和使用寿命，油量检查按下
12
述方法进行：
Check oil volume after vehicle driving with transmission still hot.
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在车辆行驶后变速器尚热时进行油量检查。
When checking, be sure to park your vehicle on a flat, level and good ground and set parking brake.
Do not proceed with the next operation until making sure the vehicle has come to a full stop.
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检查时，须把车辆停放在平坦而水平的良好地面上，并拉起驻车制动器，在确保车辆停稳后
方可进行下一步操作。
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Set shift lever to neutral position.
把变速杆置于空档位置。
Screw off filler plug at left side of transmission and wipe up filler with a clean cotton cloth. Check
that the fluid level is within the range from lower edge of filler to not lower than 5mm from the
lower edge.
拧开变速器注油口螺塞，用清洁的棉布擦净注油口，检查液面，应位于从注油口下缘至不低
于下缘5mm的范围内。
If the fluid is found dilute, gumming or too dirty, change immediately.
如液体有稀释、结胶、过脏等现象，应立即更换。
Precautions: Hybrid use of gear oils of different brands will damage transmission. Be sure to use the
designated gear oil.
注意：不同牌号的齿轮油混合使用，会损害变速器，须使用指定的齿轮油。
□ BRAKE FLUID CHECK (if any)制动液检查(如有)
The level must be between the “MIN” and “MAX” lines on the tank. Brake fluid level will slightly
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drop when brake pad is worn.
制动液的液位必须位于储液箱上“MAX”和“MIN”两个标记之间。当刹车衬块磨损时，制动
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液的液位会稍微降低。
If brake fluid level drops significantly in a short period of time, it indicates oil leaks in brake system.
If this occurs, immediately drive to a JAC approved service station to have your vehicle serviced.
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如果在不长的时间内制动液的液位明显下降，则表示制动系统存在漏油现象。如出现此情
况，应立即到JAC认可的服务站检修。
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You should use the specified brake fluid. Brake fluids are water absorbing liquids. Braking
performance will be reduced if the brake fluid contains excessive moisture. In addition, the brake
fluid cup is provided with a special sealing gland in order to prevent air entry. This gland can not be
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removed at will.
应使用指定的制动液。制动液是吸水性液体，制动液含有过多的水份会降低制动性能。此
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外，制动液储液杯上装有特殊的密封盖，以防止空气进入，不可随意拆下这个盖。
□ Brake fluid replacement (if any)制动液更换(如有)
Brake fluid will absorb moisture. So it will absorb the moisture in the surrounding air as time elapses.
However, excessive water content in the brake fluid could cause corrosion damage to the brake system.
In addition, boiling point of the brake fluid will drop significantly. Therefore, be sure to change the brake
fluid every 2 years.
制动液会吸收水分。因此随着时间的推移它会吸收周围空气中的水分。然而制动液中过高的
含水量能引起制动系统的腐蚀损伤。除此之外制动液的沸点会明显下降。因此必须每两年需更换
一次制动液。
Precautions 注意：
If the brake fluid has been used for an extended period of time, bubbles will be produced in the
brake system under extremely high braking load, thus impairing braking efficiency and driving
safety seriously.
如果制动液使用时间过长，在十分高的制动载荷下，其制动系统中能形成气泡，这样制动效
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能以及行驶安全性能会受到严重损害。
Use brake fluid approved by JAC only at brake fluid change. In addition, it is required that brake
lines be cleaned thoroughly. Ensure hybrid use of 2 types of brake fluid will not occur.
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更换制动液仅可以使用JAC认可的制动液，并要求对制动管路进行彻底的清洗，确保两种制
动液不发生同时混用。
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Brake fluids are harmful to human health! Therefore, the coolant should be kept properly in its
original sealed container and particularly out of reach of children. In addition, take care to prevent
brake fluid from corroding automobile finish.
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制动液对人体是有害的！因此，它必须妥善保存在原装密封容器中，尤其要防止儿童接触。
另外还要注意防止制动液腐蚀车面漆。
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Pay attention to disposal of brake fluid. It will impair both eyes and skin and spray-painted surfaces.
Flush clean with clear water immediately if the fluid spills on your body inadvertently.
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处理制动液要注意，它会损伤眼睛和皮肤，也会损伤喷漆表面。若不慎泼溅到人体上，应立
即用清水清洗干净。
Be sure to keep brake fluid cup clean. Its gland must be tightened to prevent dirt entry.
要保持储液杯清洁，储液杯盖要拧紧以防止脏物进入。
When filling brake fluid, wipe clean brake fluid cup gland and filler with a clean rag first and then
refill with designated clean brake fluid.
加注制动液时先用干净的抹布把储液杯盖及注油口擦净，然后再加注指定清洁的制动液。
If the brake fluid is found deteriorated, drain the fluid in brake system and then refill with clean
designated brake fluid.
若发现制动液变质，应立即排放干净制动系统中的变质制动液，然后再加注清洁干净的指定
制动液。
□ Checking brake lines and cables 制动管路和拉丝检查
Check brake lines and parking brake cables for improper positions, leaks, wear, chafing and aging,
etc.
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检查制动管路和驻车制动拉丝位置是否正确，是否有泄漏、磨损、擦伤和老化等现象。
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□ Steering gear check 转向机检查
Check gear housing and boots for looseness, damage and grease leakage.
12
检查转向机壳体和防尘套是否松动、损坏和润滑脂泄漏。
Check connection with steering column for looseness.

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检查与转向柱的连接是否松动。
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□ Steering linkage check 转向拉杆检查
Check ball joint, dust boots and other parts for looseness, wear, damage and grease leakage.
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检查球铰链、防尘套和其他零件是否松动、磨损、损坏或润滑脂泄漏。
□ Power Steering Fluid check 动力转向液检查
Check power steering fluid level in reservoir tank with engine idling.
在发动机怠速运转的状态下，检查储液罐内的动力转向液的液位。
Check brake fluid level in reservoir tank. The level must be between the “MIN” and “MAX” lines
on the tank.
检查储液罐内动力转向液的液位，液位必须位于储液罐上“MAX”和“MIN”两个标记之间。
Precautions 注意：
Please do not overfill.
请勿过量加注油液。
Use JAC specified oil.
使用JAC指定的油液。
□ POWER STEERING Circuit Check 动力转向管路检查
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Check hose for improper attachment, leaks, cracks, damage, loose connections, wear or aging.
是否有泄漏、裂纹、损坏、连接松动、磨损或老化。
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Check rack boots for accumulation of power steering fluid.
检查齿条防尘套上是否有动力转向液聚积。
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□ Axle and suspension parts 车桥和悬挂零部件检查
20
Check front and rear axle and suspension parts for excessive play, cracks, wear or other damage.
检查前后桥和悬挂零部件是否间隙过大，是否有裂纹、磨损或其它损坏。
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Shake each wheel to check for excessive play.
晃动各个车轮检查是否间隙过大。
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Check wheel bearings for smooth operation.
检查车轮轴承的操作情况。
Check axle and suspension nuts and bolts for looseness.
检查车桥和悬挂螺母和螺栓有无松动。
Check strut (shock absorber) for oil leakage or other damage.
检查支柱减震器是否有机油泄漏或其他损坏。
Check suspension ball joint for grease leakage.
检查悬挂球节有无润滑脂泄漏。
Check ball joint dust cover for cracks or other damage
检查球节防尘罩有无裂纹或其他损坏。
□ Tire inspection 轮胎检查
For safe driving of your vehicle, type and size of tires must be suitable for the vehicle model; in
addition, tire treads must be in good condition and appropriate tire pressures must be provided.
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为安全驾驶车辆，轮胎的型号和尺寸必须适合车型，并具有状态良好的胎纹和适当胎压。
Warning: Use of excessively worn or under inflated tires will cause accidents resulting in personal
26
injury or death.
警告：使用过度磨损或胎压不足的轮胎将会引发事故，造成人身伤亡。
12
Also check tires for wounds, punctures by foreign materials and other abrasions at each tire inflation
check.
20
在每次检查轮胎充气状态时，还应该同时检查轮胎有无外伤、异物刺伤及其它磨耗情况。
Damage and bulge on tread or sidewall. If any is found, replace the tire.
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胎面或侧面的损伤及凸起。如发现任何一种情况，便应更换轮胎。
Scratch, crack or fracture on sidewall. If tire fabric or cord can be seen, replace the tire.
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轮胎侧面的刮伤、裂缝或断裂。如能看到轮胎布或帘线，则应更换轮胎。
Excessive tread wear.
避免过度的胎面磨耗。
Chapter V Recommended Auxiliary material filling standard
第五章推荐辅料加注标准
Auxiliary
Volume Recommended Auxiliary material model
material name
用量推荐辅料型号
辅材名称
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Engine Oil See ENGINE register
/
发动机油详见发动机分册
26
Transmission oil See Chassis register
/
12
变速箱油详见底盘分册
85 W/90 (GL-5: Apply the lowest temperature - 12 c degrees

Celsius above ;
20
80 W/90 (GL -5: Apply the lowest temperature - 26 degrees Celsius

above;
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75W/90 (GL-5: Apply the lowest temperature - 40 c degrees

The rear axle gear
Celsius above ;
oil
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/
Some types of vehicles No Middle Bridge
中后桥齿轮油
85W/90(GL-5)：适用于最低温度-12℃以上地区；
部分车型无中桥
The Edge speed 85 W/90 (GL-5: Apply the lowest temperature - 12 c degrees
On-demand
reducer oil Celsius above ;
按需
轮边减速器油 80 W/90 (GL -5: Apply the lowest temperature - 26 degrees Celsius
above;
75W/90 (GL-5: Apply the lowest temperature - 40 c degrees

Celsius above ;
Some types of vehicles without the EDGE speed reducer
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部分车型无轮边减速器
26
- 10 °C and above using JFL318
Coolant On-demand - 10 °C ~ -35 °C use JFL 336

12
冷却液按需 -10℃及以上事宜 JFL318
-10℃~-35℃使用 JFL336
20
Air Conditioning
On-demand Model:
Refrigerant
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按需型号：
空调冷媒
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light truck model:

The clutch brake
On-demand Heavy-duty truck model: JQ 3-GB 10,830/JG 4
fluid
按需轻型卡车型号：
离合制动液
重型卡车型号：JQ3-GB10830/JG4
washing-up liquid On-demand window washer fluid and the model selection based on the local
洗涤液按需车窗清洗液，型号根据当地最低环境温度选择
Power Steering On-demand Model number: S 3 ATF MD 3.
Fluid 按需型号：S3 ATF MD3；

动力转向液
Cab turn
On-demand
hydraulic oil YH - 10 aviation hydraulic oil
On-demand
驾驶室翻转液压 YH-10航空液压油
按需
油
Urea On-demand
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尿素按需
Grease demand
26
On-demand 5671 GB car universal lithium
site
按需 GB5671汽车通用锂基
润滑脂需求部位
12
Note: Different brands work model should not be mixed.
20
备注：不同品牌不通型号不能混用
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Chapter VI Recommended tightening torque standard
第六章推荐紧固扭矩标准
I. General torque standard 一般扭矩标准
The following table applies to bolt or nut that not given specified torque values
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下表列出的扭矩值适用于没有给出规定扭矩值的螺栓或螺母
4T（Bolt螺栓） 7T（Bolt螺栓） 8T（Bolt螺栓）

Classify
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4T（Nut螺母） 6T（Nut螺母） 6T（Nut螺母）
分类
Size Tighten Tighten Tighten
Standard标 range Standard range Standard range
准
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尺寸标准标准
拧紧范围拧紧范围拧紧范围
M5×0.8 2.75 2.0-2.9 5.20 3.9-5.9 5.98 4.6-6.9
M6×1.0 (4.71) (3.9-5.9) 8.83 6.9-10.8 10.2 7.8-11.8

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M8×1.25 11.2 8.8-13.7 20.9 16.7-25.5 24.2 19.6-29.4
M10×1.25 23.1 18.6-27.5 43.2 34.3-53.9 52.4 44.1-58.8

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M12×1.25 42.2 33.3-49.0 82.1 68.6-93.2 95.2 83.4-108
M14×1.5 71.6 58.8-83.4 133 118-157 155 127-177

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M16×1.5 108 93.2-127 202 177-235 234 196-265
M18×1.5 158 137-186 294 255-343 341 294-392
M20×1.5 221 186-255 412 353-471 478 402-549
M22×1.5 296 255-343 552 471-637 641 549-735
M24×1.5 392 333-451 732 618-843 849 726-981
II. Key torque standard 关键扭矩标准
The following table applies to bolt or nut that must obey to the specified torque values
下表列出的扭矩值是维修过程中必须遵守的扭矩值
Assembly Key operation Tightening torque (N * m)
总成关键工序拧紧扭矩 N·m
Main bearing cap bolts主轴承盖螺栓 Refer to “Engine”
Connecting rod nut连杆螺母 Refer to “Engine”
Engine Cylinder Head Cap Screws 缸盖螺栓 Refer to “Engine”
发动机 The sump Assembly Cap Screw 油底壳总成螺栓 Refer to “Engine”
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ALTERNATOR BELT TENSION 发电机皮带张力 Refer to “Engine”
Flywheel Assembly Cap Screws 飞轮组件螺栓 Refer to “Engine”
26
The fork bolt拨叉螺栓 Refer to “Chassis”
6 the flange bolt六角法兰面螺栓 Refer to “Chassis”

12
Intermediate Support plate mounting bolts中间支撑板固定螺
Refer to “Chassis”
栓
20
Internet lock plate cap screws互锁板螺栓 Refer to “Chassis”
Transmission Bearing Plate bolt轴承压板螺栓 Refer to “Chassis”

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变速箱
Intermediate Shaft Front Bearing plugs中间轴前轴承螺塞 Refer to “Chassis”
Housing Cap Screws壳体螺栓 Refer to “Chassis”

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Reverse Gear Shaft bolt倒档轴螺栓 Refer to “Chassis”
oil filler plug加油螺塞 Refer to “Chassis”
Second shaft plug二轴螺塞 Refer to “Chassis”
The front U-bolt前骑马螺栓 126~154 N·m
The ear pin前吊耳销 157~196 N·m
The leaf spring pin前板簧固定销 157~196 N·m
The rear ear pin后吊耳销 157~196 N·m
The rear U-bolts后骑马螺栓 126~154 N·m
front thrust bearing nut前止推轴承螺母 20.8~34.2 N·m
Front knuckle arm mounting bolts前转向节臂固定螺栓 29~39 N·m
Chassis and Differential Housing Cap bolt差速器壳螺栓 50.96~56.84 N·m

other
reducer housing cap bolt减速器壳螺栓 108~161 N·m
底盘及其他
Pilot bearing retainer bolts导向轴承挡板螺栓 16~26 N·m
bearing cap bolts轴承盖螺栓 132.3~171.5 N·m
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Adjusting Nut lock bolts调整螺母锁片螺栓 24.5~34.3 N·m
781~15 N·m
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Rear brake backing plate nuts后制动器底板螺母
Half-shaft bolt半轴螺栓 106~158 N·m
46~62 N·m
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Drive Shaft transmission end nut传动轴变速箱端螺母
Differential end retaining nut差速器端固定螺母 46~62 N·m
485~593 N·m
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Tire Mounting Nuts轮胎固定螺母

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Chapter VII Recommended special tool
第七章推荐使用专用工具
No for the time being 暂无
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ANHUI JIANGHUAI AUTOMOBILE CO., LTD
Compiling 编制 Penny.Wang 王海艳

Audit 审核 Youwang.Zhang 张有旺
Approve 批准
WORKSHOP MANUAL
维修手册
HFC1121P70K1E1-LG016
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Body structure & electrical 车身结构与电器分册
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Chassis
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contents in this Manual. This Manual shall be 底盘分册
本手册用于帮助 JAC 授权的专业维修技术人员， Body structure& electrical

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对江淮汽车提供有效正确的保养及维修。为确保江淮车身结构与电器分册
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All rights reserved, without the written consent of JAC, it may not be reproduction all or a
part of this manual.
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Tel：0086-551-62296644
Fax：0086-551-62296633
26 JAC 国际公司客户服务部
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JAC International Customer Service Depart.
2015.05
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Content
目录
Body structure 车身结构

Electrical Appliance 电器
A/C system 空调系统
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Chapter 1 Body Structure
第一章车身结构
I. Overview 简述
Automobile body structure includes: the body shell, the front plates, door, window, the internal and
external decoration, seats and container. The main function of automobile body is as follows: ①to
provide a good operating conditions and comfortable working place for the driver; ②to assure the goods
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are intact during transport and convenient to assembly and disassembly; ③the body structure and
equipment can ensure traffic safety and reduce accident consequence; ④the reasonable external shape the
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body can effectively guide the airflow around the vehicle, improve the car's power, fuel economy and
driving stability, improve the cooling conditions of the engine and the indoor ventilation.
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汽车车身结构包括：车身壳体、车前板制件、车门、车窗、车身内外部装饰件、座椅、货箱等。
汽车车身的主要功用是：①为驾驶员提供良好的操作条件和舒适的工作场所；②保证完好无损地运
载货物且装卸方便；③车身结构和设备可以保证行车安全和减轻事故后果；④车身合理的外部形状，
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可以在汽车行驶时有效引导周围的气流，提高汽车的动力性、燃料经济性和行驶稳定性，改善发动
机的冷却条件和驾驶室内的通风。
Main parameters of the cab

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驾驶室主要参数
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Item 项目 Parameters 参数
Narrow single cabin Narrow king cabin wide single cabin wide king cabin
Type 型式
窄体单排窄体一排半宽体单排宽体一排半
Reversible or not Yes Yes Yes Yes

Cab 是否可翻转是是是是
驾驶
室 Reversing type Manual Manual Manual Manual
翻转型式手动手动手动手动
Two seats with Two seats with

Seats type Two seats Two seats
sleeper sleeper
座椅型式两座位两座位
两座位带卧铺两座位带卧铺
Length
External 1655 1985 1655 1985
长
dimension
（mm） Width 宽 1725 1725 1995 1995
外部尺寸
Height
（mm） 1775 1775 1775 1775
高
Length
Internal 1460 1790 1460 1790
长
dimension
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（mm） Width 宽 1455 1455 1725 1725
内部尺寸
Height
（mm） 1450 1450 1450 1450
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高
Cab type 本车型驾驶室类型 *

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II. Lay-out 位置图
1、 Assembly lay-out 总成位置图
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Single cabin lay-out 单排驾驶室位置图
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Narrow king cabin lay-out 排半驾驶室位置图
2、 Components lay-out 各组件位置图
1 2
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7 6 5 4 3
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8 9 10 11 12 13 14 15 16 17
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21 20 19 18
S/N 序号 DESCRIPTION 英文描述 DESCRIPTION 备件名称

1 Door 车门
2 Front windscreen 前风窗玻璃
3 Outer rearview mirror 外后视镜
4 Air-inlet grille 进气格栅
5 Front bumper 前保险杠
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6 Front outer panel 前围外板
7 Front cover 前围护面
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8 Rear windscreen 后风窗玻璃
9 Top interior trim 顶内饰

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10 Safety belt 安全带
11 Driver seat 主驾驶座椅

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12 Door interior trim panel 车门内饰板
13 Top tray 顶杂物盒

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14 Sun visor 遮阳板
15 Steering wheel 方向盘

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16 Inner rearview mirror 内后视镜
17 Dashboard panel 仪表台
18 Board handle 登车把手
19 Gear shifting handle 档位手柄
20 Passenger seat 副驾驶座椅
21 Manual brake handle 手刹
Note: the above pictures are of typical components. Some models exist differences, no detailed identification here.
备注：上述图片为典型部件图片，部分车型存在细微区别，此处不再标识。
III. Disassembly, assembly and adjustment 拆装与调整
1、Cautions 注意事项：
□ To be beautiful and protect cab lacquer, well protected to avoid scratch when disassembling parts.
为了美观和保护驾驶室漆面，拆装部件过程中，应做好防护，以免出现划伤。
□ Check whether the components are lubricant, if necessary, lubricate.
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装配某些部件时，检查部件是否润滑不良，如果有必要，应进行润滑。
□ Remove the battery anode and wait at least 3 minutes before disassemble and assemble electrical
devices; otherwise the vehicle will be damaged.
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拆装电器接插件之前必须拆下蓄电池负极并等待至少 3 分钟，否则会造成车辆损坏。
□ Disassembly and assembly steps of each component may exist differences, please subject to actual
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vehicle status.
关于各部件的拆装步骤，部分车型可能存在细微区别，以实车状态为准。
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2、Disassembly and assembly of the door 车门拆装

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□ Disassemble door, dismantling sequence is as follows,

door trim device, car doors and windows device, car
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door lock and lock device, side turn lamp, door

assembly.
拆解车门，拆解顺序为车门内饰板装置、车门窗装
置、车门锁及闭锁器装置、侧转向灯、车门总成
2.1 Disassembly and assembly of door trim device 车门内饰板装置的拆装
□ Dismantling door main handle
拆卸车门大把手
（1）Pry the door inside handle cover and main hand

cover with a flat screwdriver.用小平口螺丝刀撬开车
门内把手盖板和车门大把手盖板
（2）Remove door inside handle cover set bolts.拆下
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车门内把手盖板固定螺栓
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（3）Remove door main handle cover set bolts and
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take off main handle.拆下车门大把手固定螺栓，并取

下车门大把手
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□ Remove the door glass lift switch and inner handle

assembly.
拆卸车门玻璃升降开关和内扣手总成件
（1）Remove set bolt on inner handle.拆下车门内扣

手上固定螺栓
（2）Pry the door glass lift switch and inner handle
assembly，remove door crank handle.用平口螺丝刀撬
开车门玻璃升降开关和内扣手总成件，拆下车门玻
璃摇手柄
Note ： For electrical door, please disconnect the

connectors and remove the battery cathode for at least
3 minutes before taking off the door window switch
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and inner handle assembly.
注意：若是电动车门，此处应该在取下车门玻璃开
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关和内扣手总成件之前，请先断开接插件，断开蓄
电池3分钟。
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□ Remove door internal trim
拆卸车门内饰板
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（1）Remove clips on the internal trim, and pry it with

a flat screwdriver.拆下车门内饰板上卡扣，并用平口
螺丝刀撬开车门内饰板
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（2）Remove door lock wiredrawing，take off door

internal trim.拆下车门锁拉丝，取下车门内饰板
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Note：Pay attention to the buckle when dismantle door

internal trim, or it will be damaged.
注意：拆卸车门内饰板过程中，特别小心卡扣，否
则内饰板容易破损。
Assembly process : opposite to dismantle process , and pay attention to the following issues：
装配：按照拆解相反步骤开展，并注意以下事项：
a
□ After car door lock assembly is installed, snap door
lock assembly wire drawings "a", "b" into the card slot
"c", "d" of inner handle assembly, and to give the
b
c d handle assembly in the door trim panel some free play.
Meanwhile, wire drawings "a", "b" have anti-error
design; they cannot be mounted if they are disordered.
车门锁总成安装后将车门锁总成“a” 、“b”拉丝
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分别卡进车门内把手总成卡槽“c” 、“d”处，使
内拉手总成在车门内饰板上能有一定的自由间隙。
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同时，“a”、“b”拉丝有防错设计，相互颠倒后
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2.2 Disassembly and assembly of door windows device 车门窗装置的拆装

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□ Dismantle front door seal components system
拆卸前车门密封件系统
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（1）Remove front door inner trim 拆下前车门内饰板
（2）Remove set bolts and fixing clips on door strip,

and remove the lower door strip.拆下车门下镶条固定
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螺栓和固定卡扣，取下车门下镶条
Note: The dismantling of lower door strip is

non-essential steps for daily repair, please decide if to
remove it depends on the actual situation.
注意：车门下镶条的拆装属于日常维修中非必要步
骤，请视实际情况进行拆除。
（3）Remove front door loudspeaker fixing bolt,
disconnect the speaker connector, remove the front door
speaker.拆卸前车门扬声器固定螺栓，断开扬声器接
插件，取下前车门扬声器
（4）Removing the inner hand mounting bracket bolts,
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remove the buckle of the hand mounting bracket.拆卸
内扣手安装支架固定螺栓，取下内扣手安装支架
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（5）Detach door waterproof membrane, and remove it.
分离车门防水膜，并取下
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Note: Don't touch the adhesive surface so as not to

weaken the bonding effect again, so as not to damage it.
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注意：取防水膜时要小心，不要触摸粘合剂表面以免
削弱再次粘合的效果，损坏防水膜。
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（6）Remove door sealing strip for glass, door glass

inside and outside water splitting.拆下车门玻璃密封
条、车门玻璃内外劈水条
Note: The dismantling of door sealing strip for glasses

non-essential steps for daily repair, please decide if to
注意：车门玻璃密封条的拆装属于日常维修中非必要
步骤，请视实际情况进行拆除。
□ Disassembly of window glass and glass lifter

拆解车窗玻璃及玻璃升降器
Note: Put the glass down before you remove the

windows glasses of doors.
注意：若拆卸车门窗玻璃，请务必先将玻璃降下来。
（1）Remove the door frame adhesive tape 拆下门框

胶条
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Note: Door frame adhesive strip disassembly belongs to
non necessary steps in daily repair, please decide if to
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骤，请视实际情况进行拆除。
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（2）Remove window glass fixed bolts, take off the
glass window.拆卸车窗玻璃固定螺栓，取下车窗玻璃
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（3）Remove fixed bolt of door glass guide groove.拆

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卸车门玻璃导槽固定螺栓
Note: Each door has two glass guide grooves, this step
only to remove the glass guide groove on the side of the
door handle.
注意：每个车门有两个玻璃导槽，该步骤只拆卸在车
门把手侧的玻璃导槽。
（4）Remove the door glass guiding groove.取下车门
玻璃导槽
（5）Remove fixing bolts of glass lifter.拆卸玻璃升降
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器固定螺栓
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（6）Remove glass lifter.取下玻璃升降器
Note: For electric door, glass lifter motor is synthesized

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in the glass lifter, when removing glass lifter; please

disconnect the glass lifter motor connector.
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注意：若为电动车门，玻璃升降电机会合成在玻璃升
降器上，拆卸玻璃升降器时，请断开玻璃升降电机接
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插件。
□ When installing door sealing strip, fix the buckle of the strip onto door fixing hole in a clockwise
direction.
安装车门密封条时，按顺时针方向将胶条上的卡扣卡到车门固定孔上。
□ When installing the door waterproof membrane, you need seal the area around the door,
concentrically locate the holes on the membrane and holes on car body, then the sealing film and the
door should be tightly attached.
安装车门防水膜时，将车门中需要密封区域四周装上密封胶，以密封膜上的孔位与车身上的孔
位同心定位，密封膜跟车门密封牢固。
2.3 Disassembly and assembly of door lock and locking device 车门锁及闭锁器装置的拆装
□ Dismantle car locks assembly
拆卸车门锁总成
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（1）Remove door trim panel 拆卸车门内饰板
（2）Remove door and window glass device 拆卸车门
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窗玻璃装置
（3）Remove the front door lock cylinder fixed card,

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unplug the door lock cylinder connecting rod and car
door handle, remove the door lock cylinder 拔下前车门
锁芯固定卡片，拔开车门锁芯与车门外把手连接拉
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杆，取下车门锁芯
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（4）Disconnect the inside and outside hand drawing

and rod 断开内外把手拉丝和拉杆
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（5）Remove the car door handle mounting bolts, take

off the door handle 拆卸车门外把手固定螺栓，取下车
门外把手
（6）Remove the lock body assembly mounting bolts
拆卸锁体总成固定螺栓
（7）Remove the lock assembly 取出锁体总成
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□ Remove front car door lock: Mark the location of the
existing lock, remove the lock bolts, remove the door
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lock
拆解车门锁扣总成：标记现有锁扣的位置，拆卸锁
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扣固定螺栓，拆卸门锁锁扣
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□ Install the components according to the original position.
安装时一定要按照原来的位置进行安装。
□ After installation check if door switch is normal and door lock is solid, if abnormal or insecure, you
should re-install or adjust it.
安装后检查车门开关是否正常，门锁锁止是否牢靠，若不正常或不牢靠应重新进行安装或调整。
□ Front door lock adjustment 前车门锁扣调整：
（1）Loosen the lock screw 松开锁扣螺钉；

（2）Move the latch to the acquired direction to ensure that the latch locks the middle 将锁扣向需要
的方向移动，确保锁扣在门锁的中间；
（3）Tighten the fixing screws 拧紧锁扣固定螺钉；
（4）Close the door and insure the gap and flushness meet the requirements 关闭车门，检查面差、
间隙是否符合要求；
□ Tightening torque: lock bolts, refer to "Overview and maintenance volume"
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拧紧力矩：锁扣固定螺栓，参考《概述与保养分册》。
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2.4 Disassembly and assembly of side lights 侧转向灯的拆装
□ With a flat-blade screwdriver to gently pry the side

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lights, remove side turn signals from the door
用平口螺丝刀轻轻撬起侧转向灯，将侧转向灯从车
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门上取出
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□ Disconnect the side turn signal connectors, remove the

side lights. Counterclockwise twist the bulb holder,
then you can remove the side turn signal lamp
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断开侧转向灯接插件，取下侧转向灯。逆时针拧动
灯泡座，可将侧转向灯灯泡拆下
Assembly process: opposite to dismantle process.
装配：按照拆解相反步骤开展。
2.5 Disassembly and assembly of the front door assembly 前车门总成的拆装
□ Remove the outside rearview mirror
拆下外后视镜
□ Open the door to the maximum, disassemble the door

stopper fixing bolts
将车门开到最大开度，拆卸车门限位器的固定螺栓
□ Open the door to the maximum, disassemble the fixing
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bolts of the door assembly
将车门开到最大开度，拆卸车门总成的固定螺栓
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Note: Disassemble it from the bottom to the top,
disassembly should be carried out in several times.
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注意：拆卸时应由下往上进行拆卸，分多次进行，
切不可一次松下。
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□ Unplug the door harness pouches, disconnect the door

electrical connector. Lift door and place it in the right
place with the help of assistant.
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拔开车门线束胶套，断开车门电气接插件。在助手
的帮助下将车门抬下，放置于合适的地方
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装配：按照拆解相反步骤开展，但请注意以下事项：
□ Installation should be carried out in multiple fastening.
安装时应分多次进行紧固，切不可一次拧紧。
□ After the installation door assembly is completed, adjustment must to be done to ensure that the door
is in the correct position, so that the doors open and close flexibly, while the head of the hinge
mounting bolts need to be up painted (body color).
车门总成安装完成后，一定要进行装配调整，确保车门处于正确的安装位置，使车门开启和关
闭灵活、轻便，同时对铰链装配螺栓头部进行补漆（车身颜色）。
□ Tightening torque: door stopper bolts, door hinge bolts, refer to "Overview and maintenance
volumes."
拧紧力矩：车门限位器固定螺栓、车门铰链固定螺栓，参考《概述与保养分册》。
□ 车门的调整方法 Door adjustment method：
（1）Door up and down adjustment method 车门的上下调整方法
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First check the location of the door in the door frame and the gap between the door and the front
fenders and rocker panels. If the door is too low or too high, put a piece of wood into the frame,
strengthen the inner door panels, avoid the damage to door outer panels, loosen the door hinge bolts,
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with the jack or crowbar slowly raise or lower the door, insure the door location is appropriate with the
body frame, then on each hinge fix screw to keep the forward and outside position of the door. Finally,
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put down the jack, check whether the doors and door frames are closely matched.
先检查车门在门框内的位置以及车门与前翼子板和车门槛板间的间隙。如果车门太低或太髙，
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把一个木块放到车架下，加强车门内板，防止车门外板的损坏，拧松车门铰链的固定螺栓，用千斤
顶或撬棍慢慢升高或降低车门，使之与车身门框装配妥当，然后在每个铰链上固定一个螺钉，使车
门前移的内外位置不发生改变。最后，放下千斤顶，检查车门是否与门框紧密配合对中。
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（2）Door forward and backward adjustment method 车门的前后调整方法
Door forward and backward adjustment can only be used for 1 hinge each time, so the door
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adjustment can be easily controlled. The forward adjustment can be started with the uppermost hinge
adjustment then the lowermost hinge. You can also firstly adjust the lowermost hinge then the uppermost
one to get the suitable gap.
进行车门前后调整时，一次只能对一个铰链调整，这样，车门的调整比较容易控制。车门的前
移调整首先调整最上部的铰链，然后调整最下部的铰链。也可以先调整下部的铰链，然后再调最上
部的铰链，直到得到合适的间隙为止。
（3）Door inside and outside adjustment method 车门的内外调整方法
The door two hinges, the central post, the car door body and the door lock seat decide the installation
location, thus the inside and outside door adjustment always rely on moving these components. However,
the adjustment should be carried out carefully. For the upper part of the door hinge relocation, the impact
will be on the door position, and the door will be moved into the opposite corner as well. If you move in
the bottom of the door hinges of the door, the same causes relative upper corner out.
由于车门的两个铰链、中央门柱、车门锁体和锁座决定车门的安装位置，因而车门内外调整总
是依靠移动这几个构件来实现。但调整时应小心进行，因为只在上部铰链处将车门外移，虽然影响
车门位置，但也会移进相对的车门底角，如果在车门的底部铰链处内移车门，同样会使相对的上角
移出。如果在两个铰链处等距离地移进或移出车门，则仅会影响到车门的前部，车门后部的移动就
又会减少。
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3、Disassembly and assembly of exterior 外饰拆装
26
3.1 Disassembly and assembly of front bumper 前保险杠的拆装
□ Disassemble front bumper, the dismantling order is the

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connecting bolts front bumper and front bumper
mounting bracket, fog lamps connectors
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拆解前保险杠，拆解顺序为前保险杠与前保险杠固
定支架的连接螺栓、雾灯接插件
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□ Remove the bolts fixing the front bumper and front

bumper bracket
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拆卸前保险杠与前保险杠固定支架的连接螺栓
□ Remove the fog lamp connector, remove the front

bumper
拆下雾灯接插件，取下前保险杠
□ After installation check if there is gap and flushness between bumpers and body surface.
安装后检查，保险杠和车身配合处是否存在面差、间隙。
3.2 Disassembly and assembly of back fence 后防护栏的拆装
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□ Dismantle back fence and the fence fixing screw
mounting bracket, remove the fence
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拆卸后防护栏与后防护栏固定支架的固定螺钉，取
下后防护栏
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3.3 Disassembly and assembly of JAC logo JAC 字标的拆装

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□ JAC logo is a glue mask directly pasted to front panel,

so you can directly pull out when removing
由于 JAC 字标是由胶直接粘在前面罩外板上的，所
以拆卸时直接拽掉即可
Assembly 装配：
□ Clean the JAC logo metal mounting surface with a clean rag.
将 JAC 字标钣金安装面用干净的抹布擦拭干净
□ Uncover J, A, C words marked on the back of double-sided adhesive release paper, then J, A, C
positioning cylinder alignment words marked behind the sheet metal over the holes and insert and
press them to make double-sided adhesive and sheet metal surfaces fully bonded.
揭开 J、A、C 三个字标背面双面胶隔离纸，然后将 J、A、C 三个字标背后定位圆柱对准钣金过

孔、插入并压紧，使双面胶与钣金面充分粘结
Note for assembly 装配注意事项：
□ The installation of JAC logo can be done after the outside panel of the front surface is pasted.
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JAC 字标的安装可以在前面罩外板安装后再粘上去。
□ Ensure the marks that will be repeated used have enough stickiness.
重复使用的字标要确保背胶要有充分的粘性。
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3.4 Disassembly and assembly of grille device 进气格栅装置的拆装
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□ The order of dismantling grille device is grille fixing

bolts, fixed grille snaps
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拆解进气格栅装置，拆解顺序为进气格栅固定螺栓、
进气格栅固定卡扣
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□ Remove the grille fixing bolts
拆卸进气格栅固定螺栓
□ Use a flat-blade screw driver separate grille fixing
snaps in turn, remove the grille
用平口螺丝刀依次将进气格栅固定卡扣分离，取下
进气格栅
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3.5 Disassembly and assembly of front outer panel device 前围外板装置的拆装
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□ The order of dismantling front outer panel device is
grille, front outer plate fixing bolts, front outer panel
connecting snaps
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拆解前围外板装置，拆解顺序为进气格栅、前围外
板固定螺栓、前围外板连接卡扣
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□ Remove the grille【Reference grill dismantling】

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拆下进气格栅【参考进气格栅的拆解】
□ Remove front outer panel fixing bolts
拆卸前围外板固定螺栓
□ With a flat-blade screwdriver to pry connection snaps

of front outer panel, take off front outer panel
用平口螺丝刀撬开前围外板连接卡扣，取下前围外
板
Assembly
江淮汽车 process:部门：[客户服务部]
opposite to dismantle process.
3.6 Disassembly and assembly of exterior mirrors 外后视镜的拆装
□ Disassemble exterior mirrors, the dismantling order is

exterior mirrors cover, small front side panels, front
side panels, exterior mirror fixing bolts
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拆解外后视镜，拆解顺序为外后视镜盖罩、前围小
侧板、前围侧板、外后视镜固定螺栓
26□ Push exterior mirror cover , and remove it

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将外后视镜盖罩往外推，取下外后视镜盖罩
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□ With a flat-blade screwdriver to pry snaps of small

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front side panel , and take off the small front side panel
用平口螺丝刀撬开前围小侧板卡扣，取下前围小侧
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□ With a flat-blade screwdriver to pry snaps of front side

panel , and take off the front side panel
用平口螺丝刀撬开前围侧板卡扣，取下前围侧板
□ Dismantle fixing bolts of exterior mirrors and remove
exterior mirrors
拆卸外后视镜固定螺栓，取下外后视镜
□ Do not run into the body paint during removal and installation.
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拆卸与安装时不要碰上车身漆面。
□ When installing, adjust the gap between the envelope surface and the front wall panels, doors, so as
26
to meet gap and flushness designed standard.
安装时，要调整前围护面与前围面板、车门的间隙，满足间隙面差设定标准。
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3.7 Disassembly and assembly of back panel 后围挡板的拆装
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□ Dismantle back panel fixing bolts, take off back panel.

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拆卸后围挡板固定螺栓，取下后围挡板
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Dismantle back panel fixing bolts, take off back panel.
3.8 Disassembly and assembly of front fender 前挡泥板的拆装
□ Disassemble front fender, the dismantling order is
fender rubber sheet, the fender bolts
拆解前挡泥板，拆解顺序为挡泥橡胶板、挡泥板上
固定螺栓
□ Remove fender rubber plate fixing bolts, remove the
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fender rubber sheet
拆卸挡泥橡胶板固定螺栓，取下挡泥橡胶板
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12
□ Dismantle the fender mounting bolts, remove the
fender
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拆卸挡泥板上固定螺栓，取下挡泥板
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3.9 Disassembly and assembly of pedal device 脚踏板装置的拆装
□ Dismantle the pedal bolts, remove the pedals
拆卸脚踏板固定螺栓，取下脚踏板
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3.10 Disassembly and assembly of the front windshield 前挡风玻璃的拆装
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□ Disassemble front windshield, the dismantling order is
front windshield wiper arm and blade, front post
interior panels, front windscreen seals
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拆解前挡风玻璃，拆解顺序为前挡风玻璃雨刮器臂
和刮片、前门柱内饰板、前挡风玻璃窗密封条
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□ Dismantle front windshield is front windshield wiper

arm and blade【Refer to front windshield wiper arm and
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blade dismantling】
拆卸前挡风玻璃雨刮器臂和刮片【参考玻璃雨刮臂
和刮片的拆装】
□ Dismantle front post interior panels【Refer to front post

interior panels dismantling】
拆卸前门柱内饰板【参考前门柱内饰板的拆装】
□ Dismantle the front windscreen seal from the upper
flange of body flange and the corners
从车身凸缘的上凸缘和各角，拆卸前挡风玻璃窗密
封条
□ Use a φ0.5mm copper wire to go through the glass
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plastic on the upper corner at the front post, drag the
copper wire down from both inside and outside of the
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windshield to separate the glass and sheet metal, then
push the glass out. Dismantle the front windshield glass
with the help of the assistant.
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用φ0.5mm 的铜丝穿过前门柱上端圆角处的玻璃胶，
在风窗内、外各一人向下拉拽铜丝，将玻璃与钣金
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分开，并渐渐的将玻璃推出。在助手的帮助下，从
车辆上拆下前挡风玻璃
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Inspection after disassembly 拆卸后检查：
□ Check the following parts that may cause windshield broken: the edge of the windshield
frame, windshield stocks or windshield glass.
JA
检查可能导致挡风玻璃破碎的以下部件：挡风玻璃窗框边缘，挡风玻璃窗饰条或挡风玻璃。
□ Check the status of windshield frame and the adhesive flange.
检查挡风玻璃窗框和粘合胶翻边的状态。
□ Remove all the broken glasses from the front cover plate, seats, floor and defroster duct,
clean the surface of windshield edges with a lint-free cloth which is moist by50/50(volume ratio)
isopropyl alcohol and water mixture.
从前罩板、座椅、地板和除霜器导管上清除所有碎玻璃，用体积比为 50/50 的异丙基乙醇和水

的混合液湿润不起毛的抹布，清理挡风玻璃内表面边缘。
Assembly 装配：
□ Clean the frame install sheet metal surface with a cloth

dampened with glass cleaner , dry it for 1-2 minutes.
将车框安装钣金面使用干净的蘸有玻璃清洗剂的布
擦拭干净，晾置1-2分钟
□ Ensure glass primer evenly coated on surface of car
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window frame with a brush
将玻璃底涂用毛刷均匀地涂在车窗框表面
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□ Placed the front windshield on glass gummed station
device, clean the black glass frame with glass cleaner
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将前风窗放置在玻璃涂胶的工位器具上，使用玻璃
清洗剂清洁玻璃黑框部分
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□ Installed the front windshield strip assembly along the

edge, and ensure the strip is docile strip
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沿风窗玻璃边缘安装前风窗胶条总成，保证胶条良
好服帖
Note: Under low temperatures, put the front windscreen

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shall strip assembly into the oven to be reheated before

assembling, so as to avoid hard tape and bad snap
注意：气温低时，须将前风窗胶条总成放入烘箱内烘
热后再进行装配，防止胶条过硬，卡接不良。
□ Coat primer evenly in glass sealant and dry it
在玻璃打胶部位均匀涂抹底涂并晾干
□ With glue gun coat the glass glue along the front
windshield glass adhesive tape, sealant specifications:
soled edge width 8m, height 12m, triangular outer edge
of the bottom of the glass glue should cover glass strip
inside edge
使用打胶枪沿前风窗胶条将玻璃涂胶在玻璃涂胶部
位；打胶规格：胶底边宽8m，高12，三角形玻璃胶
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底部外边缘覆盖住玻璃胶条内边
□ After gluing, press windshield into the body sheet
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metal windscreen frame，align the limit column with
sheet metal stopper hole，Bundle them with a bandage
to avoid shedding, and place it more than 12 hours,
12
during this period please avoid turning the cab
涂胶后将前风窗装置压在车身钣金风窗边框，限位
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柱对准钣金限位孔，用绷带捆绑，防脱落，并静止
放置12小时以上，在此期间避免翻动驾驶室
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3.11 Disassembly and assembly of the rear windshield 后风窗玻璃的拆装

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□ Inside cab, stripping windshield rubber strip from body

sheet metal flange, and forcibly pushed rear window
glass outward. With the rubber strip and sheet metal
flange stripping length increasing, the rear windshield
glass and rubber strip can be taken down.
在驾驶室内侧，将风窗胶条剥离车身钣金凸缘，并
用力向外推后风窗玻璃。随着胶条与钣金凸缘剥离
的长度增大，即可以将后风窗玻璃和胶条整体取下
Assemble 装配：
□ Rip rope which diameter is 5-6mm into the margin of
rubber strip, and make it superposition in lower center
of window
将 Ф5-6mm 绳穿进缘中，绳绕一圈后，使其在玻璃
下部中心处重合
□ Lay the window trademark position left bottom, and
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adjust the window center and seal strip.
将玻璃商标位置放在左下，调节玻璃中心与密封条
26
下接头处对正
12
□ Adjust the window to the center of body, press window
from outside, and pull the rope from the inside window
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center, making the rear window rubber strip onto the

body flange. Using a rubber hammer gently knocking
on the strip, making the body flange and sealing strip
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fully contact.
调节玻璃使在车身风窗口中心，从外压住玻璃，然
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后从内向玻璃中心拉绳，将后风窗胶条装到车身凸
缘上。用橡胶锤子轻轻敲胶条，使车身凸缘和密封
条间充分接触
3.12 Disassembly and assembly of side windows 侧窗的拆装
□ Disassemble side windows, the dismantling order is
side window hinge, side mounting bracket bolts
拆解侧窗，拆解顺序为侧窗铰链、侧窗安装支架固
定螺栓
□ Pull out side window hinge
42
扳开侧窗铰链
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□ Remove the side window mounting bracket bolts,
remove the side windows along the side windows strip
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from the sheet metal
拆卸侧窗安装支架固定螺栓，沿着侧窗胶条从钣金
C-
上取下侧窗
Assembly: Follow the opposite steps of dismantling:

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装配：按照拆解相反步骤开展，但请注意以下事项。
□ When installing, firstly along the side window seal

strip, make the side window fixed on the seal strip
安装时，首先沿着侧窗密封胶条，将侧窗固定在密
封胶条上
3.13 Disassembly and assembly of shroud device 导流罩装置的拆装
□ Remove shroud fixing bolts cover plate, remove shroud

fixing bolts and take off the shroud with the help of the
assistant
拆下导流罩固定螺栓盖板，拆卸导流罩固定螺栓，
在助手的帮助下，取下导流罩
42
Assembly: Follow the opposite steps of dismantling.
26
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4、Disassembly and assembly of cab 拆装驾驶室
4.1 Dismantle the tilting structure in the cab 拆解驾驶室翻转支撑机构

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□ The order of the dismantling is strut assembly, torque

arm rod assembly, left and right support arm mounting
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bolts, front supporting fixing bolts, torsion bar, shaft

tube assembly, left and right support seat assembly
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拆解驾驶室翻转机构，拆解顺序为撑杆总成、扭臂
杆总成、左右支撑臂安装螺栓、前支撑固定螺栓、
扭杆、轴管总成、左右支承座总成
1 □ Separate strut assembly from the cab assembly and

frame separation
将撑杆总成从驾驶室总成、车架分离
Note: It can also be dismantling from connecting pin

shaft of the upper bearing and upper support rod.
注意：亦可以从上支座与上撑杆连接销轴处拆解。
□ Dismantle arm twisting rod assembly
拆卸扭臂杆总成
（1）Remove the snap ring, turn the cab up at a angle

of 50 ° (torsion bar pre-twist angle), uninstall the
torsion bar torque 取出卡环，将驾驶室翻起50°（扭
杆预扭角度），卸载扭杆扭力
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（2）Slightly loose the torsion arm mounting bolts 将
扭杆臂安装螺栓微松
（3）Remove the torsion arm adjusting screw 2 and
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remove the lever arm mounting bolts 1 取下扭杆臂调
节螺栓2，取下杆臂安装螺栓1
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（4）Remove the torque arm assembly, and put down
the cab 取下扭臂杆总成，并将驾驶室落下
20
Note: Before the cab falls down , remove the left and
right strut mounting bolts in the last portion.
注意：在驾驶室落前，先将最后部左右支撑杆安装螺
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栓取下。
□ Removing the left support arm mounting bolts

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拆卸左右支撑臂安装螺栓
（1）After the cab falls down，remove 4 supporting

arm bolts in the front portion 驾驶室降落后，将支撑臂
前部4个螺栓拆下
（2）Lift the cab and place it onto a prepared shelf 将

驾驶室吊起，放在预先准备好的货架上
□ Dismantle front supporting fixing bolts
拆卸前支撑固定螺栓
□ Dismantle torsion bar ①, shaft tube assembly ②,left
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and right supporting seats assembly③
②
③ 拆卸扭杆①、轴管总成②、左右支承座总成③
26
① ③
12
Assembly: Follow the opposite steps of dismantling, but please note the following issues：
20
□ Install torsion shaft, tube assembly, left and right

supporting seats assembly
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安装扭杆、轴管总成、左右支撑座总成
（1）Assemble the shaft tube assembly and left and

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right supporting seats together 将轴管总成、左右支撑

座装配在一起
（2）Let the torsion bar penetrates the shaft tube mark

the torsion and align it with the mark I on the shaft tube
assembly, after assembly ensure the end face of the
torsion bar flushes with the end face of the shaft tube
扭杆穿入轴管中，将扭杆上标记Ⅰ与轴管总成上Ⅰ
标记对准，装配完成后保证扭杆端面与轴管端面平
齐
□ Install front rod bolts: ensure the front support frame
mounting bolts penetrate the frame casing, flip left and
right supports before installation
安装前支撑杆固定螺栓：将前支撑固定螺栓穿入车
架套管中，安装前翻转左右支座
□ Install left and right support arm mounting bolts:
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ensure cab guide pin is aligned with the left and right
support arm, put down the cab, and tighten it
26
安装左右支撑臂安装螺栓：驾驶室导销与左右支撑
臂对准，放下驾驶室，并将其紧固
12
□ Install twist arm assembly
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安装扭臂杆总成
（1）Incline the cab inclined, install them with the

mark I on the torsion arm bar assembly aligned with
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the mark I on the twist rod , and pre-tightened the bolt1

将驾驶室倾斜，扭臂杆总成上Ⅰ标记对准扭杆上标
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记Ⅰ装上，并把螺栓1预拧紧
（2）Pull down the cab after the bolt 2 is tightened to

the designated spot, test the tilting force and adjust
bolts 2 to ensure the force can meet the request, then
tighten bolt 螺栓2紧固到指定位置后，放下驾驶室，
检测翻转力大小，通过调整螺栓2，使翻转力满足要
求，拧紧螺栓1
□ Install strut assembly 安装撑杆总成
□ Install the snap ring 安装卡环
If the cab tilting部门：[客户服务部]

□ 江淮汽车 device is not dismantled before dismantling the locking structure, please confirm the
following states first then dismantling the locking structure in accordance with the above sequence 若
拆解锁止机构前驾驶室翻转装置未拆解，需确认以下状态后再按照以上顺序拆解锁止机构：
（1）Rod Torque Uninstall: dismantle the torsion arm assembly, remove torsion torque.杆扭力卸载：将
扭杆臂总成拆解，卸载扭杆扭力。
（2）Mount the support assembly on the frame, mount the rear support assembly onto the frame after the
cab is located on the rear support assembly on the frame, then let the cab locate on the rear support
assembly 后支撑总成装配在车架上，驾驶室坐落在后支撑总成上后支撑总成装配在车架上，驾驶室
42
坐落在后支撑总成上。
（3）The locking mechanism in the unlocked state: Operation tilting locking mechanism assembly and
26
ensure the locking mechanism is unlocked.锁止机构在解锁状态：操作翻转锁紧机构总成，使锁止机
构处于解锁状态。
Assembly: Follow the opposite steps of dismantling, but please note the following issues：
12
20
□ Mount the handle on the cab rear bracket
将拉手装在驾驶室后支架上
C-
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□ with a one bolt on the front side, two bolts on the side
Install bolt to flip the locking control mechanism assembly and
安装螺栓
mount it on the cab rear stand
正面用一个、侧面用两个螺栓将翻转锁紧操纵机构
总成装在驾驶室后支架上
Install nut
安装螺母 □ Mount the locking mechanism on rear cab support as
left / right mode assembly
将锁紧机构左/右总成方式装在驾驶室后支撑上
安装螺栓
Install bolt
□ Install vice shackle rod, short rod, long rod assembly
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安装副锁钩拉杆、短拉杆、长拉杆总成
（1）Install ends of the long rod on the left and right
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locking mechanism pivot pin, on the right side install
wave pads, gaskets, and fix them with a locking pin;
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right side connection order: right locking mechanism -
a long rod assembly - wave pad - flat pad - safety pins
将长拉杆两端安装在左右锁止机构轴销上，右侧先
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后安装波垫、垫片，并用锁销固定；右侧连接顺序
为：右锁紧机构—长拉杆总成—波垫—平垫—安全
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（2）Mount pads on the hand pin and left long rod

assembly; mount short rod on the left side (groove-type
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surface characteristics outwards), install wave pads,

gaskets, and fix them with a locking pin. Short-and
long-rod joints connecting rod sequence: long rod - flat
pad - short rod - wave pad - flat pad - safety pins;
manipulating structure and short rod connection order:
control mechanism - flat pad - short rod - wave pad -
flat pad - safety pin 分别把手销轴和左侧长拉杆总成
处安装垫片；左侧安装短拉杆（凹槽型面特征朝外），
先后安装波垫、垫片，并用锁销固定。短拉杆与长
拉杆接头连接顺序：长拉杆—平垫—短拉杆—波垫
江淮汽车部门：[客户服务部] —平垫—安全销；操纵机构与短拉杆连接顺序：操

纵机构—平垫—短拉杆—波垫—平垫—安全销
□ After installation, smear grease on parts of contacting,

friction and rotation axis.
安装完成后，在接触、摩擦、旋转轴部位涂抹润滑
油脂。
Check and adjust 检查与调整：
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□ Pull up the handle of the cab lock mechanism of cab
from A to B. Regulating long rod adjusting nuts 1,2, let
the left and right axles pin locking mechanism to reach
26
the same position, and tighten the adjusting nuts
将驾驶室锁机构的手柄由 A 向上扳到 B 位置。调节

12
长拉杆调节螺母1、2，使左右锁止机构轴销到达相
同位置，并锁紧调节螺母
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5、Disassembly and assembly of interior 内饰拆装
5.1 Disassembly and assembly of upper apex interior 顶内饰的拆装
Note 注意：
□ Dismantle of upper apex interior is carried out after the dismantling of roof light，car pedal assembly，
sun visor, roof debris boxes.
顶内饰拆解是在顶灯、车内蹬车把手总成、遮阳板、顶杂物盒拆卸完毕后进行。
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□ Disassemble upper apex interior, dismantling order is
the sun visor, roof debris boxes, roof ventilation, roof
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light, left and right pedal grip ,left and right front posts
interior panels, interior handrails, interior panels on left
and right goal post, roof inside decorative plate
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拆解顶内饰，拆解顺序为遮阳板、顶杂物盒、顶通
风、顶灯、左右蹬车把手、左右前门柱内饰板、车
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内扶手、左右门柱上内饰板、顶内饰压板
□ Sun visor dismantle 拆卸遮阳板

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（1）Remove sun visor fixed bolts 拆下遮阳板固定

螺钉
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（2）Pull the half-sleeve visor out from the mounting

hooks, remove the visor 将遮阳板半轴套从安装挂钩
拔出，取下遮阳板
□ Dismantle roof debris boxes 拆卸顶杂物盒
（1）Remove sun visor 拆卸遮阳板
（2）Remove roof debris boxes fixed bolts 拆卸顶杂

物盒固定螺栓
（3）Remove the roof debris box fixed expansion
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snaps, remove the roof debris box 拆卸顶杂物盒固定
膨胀卡扣，取下顶杂物盒
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（4）Remove roof debris box left and right fixed
bolts, remove the roof debris box left and right fixed
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bracket 拆卸顶杂物盒左、右固定支架固定螺栓，取
下顶杂物盒左、右固定支架
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□ Dismantle roof ventilation 拆卸顶通风

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（1）Remove roof vent cover mounting bolts, pry the

roof vent cover 拆卸顶通风盖板固定螺栓，撬开顶通
风盖板
（2）Remove the roof vent mounting bolts, remove
the roof ventilation 拆卸顶通风固定螺栓，取下顶通
风
□ Dismantle roof light 拆卸顶灯
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（1）Pry the roof light with a flat-blade screwdriver 用
平口螺丝刀撬开顶灯
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（2）Disconnect the lights connectors, remove the
roof light 断开顶灯接插件，取下顶灯
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□ Remove left and right handle 拆卸左、右蹬车把手
（1）Open pedal handle decorative cover 掀开蹬车把

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手装饰盖
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（2）Dismantle handle fixed bolts, remove the handle

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拆卸蹬车把手固定螺栓，取下蹬车把手
□ Dismantle left and right front posts interior panels
拆卸左、右前门柱内饰板
（1）Dismantle left and right handles 拆卸左、右蹬车

把手
（2）Dismantle door sealing strips 拆卸车门密封条
（3）Pry the front post interior panels with a flat-blade
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screwdriver, remove the front post interior panels 用
平口螺丝刀撬开前门柱内饰板，取下前门柱内饰板
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□ Dismantle inner armrest 拆卸车内扶手
（1）Open inner armrest decorative cover 掀开车内扶

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手装饰盖
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（2）Dismantle inner armrest fixed bolts and take off

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the armrest 拆卸车内扶手固定螺栓，取下车内扶手

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□ Remove interior panels on left and right posts
拆卸左、右门柱上内饰板
（1）Dismantle interior panel on front post;【Refer to

front post interior panel dismantle】拆卸前门柱内饰
板；【参考前门柱内饰板拆卸】
（2）With a flat-blade screwdriver to pry the doorpost

interior panels, remove interior panels from the post 用
平口螺丝刀撬开门柱上内饰板，取下门柱上内饰板
□ Remove the roof plate interior fixed snaps, take off the
roof plate interior
拆卸顶内饰压板固定卡扣，取下顶内饰压板
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□ Dismantle the roof interior assembly installation
snap , remove the roof trim assembly
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12 拆卸顶内饰总成安装卡扣，取下顶内饰总成
Assembly: Follow the opposite steps of dismantling , but please note the following issues：
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□ Roof handrail assembly must be installed after the roof interior is installed
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车顶扶手总成安装必须保证顶内饰安装完毕
□ For the front roof interior installation, the 3 holes in the middle must be installed firstly, first
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install the middle holes, then the left side holes, and finally the right holes, and then install the side
snaps.
前顶内饰安装必须先安装中间三个孔，先装中间孔，然后安装左侧孔，最后固定右侧孔，安装
过后再进行侧边卡扣安装。
5.2 Disassembly and assembly of the rear interior panels 后围内饰板的拆装
□ Disassemble rear interior panels, the dismantling order
is low interior panel of left and right posts, rear debris
box
拆解后围内饰板，拆解顺序为左右后门柱下内饰板、
后杂物盒
□ The order of dismantling rear interior panels is low
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interior panel of left and right posts, rear debris box
拆卸左、右后门柱下内饰板：用平口螺丝刀撬开后
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门柱下内饰板固定卡扣，取下后门柱下内饰板
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□ Dismantle rear debris box 拆卸后杂物盒
（1）Dismantle debris box mounting bracket bolts 拆

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卸后杂物盒安装支架固定螺栓
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（2）Dismantle debris box fixed buckle, remove the

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box from the interior panel mounting bracket 拆卸后杂

物盒固定卡扣，将后杂物盒从后围内饰板固定支架
上取下
□ Dismantle the rear interior panel: With a flat-blade
screwdriver to pry the retaining tabs on interior panels,
remove interior panels
拆卸后围内饰板：用平口螺丝刀撬开后围内饰板固
定卡扣，取下后围内饰板
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5.3 Disassembly and assembly of seat and safety belt 座椅及安全带的拆装
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□ Dismantle driver’s seat 拆卸驾驶员座椅
（1）Adjust the seat to the proper position to

disassemble mounting bracket bolts 调节座椅至合适
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位置，以便于拆卸座椅安装支架固定螺栓
（2）Remove the seat assembly and the seat mounting

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bracket fixing bolts 拆下座椅总成与座椅安装支架固

定螺栓
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（3）Move the seat out 移出座椅
□ Dismantle passenger seat 拆解副驾驶座椅
（1）Dismantle passenger seat mounting bracket

fixing bolts 拆卸副驾驶座椅安装支架固定螺栓
（2）Remove the passenger seat cushion retaining

tabs, remove passenger seat 拆卸副驾驶座椅坐垫固定
卡扣，移出副驾驶座椅
□ Dismantle the driver seat belt 拆解驾驶员安全带
（1）Remove the lower trim panel on left rear post

assembly【Refer to the left rear post lower trim panel
dismantle】拆卸左后门柱下内饰板总成【参考左后
门柱下内饰板的拆卸】
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（2）With a flat-blade screwdriver to pry the height
adjuster hood and remove the driver seat belt mounting
bolts, remove the driver's seat belt assembly 用平口螺
26
丝刀撬开高度调节器护罩，拆卸驾驶员安全带固定
螺栓，取下驾驶员安全带总成
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（3）Remove the driver safety belt buckle lock
assembly mounting bolts, remove the driver safety belt
buckle lock assembly 拆卸驾驶员安全带扣锁总成固
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定螺栓，取下驾驶员安全带扣锁总成
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□ Dismantle occupant seat belt 拆解乘员安全带

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（1）Dismantle the lower trim panel on left rear post

assembly 【Refer to the left rear post lower trim panel
dismantle】拆卸左后门柱下内饰板总成【参考左后
门柱下内饰板的拆卸】
（2）Remove the occupant seat belt fixing bolts,

remove the occupant belt assembly 拆卸乘员安全带固
定螺栓，取下乘员安全带总成
（3）Dismantle the occupant safety buckle lock

assembly fixing bolts, remove the occupant safety
buckle lock assembly 拆卸乘员安全带扣锁总成固定
螺栓，取下乘员安全带扣锁总成
（4）Dismantle the middle pedestal buckle lock

assembly mounting bolts, remove the middle pedestal
buckle lock assembly 拆卸中间加座安全带扣锁总成
固定螺栓，取下中间加座安全带扣锁总成
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5.4 Disassembly and assembly of carpet 地毯的拆装

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□ Disassemble carpet, the dismantling order is seat
assembly, seat belts, handbrake cover and optional shift
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guard, the floor surface protection devices, carpet

buckle cover
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拆解地毯，拆解顺序为座椅总成、安全带、手刹车
护罩及选换挡护罩、地板护面装置、地毯扣盖
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□ Dismantle the seat assembly seat disassembly【Refer to

seat disassembly steps】
拆卸座椅总成【参照座椅拆装步骤】
□ Dismantle the seat belts 【 Refer to seat belts

disassembly steps】
拆卸安全带【参照安全带拆装步骤】
□ Dismantle the handbrake cover and gear shift cover

election
拆卸手刹车护罩及选换挡护罩
（1）Remove the handbrake cover retaining tabs 拆卸

手刹车护罩固定卡扣
（2）Dismantle the bolts and the snaps of shifting

cover, remove the shift cover 拆卸选换挡护罩固定螺
栓和卡扣，取下选换挡护罩
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26
12
20
□ Dismantle the floor protective cover bolts, remove the

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floor protective cover device
拆卸地板护面固定螺栓，取下地板护面装置
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□ Release the carpet snap buckle, open the carpet and

remove it
将地毯扣盖卡接松开，掀开地毯，并取下地毯
□ Ensure the carpet installation is fit with the floor surface.
地毯的安装必须保证地毯与地板型面贴合。
5.5 Disassembly and assembly of the instrument panel 仪表台的拆装
□ Disassemble instrument, the dismantling order is
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steering wheel, brake fluid spout cover, meter cover,
the under guard in crew area, right guard in manipulate
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area, washing pots, dashboard debris boxes, cassette
players, air-conditioning control panel, instrument
cluster, left fender in steering area , right cover
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assembly, pedal handles, front post trim panels,
instrument panel bolts
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拆解仪表台，拆解顺序为方向盘、制动液壶口盖、
仪表罩、乘员区下护板、操纵区右下护板、洗涤壶、
仪表台杂物盒、收放机、空调控制面板、组合仪表、
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操纵区左下护板、右侧盖板总成、蹬车把手、前门
柱内饰板、仪表板固定螺栓
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□ Dismantle steering wheel 拆卸方向盘
（1）Turn the ignition switch to "OFF" position and

remove the battery negative 将点火开关置于“OFF”
位置，拆下蓄电池负极
（2）With a flat-blade screwdriver to pry the speaker,

disconnect the speaker connector 用平口螺丝刀撬开
喇叭盖，断开喇叭接插件
（3）Draw alignment marks on the steering wheel
hub, let the mark align with the score on the steering
shaft spine , dismantle steering wheel retaining bolts,
remove the steering wheel 在方向盘轮毂上划定位标
记，将标记与转向轴花键上的刻痕对准，拆卸方向
盘固定螺母，取下方向盘
Note：Do not completely loosen the nut immediately ,
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and completely loosen the nut after the wheel looses, so
as to avoid personal injury during steering dismantling
by excessive force
26 注意：先不要完全松开螺母，待方向盘松动后再完
全松开螺母，以免拆方向盘时用力过猛，造成人员
12
伤害
□ Unplug the brake fluid spout cover 拔开制动液壶口盖

20
C-
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□ Dismantle the meter cover assembly 拆卸仪表罩总成
（1）With flat-blade screwdriver to gently pry the

instrument cover 用平口螺丝刀轻轻撬开仪表罩
（2）Disconnect the hazard warning lights connectors,
remove the instrument cover assembly 断开危险警报
灯接插件，取下仪表罩总成
□ Dismantle crew area under guard plate assembly:
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Remove the guard plate assembly fixed expansion
buckle, remove the occupant area under guard plate
26
assembly
拆卸乘员区下护板总成：拆卸乘员区下护板总成固
12
定膨胀卡扣，取下乘员区下护板总成
□ Dismantle the manipulation area right guard plate

20
拆卸操纵区右下护板
（1）Dismantle the cab fuse box cover assembly,

disassemble manipulation area right guard plate
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assembly mounting bolts, remove the manipulation

area right guard plate 拆下驾驶室保险丝盒盖总成，拆
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卸操纵区右下护板总成固定螺栓，取下操纵区右下
护板
（2）Disconnect the cigarette lighter connector,

remove the steering area right guard plate assembly 断
开点烟器接插件，取下操纵区右下护板总成
□ Dismantle washing pot assembly: remove washing pots
bolts, disconnect the washing motor connector, remove
the pot washing assembly
拆卸洗涤壶总成：拆卸洗涤壶固定螺栓，断开洗涤
电机接插件，取下洗涤壶总成
□ Dismantle instrument panel debris box assembly:
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Remove the instrument panel debris box fixing bolts,
remove the instrument panel debris box assembly
26
拆卸仪表台杂物盒总成：拆卸仪表台杂物盒固定螺
栓，取下仪表台杂物盒总成
12
□ Dismantle cassette players 拆卸收放机总成
（1）Dismantle cassette players fixing bolts 拆卸收放

20
机固定螺栓
C-
（2）Disconnect cassette players connectors and the

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antenna, remove cassette players assembly 断开收放机

接插件和天线，取下收放机总成
□ Dismantle the air conditioning control panel
拆卸空调控制面板
（1）Dismantle the air conditioning control panel

inner loop adjustment drawing (black), temperature
regulation drawing (green) and mode regulation
drawing (blue)拆卸空调控制面板内循环调节拉丝
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（黑色）、温度调节拉丝（绿色）和模式调节拉丝
（蓝色）
（2）Dismantle the air conditioning control panel
26
fixing bolt，disconnect the air conditioning control
panel connector, remove the air conditioning control
panel 拆卸空调控制面板固定螺栓，断开空调控制面
12
板接插件，取下空调控制面板
□ Disassemble the instrument cluster 拆卸组合仪表

20
（1）Disassemble the instrument cluster fixing bolts

拆卸组合仪表固定螺栓
C-
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（2）Disconnect the instrument cluster connector,

move the instrument cluster 断开组合仪表接插件，取
下组合仪表
□ Dismantle the manipulation area left guard plate
assembly: remove the manipulation area left guard
plate assembly fixed expansion snaps, remove
manipulate area left guard plate assembly
拆卸操纵区左下护板总成：拆卸操纵区左下护板总
成固定膨胀卡扣，取下操纵区左下护板总成
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□ Dismantle the right cover assembly: disassemble the
right side cover fixed expansion snaps, remove the
right side cover assembly
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拆卸右侧盖板总成：拆卸右侧盖板固定膨胀卡扣，
取下右侧盖板总成
12
□ Dismantle the pedal handrail disassembly【Refer to
pedal handrail dismantle】
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拆卸蹬车把手【参考蹬车把手的拆装】
□ Dismantle front post interior panel【Refer to front post

C-
interior panel dismantle】
拆卸前门柱内饰板【参考前门柱内饰板的拆装】
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□ Dismantle the instrument dashboard bolts and remove

the dashboard
拆卸仪表板固定螺栓，取下仪表板
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Air conditioning control panel installation steps:
26
空调控制面板安装步骤：
□ Send the control line into the instrument panel, and
Control drawing "A"
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assemble the air conditioning panel assembly firmly.
Control drawing "B"
Switch the mode knob to the far left (the FACE
direction), and the temperature control knob to the far
20
Heater
left (the COLD direction), the inner and outer loop
levers to the left (to INSIDE direction).
C-
Control drawing "C"

将控制线穿进仪表面板，然后将空调面板装配牢固。
将方式切换旋钮转到最左端（向 FACE 方向），将温
度控制旋钮转到最左端（向 COLD 方向），将内、外
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循环杆扳向最左端（向 INSIDE 方向）。

□ After the control drawing "A" linked to the blower
Blower
claw, pull the butterfly valve to the full push position,
and then fix the cable in the clip; after the drawing
control "B" linked to the heater claw, pull the butterfly
valve to the lowest position, and then fix the cable in
the clip; after the control drawing "C" linked to the
blower claw, pull the butterfly valve to the full push
position, and then fix the cable in the clip
将控制拉丝“A”挂到鼓风机爪钩上后，将蝶形阀扳
到全推位置，然后将电缆固定在卡子上；将控制拉
丝“B”挂到暖风机爪钩上后，将蝶形阀扳到最低位
置，然后将电缆固定在卡子上；将控制拉丝“C”挂
到鼓风机爪钩上后，将蝶形阀扳到全推位置，然后
将电缆固定在卡子上
5.6 Disassembly and assembly of insulation pad 拆解隔热垫
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□ Tilt the cab 翻转驾驶室
□ With a snap screwdriver to take off the insulation pad
26
snaps, remove the insulation pad 用卡扣起将隔热垫卡
扣起下，取下隔热垫
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6、Cab coatings cracking revamp 驾驶室面漆开裂修补
Tools and materials使用工具及材料：

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Pneumatic burnishing machine, disc abrasive paper, compressed air, tank gun, burnishing liner, waterproo
f abrasive paper, white cotton wiper, water, sticky gauze, masking paper, interface solvation of tank gun, i
nfrared ray hot lamp, pneumatic polisher, polishing solution, polishing pad
气动打磨机、圆盘砂纸、压缩空气、罐枪、打磨衬板、水砂纸、白色棉质擦布、自来水、粘性纱布、
遮蔽纸、罐枪接口溶化剂、红外线烤灯、气动抛光机、抛光液、抛光棉
Notice: The mixed mending paint must be exhausted within 8 hours
注意：调配好的修补漆必须8小时内使用完。
驾驶室面漆开裂修补步骤：
（1）Burnishing: use disc abrasive paper to clear the cracking and corrosion place till the metal plate exp
osed打磨：使用圆盘砂纸对油漆开裂锈蚀的部位进行打磨，打磨至钣金
（2）Re-spray the undercoat: spray electrophoretic paint to mend the burnished undercoat in step one, fil
m thickness≥20µm, costs 25-30 minutes for air dry补喷漆底：在打磨漏底部位喷涂电泳漆修补底漆，
膜厚≥20µm，自干25~30分钟
Notice:Electrophoretic paint for mending: base, hardener and thinner agent of electrophoretic paint. The r
atio of base, thinner and hardener is 4:2:1. And the application amount of thinners can be slightly adjusted
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according to the actual conditions.
注意：电泳漆修补漆：电泳漆修补底漆主剂、固化剂、稀释剂。电泳漆修补底漆主剂：稀释剂：固
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化剂配比=4:2:1，稀释剂使用量可以根据现场实际情况进行微量调整。
（3）Water milling: use waterproof abrasive paper to grind the re-sprayed place, and then wipe the stain
up with white cotton wiper, finally blow-dry the cab surface with compressed air水磨：用水砂纸对喷涂
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部位进行水磨，之后使用白色棉质棉布将打磨部位的水渍等擦拭干净，最后使用压缩空气对驾驶室
表面吹干
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（4）Cleaning: use sticky gauze to clean the particular places need to be mended and places around them
擦净：用粘性纱布清洁待修补区及周围
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（5）Masking: use masking paper to cover those accessories with different colors in the mending area 遮
蔽：将打磨修补区域平面其他颜色配件使用遮蔽纸遮蔽
（6）Finish paint mending: evenly spray two metallic undercoat mending paint at repairing places, wait
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5-10minutes for air dry, then evenly spray two overcoat vanish mending paint at repairing places, finally
evenly spray the interface solvation twice at the overlapping places of old and new film to eliminate the m
ending stain面漆修补：在待修补部位均匀地喷两道金属底色漆修补漆，风干5~10m后再在待修补部
位均匀地喷两道罩光清漆修补漆，在新旧漆膜接口部位均匀地喷两遍接口溶化剂，以消除修补痕迹。
Notice:Revamp metal surface paint: use surface paint or surface paint redemption paint. Use diluent
according to needed.
注意：修补金属面漆：使用面漆或面漆修补漆。稀释剂根据现场使用情况添加。
（7）Drying: use infrared heat lamp 60~80 degrees to bake after spraying for 25~30 minutes烘干：喷涂
完毕后使用红外线烤灯60~80℃，烘烤25~30分钟
IV. Fault diagnosis and treatment 故障诊断与处理
Cab body structure fault is mainly components damage, relatively easy to observe. If components are
damaged, replace them. In addition, following failures may appear:
驾驶室车身结构故障主要为部件损坏，大多是比较容易观察到的，如出现部件损坏故障，请更
换部件。除此之外，还可能会出现以下故障：
□ Abnormal sound of the cab 驾驶室异响
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Abnormal sound of the cab should be decided from the following points：
驾驶室异响应从以下几点判断：
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（1）Check if the flip lock mechanism is intact 检查翻转锁止机构是否完好；
（2）Check all connections parts of cab for loose or damage 检查驾驶室所有连接部位是否有松

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动或损坏；
（3）Check if the front wheel speed mud skin rubs with the front wheel 前轮档泥皮是否与前轮摩
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擦；
□ Seat noise 座椅噪音
Way to judge seat noise: pay special attention to the goods on the seat as well as the seat position
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when isolating the noise. Reproduce these conditions when you check and isolate the noise source.
Reasons for seat noise include：
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判断座椅噪音方法：隔离座椅噪音时要特别注意产生噪音时座椅的位置以及座椅上的物品，在
确认和隔离噪音源时需要重现这些条件。座椅噪音的原因包括：
（1）Headrest rods and holder 头枕推杆和支架
（2）Seat cushion and seat frame 座椅垫和座椅架
（3）Rear seatback lock and bracket 后排座椅背锁和支架
It is possible to isolate these noises by move and press suspicious components. Most malfunctions
can be cleared by repositioning components in the contact area or by use of polyurethane adhesive tape.
重现噪音可以移动或按住可疑的元件来隔离这些噪音，可以通过重新放置元件或在接触区域使
用聚氨酯胶带排除大多数故障。
Chapter II Electrical Appliances
第二章电器
I. Brief Introduction 简述
As an important part of a vehicle, the automotive electrical system mainly consists of the starting &
charging system, lighting & signaling system, instrument system, wiper & washer system, sound
entertainment system, body accessories and electrical system (lighter, horn, etc) and so on. The
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performance of the automotive electrical system has a direct impact on many aspects of a vehicle
including power, economy, reliability, security, comfort, and emission as well.
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汽车电器系统主要包括启动充电系统、照明信号系统、仪表系统、雨刮与洗涤系统、音响娱乐
系统、车身附件及电器系统（点烟器、喇叭等）等，是汽车的重要组成部分, 其性能好坏直接影响
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到汽车的动力、经济性、可靠性、安全性、舒适性以及排放等性能。
Light truck combination meter indicator light symbol and meaning

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轻卡组合仪表指示灯标志及含义
NO.序号 Indicator light symbol 指示灯标志 Meaning 含义

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1 Left turning light 左转向灯
2 Warning light 安全警示灯

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3 Right turning light 右转向灯
4 High beam light 前照灯
5 Rear fog light 后雾灯
6 Safety belt unfasten warning light 安全带未系警示灯
7 Air bag fault warning light 安全气囊故障警示灯
8 Exhaust brake light 排气制动灯
9 Door unclosed warning light 门未关警示灯
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10 Cab lock warning light 驾驶室锁止警示灯
11 Low fuel warning light 低燃油警示灯
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26 ABS fault warning light ABS 故障警示灯

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13 STOP warning light STOP 警示灯
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14 Charging indicator light 充电指示灯
15 Oil pressure warning light 机油压力警报灯

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16 Parking brake light 驻车制动警示灯

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17 Brake fault warning light 制动故障警示灯
18 Engine overheat warning light 发动机过热警示灯
19 Low coolant level warning light 冷却液低液位警示灯
20 Fuel and water separation warning light 油水分离器警示灯
21 Engine emission fault light 发动机排放故障灯
22 Engine fault indicator light 发动机故障指示灯
23 Air filter clog warning light 空气滤清器堵塞警示灯
24 Pre-heating indicator light 预热指示灯
Note: The above pictures are of typical parts. Some models have slight difference. Do not mark out here.
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备注：上述为典型部件图片，部分车型存在细微区别，此处不再标识。
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II. Layout 位置图
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2
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1 3 4
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8
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6 7
10
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11 12
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序号 S/N 英文描述 DESCRIPTION 备件名称 DESCRIPTION
1 Turning lamp 转向灯

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2 Top outline marker lamp 顶示廓灯
3 Front combination lamp 前组合灯

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4 Fog lamp 雾灯
5 Wiper 雨刮
6 Side marker lamp 侧标志灯
7 Rear combination lamp 后组合灯
8 Rear outline marker lamp 后示廓灯
9 Dashboard meter 组合仪表
10 Audio 收放机
11 Combination switch 组合开关
12 Cigar lighter 点烟器
Note: The above pictures are of typical parts. Some models have slight difference. Do not mark out here.
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III. Removal-installation and Adjustment 拆装与调整
1、Caution 注意事项：
□ To be beautiful and protect cab lacquer, well protected to avoid scratch when disassembling parts.
为了美观和保护驾驶室漆面，拆装零部件过程中，应做好防护，以免出现划伤。
□ Before removing and installing the electrical connector, please remove the battery negative pole and
wait for at least 3 minutes. Otherwise, the vehicle will be damaged.
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拆装电器接插件之前必须拆下蓄电池负极并等待至少 3 分钟，否则会造成车辆损坏。
□ Please do not touch the port of the electronic component which consists of microcomputer (such as
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ECU). Static electricity can damage the internal electronic components.
请勿用手触摸使用微电脑（例如 ECU）的电子元件的端口，静电可能会损坏内部的电子元件。
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□ Do not expose the bulb and back cover which are removed from the lamp body for a long time as the
dust, moisture, smoke, etc., may enter the light which may affect its performance. Please install a new
light bulb and return the back cover immediately after removing the bulb or back cover.
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不要将灯泡和后盖从灯体上拆下时间过长，因为灰尘、湿气、烟雾等进入灯内可能会影响灯的
性能，应在拆下灯泡或后盖后立即安装新灯泡并让后盖归位。
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□ Be sure to use a new light bulb of the same wattage rating to replace the burned bulb. Otherwise, the
fuse or electrical circuit system will be damaged.
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一定要用有相同瓦特数额定值的新灯泡更换烧坏灯泡，否则会导致保险丝或电路系统损坏。
□ When operating on the light bulb, only hold the plastic seat of the light bulb and do not touch the
glass enclosure. Do not shake or rotate the light bulb during removing.
对灯泡进行操作时，只能握住灯泡的塑料座，切勿触摸玻璃外壳，拆卸时不要摇晃或转动灯泡。
2、Disassembly and assembly of battery removal 蓄电池的拆装
□ Battery precautions: refer to “Overview and maintenance”
蓄电池注意事项：详见《概述与保养分册》
□ Disassemble battery, the sequence of disposing is:
battery press plate, battery negative pole cable, and
battery positive pole cable.
拆解蓄电池，拆解顺序为蓄电池压板、蓄电池负极
连线、蓄电池正极线
□ Remove battery press plate: loosen the battery press
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plate nuts, and remove the battery press plate.
拆卸蓄电池压板：拧松蓄电池压板螺母，取下蓄电
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池压板
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□ Remove battery negative pole cable: pull out upward
the battery negative pole cover, loosen the battery
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negative pole mounting bolts, and remove the battery

negative pole cable.
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拆卸蓄电池负极线：向上拨开蓄电池负极护套，拧
松蓄电池负极固定螺栓，取下蓄电池负极线
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□ Remove battery positive pole cable: pull out upward

the battery positive pole cover, loosen the battery
positive pole mounting bolts, and remove the battery
positive pole cable
拆卸蓄电池正极线：向上拨开蓄电池正极护套，拧
松蓄电池正极固定螺栓，取下蓄电池正极线
□ Remove the battery from the vehicle.
将蓄电池从车上取下
Installation: follow the reverse order of removal. Pay attention to the following issues:
装配：按照拆解相反步骤开展，但是需要注意以下事项：
□ Before connecting the ground wire of the battery, please ensure that all the electrical systems are
turned off to avoid damaging the automotive electrical system.
在连接蓄电池的搭铁线之前，要确认所有电气系统都已经关闭，以免损坏汽车电气系统。
□ The sequence of connecting the battery: first connect the battery positive pole cable, and then connect
the battery negative pole cable.
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连接蓄电池的顺序：先连接蓄电池正极连线，后连接蓄电池负极连线。
□ It is prohibited to shake and rotate the pole during installation.
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安装时禁止对端柱敲击，扭动。
□ Do not exceed 40 degrees upside-down when the battery is placed upside down,side or tilt.
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蓄电池倒置、侧向放置或倾斜不要超过 40 度倒置。
□ The leaked battery is not allowed to be installed on the vehicle.

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禁止将漏电的蓄电池装车。
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3、Disassembly and assembly of combination switch 组合开关的拆装
□ Disassemble combination switch, the disassembling

sequence is: steering wheel, steering column cover up
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and down cover, combination switch connector and

mounting bolts.
拆解组合开关，拆解顺序为方向盘、转向管柱罩上
下盖、组合开关接插件和固定螺栓
□ Remove the steering wheel: refer to “removal of
steering wheel”.
拆解方向盘：【参考方向盘的拆解】
□ Disassembly the steering column up and down cover:
拆解转向管柱罩上下盖：
（1）Remove the steering column cover mounting bolts 拆
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下转向管柱罩固定螺栓
（2）Remove the steering column up and down cover 取下
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转向管柱罩上下盖
□ Disconnect the combination switch connector

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断开组合开关接插件
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□ Remove the two mounting screws of the combination

switch, and remove the combination switch assembly
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拆卸组合开关两个固定螺钉，取下组合开关总成
Assembly: follow the reverse order of disassembly. But be aware of the following issues:
□ Test after installation 安装后的测试
（1）Operate the combination switch light handle, and check the working conditions of each light and
switch:操纵组合开关灯光手柄，检测各灯及开关工作状况：
① When the light rotary handle is on the "OFF" position, all the external lights of the vehicle and the
night lights of the electrical equipment inside the vehicle should be off.灯光旋柄在“OFF”档时，车辆
所有外部照明灯及车内电器设备的夜间照明灯应熄灭
② When the light rotary handle is on the small light position, the clearance lamps, front and rear position
lamps, license plate lights, instrument lights, and the night lights of all the electrical equipment should be
on. If the vehicle is running, the side marker lamp should also be on.灯光旋柄在小灯档时，车辆示廓灯、
前后位置灯、牌照灯、仪表照明及车内所有电器设备的夜间照明灯应点亮，如果在行车状态，侧标
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志灯也同时点亮
③ When the light rotary handle is on the small light position, and rotary handle is on the front (rear) fog
light switch, all the front (rear) fog lights should be on.灯光旋柄在小灯档，旋柄在前（后）雾灯开关时，
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所有前（后）雾灯应点亮
④ When the light rotary handle is on the big light position, the headlight low beam light is on, and all the
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small lights are also on. Push down the handle, the headlight high beam light is on, and rotate the handle
to its normal position, and pull upward, high beam light will be immediately. The switch will
automatically return to its normal position when letting it go.灯光旋柄在大灯档时，大灯近光点亮，同
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时所有小灯保持点亮状态，这时将手柄向下推，大灯远光点亮，将手柄转回原位，再向上拉，远光
瞬时点亮，松手后开关自动复位
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⑤ The light handle rotate forward (backward) by 12 degrees, all the right (left) turning lights start
flashing, and at the same time the right (left) turning indicator on the instrument starts flashing. Rotate the
handle back to its original position, and then the lights will stop flashing. The handle move forward
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(backward) by 9 degrees, the right (left) turning light starts momentary flash. After releasing, the handle
will automatically return to its original position.灯光手柄向前（后）转 12°，所有右（左）转向灯开
始闪烁，同时仪表上的右（左）转向指示灯开始闪烁，将手柄转回原位停止闪烁。手柄向前（后）
转 9°，右（左）转向灯瞬时闪烁，松手后手柄自动复位
⑥ Press the alarm switch, all the turning lights will start flashing at the same time, and the turning
indicators on the instrument should also start flashing at the same time.按下报警开关，所有转向灯应同
时闪烁，仪表上的左右转向指示灯也同时闪烁
（2）Operate the combination switch wiper and washer; check the working status of wiper and washer 操
纵组合开关的刮水/洗涤，检测刮水器、洗涤器的工作状态：
① When the rotary handle is on the OFF position, the wiper and washer do not work.旋柄在 OFF 状态
时，刮水器、洗涤器不动作
② When the rotary handle is on the INT position, the wiper scraper will move at a certain-time interval.旋
柄在 INT 档时，刮水器刮杆按一定的时间间隔间歇运动
③ Rotate interval time adjustment knob, and the time varies between FAST and SLOW, the interval
time of scraper movement changes.旋转间歇时间调节旋钮，使时间在 FAST 和 SLOW 之间变化时，
刮杆运动的间隔时间发生变化
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④ When the rotary handle is on LO position, the scraper will move continuously at a low speed.旋柄在
LO 档时，刮杆以较低速度连续运动
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⑤ When the rotary handle is on HI position, the scraper will move continuously at a high speed.旋柄在
HI 档时，刮杆以较高速度连续运动
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⑥ Press the washing button at the end of the handle when the wiper is working, and rotate the
combination switch right operation handle inner side by 6 degrees, the wiper nozzle will inject washing
liquid on the front windshield.刮水器工作的同时按下手柄末端的洗涤按钮，将组合开关右操纵手柄
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向身体内方向拨动 6°，洗涤器喷嘴会将洗涤液喷向前风窗
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4、Disassembly and assembly of lighting system 灯光系统的拆装
4.1 Disassembly and assembly of the front combination lamp 前组合灯的拆装

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□ Disassemble the front combination lamp, the

disassembling sequence is: front bumper, intake grille
and front wall outer plate, angle plate, front
combination lamp mounting bolts and plug-ins, and
high/low beam light bulb.
拆解前组合灯，拆解顺序为蓄电池负极、前保险杠、
进气格栅和前围外板装置、角板、前组合灯固定螺
栓和接插件、远/近光灯泡
□ Remove the front bumper. Please refer to "Removal of

Front Bumper"
拆卸前保险杠【参考前保险杠的拆卸】
□ Remove the intake grille and front wall outer plate.

Please refer to "Removal of intake grille and front wall
outer plate".
拆卸进气格栅和前围外板装置【参考进气格栅的拆
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卸和前围外板的拆卸】
□ Disassemble the angle plate 拆解角板
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（1）Remove the angle plate mounting bolts 拆卸角板固
定螺栓
（2）Remove the angle plate 取下角板

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□ Remove the front combination lamp mounting bolts
拆卸前组合灯安装固定螺栓
□ Move the front combination lamp carefully, remove the
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electrical plug-in, and remove the front combination
lamp assembly
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小心移动前组合灯，拆卸电气接插件，取下前组合
灯总成
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□ Remove the low beam/high beam back cover from the
lamp seat following counter clock direction.
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Disconnect the plug-in from the back of the lamp, and

loosen the spring clip, and remove the low/high beam
light bulb
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将近光/远光后盖从灯体上逆时针方向取下，从灯泡
后部断开接插件，并松下弹簧卡扣，小心地拆下远/
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近光灯泡
Assembly: follow the reverse order of disassembly. But be aware of the following issues:
□ The front combination lamp is semi-closed, and uses a replaceable halogen bulb. Please replace the
bulb after the disassembly.
前组合灯是半封闭式的，使用可更换的卤素灯泡。更换灯泡最好是拆卸后进行更换。
□ After installation, please check whether the light can meet the requirements.
安装后，检查灯光是否符合要求。
Adjustment Method of front combination lamp light 前组合灯光调整方法：
（1）Confirm that all the tire pressure is normal 确认所有轮胎气压正常；
（2）Place the vehicle and test equipment on the same flat surface 将车辆和测试仪置于同一平整
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表面上；
（3）Confirm the vehicle is in idle status except the driver (or place a equal weight object on the
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driver's side)确认除驾驶员外（或在驾驶员位置放置相等重物）车辆处于空载状态；
（4）Open the front combination low beam 打开前组合灯近光灯；

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（5）Use the adjustment screw or the headlight switch for optical adjustment 使用调整螺钉或电调
大灯开关进行对光调整；
（6）Adjust low beam and high beam at the same spot. You can adjust the up-down height of low
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beam and high beam during adjustment. Adjust high beam and low beam at the same spot. You can adjust
the left-right height of low beam and high beam during adjustment. If you repair the front body of the
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vehicle/or replace the front combination lamp assembly, you should check the beam-focusing and use the
light detector for adjustment 近光、远光上下调节在一个调光点，调节时可调整近光、远光上下高度；
远光、近光左右调节在一个调光点，调节时可调整近光、远光左右高度。如果修理了车辆的车身前
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部和/或更换了前组合灯总成，应检查对光，请使用灯光检测仪调整到位；
（7）Use a beam-focusing chart for beam-focusing until it is adjusted properly 按照对光表进行对

光，直到调整到位。
4.2 Disassembly and assembly of fog light 雾灯的拆装
□ Disassemble fog light, the disassembling sequence is
front bumper, front fog light mounting bolts and
plug-ins, front fog light bulb.
拆解雾灯，拆解顺序为蓄电池负极、前保险杠、前
雾灯固定螺栓和接插件、前雾灯灯泡
□ Remove the front bumper: refer to “Front Bumper
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Removal Procedure”.
拆卸前保险杠：参考【前保险杠的拆卸步骤】
26 □ Remove the fog light mounting screws from the front

bumper.
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从前保险杠上拆下雾灯上的固定螺钉
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□ Disconnect the electrical plug-ins, and remove the fog

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light assembly.
断开电气接插件，拆下雾灯总成
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□ Rotate the bulb seat cover in counter lock direction,

and remove the bulb seat cover, and remove the fog
bulb from the seat.
逆时针旋转灯泡座盖，取下灯泡座盖，从灯泡座上
拆下雾灯灯泡
Installation: follow the reverse order of removal.

4.3 Disassembly and assembly of turn signal lamp 转向灯的拆装
□ Disassemble turn signal lamp, the removing sequence

is the battery negative pole, turn signal lamp plug-in,
turn signal lamp bulb.
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拆解转向灯，拆解顺序为蓄电池负极、转向灯接插
件、转向灯灯泡
26 □ Use a flat-blade screwdriver to gently pry the side turn

signal lamp, and take out the side signal lamp from the
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door.
用平口螺丝刀轻轻撬起侧转向灯，将侧转向灯从车
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门上取出
□ Disconnect the side turn signal plug-in, and remove the

C-
side turn signal lamp. Rotate bulb seat in

counterclockwise direction, and remove the side turn
JA
signal lamp bulb.
断开侧转向灯接插件，取下侧转向灯。逆时针拧动
灯泡座，可将侧转向灯灯泡拆下
4.4 Disassembly and assembly of side marker lamp 侧标志灯的拆装
□ Disassemble side marker lamp, the removing sequence
is side marker lamp mounting bolts and plug-ins.
拆解侧标志灯，拆解顺序为蓄电池负极、侧标志灯
固定螺栓和接插件
□ Remove side marker lamp and the bracket mounting
42
bolts.
拆卸侧标志灯与安装支架固定螺栓
26
12
□ Disconnect side marker lamp plug-in, and remove the
side marker lamp
20
断开侧标志灯接插件，取下侧标志灯
C-

JA
4.5 Disassembly and assembly of top clearance lamp 顶示廓灯的拆装
□ Disassemble top clearance lamp, the removing
sequence is top interior, top clearance lamp mounting
bolts and plug-ins.
拆解顶示廓灯，拆解顺序为蓄电池负极、顶内饰、
顶示廓灯固定螺栓和接插件
□ Remove top interior: Refer to “Top Cover Removal”.
42
拆卸顶内饰：参考【顶内饰的拆卸】
□ Remove top clearance lamp mounting bolts.
26 拆卸顶示廓灯固定螺栓
12
□ Disconnect clearance lamp plug-ins, and remove the
clearance lamp.
20
断开位置灯接插件，取下位置灯
C-

JA
4.6 Disassembly and assembly of rear clearance lamp 后示廓灯的拆装
□ Disassemble rear clearance lamp, the removing
sequence is rear clearance lamp mounting bolts and
plug-ins.
拆解后示廓灯，拆解顺序为蓄电池负极、后示廓灯
固定螺栓和接插件
□ Remove rear clearance lamp mounting bolts.
42
拆卸后示廓灯固定螺栓
□ Disconnect rear clearance lamp plug-ins, and remove

the rear clearance lamp.
26 断开后示廓灯接插件，取下后示廓灯
12
20
4.7 Disassembly and assembly of turn signal lamp 后组合灯的拆装

C-
□ Disassemble turn signal lamp, the removing sequence

is rear combination lamp mounting bolts and plug-ins,
brake light/reverse light bulb.
JA
拆解后组合灯，拆解顺序为蓄电池负极、后组合灯
固定螺栓和接插件、制动灯/倒车灯灯泡
□ Remove the rear combination lamp mounting bolts.
拆卸后组合灯固定螺栓
□ Disconnect the rear combination lamp plug-ins, and
remove the rear combination lamp.
断开后组合灯接插件，取下后组合灯
□ Use a flat-head screwdriver to pry off the rear
42
combination lamp rear cover, and follow counter-clock
direction to rotate each bulb seat to remove the bulb.
26
用一字螺丝刀撬开组合后灯后盖，然后逆时针拧动
各个灯泡座可取下以取下灯泡
12
20
4.8 Disassembly and assembly of license plate lamp 牌照灯的拆装

C-
□ Disassemble license plate lamp, the removing sequence

is license plate lamp mounting bolts and plug-ins.
JA
拆解牌照灯，拆解顺序为牌照灯固定螺栓和接插件
□ Use a Phillips screwdriver to remove the license plate

lamp mounting screws.
用十字螺丝刀拧下牌照灯固定螺钉
□ Disconnect license plate lamp plug-ins, and remove the

license plate lamp. The light bulb replacement needs to
replace the license plate lamp assembly
断开牌照灯接插件，取下牌照灯。灯泡更换需更换
牌照灯总成。
4.9 Disassembly and assembly of internal lamp 内部照明灯的拆装
42
□ Disassemble internal lamp, the removing sequence is
internal lamp cover, internal lamp mounting bolts and
plug-ins.
26
拆解内部照明灯，拆解顺序为蓄电池负极、内部照
明灯护罩、内部照明灯固定螺栓和接插件
12
□ Use a flat-blade screwdriver to gently pry up the
internal lamp cover, and remove internal lamp
20
mounting bolts.
用平口螺丝刀轻轻撬起内部照明灯护罩，拆卸内部
C-
照明灯固定螺栓
JA
□ Disconnect the internal lamp plug-ins, and remove the

internal lamp.
断开内部照明灯接插件，取下内部照明灯
5、Disassembly and assembly of combination dashboard 组合仪表的拆装
□ Disassemble the combination dashboard, the removing

sequence is dashboard cover assembly, combination
dashboard mounting bolts and plug-ins.
拆解组合仪表，拆解顺序为蓄电池负极、仪表罩总
成、组合仪表固定螺栓和接插件
42
□ Remove dashboard cover assembly: Refer to
“Dashboard Cover Removal”.
26
拆卸仪表罩总成：【参考仪表罩的拆卸】
□ Remove the radio cassette player mounting bolts.

12
拆卸收放机固定螺栓
20
C-
□ Disconnect the combination dashboard plug-ins, and

remove the combination dashboard assembly.
JA
断开组合仪表接插件，取下组合仪表总成
6、Disassembly and assembly of Sound System 音响系统的拆装
6.1 江淮汽车
Disassembly and assembly of radio cassette player 收放机的拆装
部门：[客户服务部]
□ Disassemble radio cassette player, the removing
sequence is dashboard cover assembly, dashboard
glove box assembly, radio cassette player mounting
bolts and plug-ins.
拆解收放机，拆解顺序为蓄电池负极、仪表罩总成、
仪表台杂物盒总成、收放机固定螺栓和接插件
42
□ Remove the dashboard cover assembly: Refer to
"Dashboard Cover Removal".
26
拆卸仪表罩总成：【参考仪表罩的拆卸】
□ Remove the dashboard glove box assembly: Refer to

"Dashboard Glove Box Removal".
12
拆卸仪表台杂物盒总成：【参考仪表台杂物盒的拆
卸】
20
□ Remove radio cassette player mounting bolts.
拆卸收放机固定螺栓
C-
JA
□ Disconnect radio cassette player plug-ins and antenna,

and remove the radio cassette player assembly.
断开收放机接插件和天线，取下收放机总成
6.2 Disassembly and assembly of the speaker assembly 扬声器的拆装
□ Disassemble the speaker assembly, the removing

sequence is front door trim panel, speaker mounting
bolts and plug-ins.
拆解扬声器总成，拆解顺序为蓄电池负极、前车门
42
内饰板、扬声器固定螺栓和接插件
□ Remove the front door trim panel: Refer to “Front
26
Door Trim Panel Removal”.
拆解前车门内饰板：【参考前门内饰板的拆卸】
12
□ Remove the speaker mounting bolts, disconnect the
speaker plug-ins, and remove the speaker assembly.
20
拆卸扬声器固定螺栓，断开扬声器接插件，取下扬
声器总成
C-

JA
6.3 Disassembly and assembly of the antenna 天线的拆装
□ Disassemble the antenna, the removing sequence is

radio cassette player, and antenna mounting bolts.
拆解天线，拆解顺序为收放机、天线固定螺栓
□ Remove the radio cassette player. Refer to “Radio
Cassette Player Removal”.
拆解收放机【参考收放机的拆卸】
□ Remove the antenna mounting bolts, and remove the

antenna.
拆卸天线固定螺栓，取下天线
42
26
12
7、Disassembly and assembly of Cigarette Lighter 点烟器的拆装
20
□ Disassemble the cigarette lighter, the removing

sequence is battery negative pole, control area right
down cover assembly, cigarette lighter plug-ins.
C-
拆解点烟器，拆解顺序为蓄电池负极、操纵区右下
护板总成、点烟器接插件
JA
□ Remove the control area right down cover assembly:

Refer to “Control Area Right Down Cover Assembly
Removal”.
拆解操纵区右下护板总成：【参考操纵区右下护板
总成的拆卸】
□ Disconnect the cigarette lighter plug-ins, and remove
the cigarette lighter.
断开点烟器接插件，取下点烟器
42
8、Disassembly and assembly of Horn 喇叭的拆装
26
12
□ Disassemble horn, the removing sequence is front
bumper, horn mounting bolts and plug-ins.
20
拆解喇叭，拆解顺序为蓄电池负极、前保险杠、喇
叭固定螺栓和接插件
□ Remove the front bumper: Refer to “Front Bumper

C-
Removal”.
拆解前保险杠：【参考前保险杠的拆卸】
JA
□ Remove the horn mounting bolts.
拆下喇叭固定螺栓
□ Disconnect the horn plug-ins, and remove the horn
assembly.
断开喇叭接插件，取下喇叭总成
42
9、Wiper and washer system 雨刮与洗涤系统的拆装
26
9.1 Disassembly and assembly of wiper arm and wiper blade 雨刮器臂和雨刮片的拆装
12
□ Disassemble wiper arm and wiper blade after remove
wiper cover and fixing nut
20
拆解雨刮器臂和雨刮片，拆解顺序为前雨刮堵盖、
前雨刮器固定螺母
C-
JA
□ Remove wiper cover
掀开前雨刮堵盖
□ Remove wiper fixing nut, then the wiper arm and wiper
blade
拆卸前雨刮器固定螺母，取下前雨刮器臂和雨刮片
□ Pull up the wiper adapter cover and remove wiper
42
blade
拆卸雨刮片，向上拉雨刮片适配器盖帽，将刮臂的 U
26
型钩扣通过雨刮片适配器盖帽卸下雨刮片
12
Installation:Opposite procedure to removal
20
9.2 Disassembly and assembly of wiper linkage assembly 雨刮连杆总成的拆装

C-
JA
□ Dismantling wiper linkage assembly, dismantling

order: front outer panel, dashboard, wiper linkage and
wiper motor mounting plate snaps, wiper rod bolts,
wiper linkage
拆解雨刮连杆总成，拆解顺序为前围外板、仪表台、
雨刮连杆与雨刮电机安装板连接卡扣、雨刮连杆固
定螺栓、雨刮连杆
NOTE: Before removing the wiper linkage assembly,

make sure the wiper stay at the stop position (Stop
position: Turn off the wiper switch when vehicle
powered, where the wiper blade stop)
注意：拆卸雨刮连杆总成前，确定连杆停止在自动
停止位置（在上电的情况下关闭雨刮开关，雨刮系
统自然停止的位置即为自动停止位置）
□ Dismount front outer panel(refer to Front outer panel

removal)
42
拆解前围外板【参考前围外板的拆卸】
□ Dismount dashboard(refer to Dashboard removal)
26
拆解仪表台【参考仪表台的拆卸】
□ Remove the wiper linkage and wiper mounting plate

snaps
12
拆卸雨刮连杆与雨刮电机安装板连接卡扣
20
□ Remove the wiper linkage fixing bolts, and

disassemble the linkage
C-
拆卸雨刮连杆固定螺栓，取下雨刮连杆
JA
9.3 Disassembly and assembly of wiper motor and mounting plate assembly 雨刮电机及安装板总成的
拆装
□ Dismantling wiper motor and mounting plate assembly,
dismantling order: front outer panel, dashboard, wiper
linkage and wiper motor mounting plate snaps, wiper
rod bolts, wiper linkage
拆解雨刮电机及安装板总成，拆解顺序为前围外板、
仪表台、雨刮连杆与雨刮电机安装板连接卡扣、雨
刮电机安装板固定螺栓、雨刮电机接插件
42
□ Dismount front outer panel(refer to Front outer panel
removal)
26
拆解前围外板【参考前围外板的拆卸】
□ Dismount dashboard(refer to Dashboard removal)

12
拆解仪表台【参考仪表台的拆卸】
□ Remove the wiper linkage and wiper mounting plate

20
snaps
拆卸雨刮连杆与雨刮电机安装板连接卡扣
C-
□ Remove the wiper motor mounting plate fixing bolts
拆卸雨刮电机安装板固定螺栓
JA
□ Disconnect wiper motor connector
断开雨刮电机接插件
□ Remove wiper motor and mounting plate assembly
取下雨刮电机及安装板总成
42
26
9.4 Disassembly and assembly of washer liquid pot 洗涤液壶的拆装
12
□ Washer motor dismantling, dismounting order:
passenger side dashboard lower guard panel assembly,
washing liquid tank fixing bolts, washing motor
20
connectors, washing pipe
拆解洗涤液壶，拆解顺序为仪表台乘员区下护板总
C-
成、洗涤液壶固定螺栓、洗涤电机接插件，洗涤水
管
JA
□ Remove passenger side dashboard lower guard panel

snaps
拆卸乘员区下护板总成固定膨胀卡扣，取下乘员区
下护板总成
□ Remove washer reservoir fixing bolts
拆卸洗涤液壶固定螺栓
□ Disconnect washer motor connectors, remove the
42
washing pipe, dismount the reservoir.
断开洗涤电机接插件，拆卸洗涤水管，取下洗涤液
26
壶
12
Installation:Opposite procedure to removal and be noted
20
□ Before installing the washing motor, check for impurities or contamination, if necessary, clean the
filter and wash motors.
C-
安装洗涤电机之前，检查是否有杂质或污染，如有必要，清洁滤清器和洗涤电机。
JA
IV.Troubleshooting 故障诊断与处理
1、Battery 蓄电池
□ Visual inspection 外观检查
Item 检查内容 Reason 原因 Solution 处理方法
①Cover damaged 蓄电池外壳碰损

Crack 破损 Replace 换新
②Improper installation 安装不当
42
①端柱电线接头松动或接触不良 Loose plug or false
Burn 烧损 contact Replace 换新
26
②外部短路 Outer short-circuit
Cover 外
①内部短路 Inner short-circuit
壳
Explosion 爆裂 ②电解液液位过低，内部产生火花 Electrolyte shortage Replace 换新
12
③排气孔阻塞 Vent hole blocked
①过充电 Over charged

20
Deformed 变形 ②过大电流充电 Over charging current Replace 换新
③排气孔阻塞 Vent hole blocked

C-
①外力碰击塑料壳受损 Outer force crack battery cover
电池漏酸 Electrolyte leakage ②电池倒置或倾斜过大 Upside down or over inclined Replace 换新
③热封不良 Abnormal heat sealing

JA
①外部短路 Outer short-circuit
端柱熔损 Pin burn up ②接触不良 Bad contact Replace 换新
③焊接不良 Improper welding
□ 故障诊断与处理 Troubleshooting
故障 Inform 不良现象 Symptom 原因分析 Reason 处理方法 Solution
①regulator setup too low 车辆调

Lack electricity ①density<1.220g/cm3 ①replace regulator 更换
节器设定值低
电量不足调节器
②Dim light, low horn sound 起动
②charging capacity low than
无力、灯光暗淡、叭喇声弱 discharging capacity 用电量大于 ②recharge 车下充电
充电量
③Capacity in yellow 容量测试在 ③fix the generator or
黄色区域 ③short range driving when start 起 circuit 排除发电机或线
动频次多行驶距离短路故障
④generator electricity lack or ④clean the corrosion on

circuit fault 发电量不足或线路故 pin 清除端柱腐蚀物
障
⑤pin corrosion or false contact 端

柱腐蚀或接虚
42
①Battery cover inner turn yellow
permanently 电池壳体内壁永久性 ①replace the regulator 调
红黄色（工作栓） ①regulator setup too high 车辆调整或更换调节器
26
②clapboard softened 隔板炭化或节器设定值高
②charging following
Over charged 软化 ②charging time or current standard procedure 充电
过充电 ③Electrolyte turn red and thick 电 excessive 充电时电流大且时间长时按规程充电
③charge without working valve ③water clean 过充电程

12
解液红褐色且浓
④Battery cathode active material open 充电时不打开工作栓度轻的，水洗后再充电使

shedding mashed 正极活性物质泥用
状脱落
20
①replace circuit adapter

①battery work when not full
更换电路调节器
charged 电池充电不足就使用
②standard charging
C-
②generator electricity lack causing

procedure 车下充电时保
battery work frequently 车辆发电
Over ①Density（比重）1.100g/cm3 不足，电池长期使用
质保量
discharged ③fix the circuit fault 排
②Electrolyte turn gray and thick 电 ③short circuit 车辆线路短路
JA
过放电解液灰白色且浓除线路故障

④power switch always on 忘记关
④turn off switch when
掉电源开关
parking 停车时关掉开关
⑤electrolyte impure 电解液不纯
⑤replace with new
电池自放电严重
battery 更换新电池
①No voltage in failure grid 故障格 ①impurity access when assembly

没有电压电池组装时漏铅或掉入异物
①disassemble analysis 解
②No density in failure grid 故障格 ②electrode board bend 电池组装
Short circuit 剖分析
没有比重时极板弯曲
短路 ②replace with new
③smoke and bulb when ③board burr 极群板脚有毛刺
battery 更换新电池
discharging 放电时冒烟冒泡 ④grid crack or perforate 隔板孔洞
④no reaction in failure grid 充电时或裂纹
故障格没反应 ⑤human damage 人为损坏
①improper pin welding 端柱焊接

①unstable voltage 电压异常不稳不良
②discharge to zero 放电归零 ①fix 修理
Open circuit ②inner cut off 汇流排断
③no input current when charging ②replace with new
断路 ③false welding 穿壁焊开焊
or sound 充电时电流无法输入或 battery 更换新电池
有响声 ④neutral electrode broke 中间极
柱断
①lack charging while long term
42
①capacity too low when discharging 初充电不足且使用时
discharging 电池放电时容量偏低间长
②voltage drop fast when ②unused for long time 电池带液

①over charge 过充电法
26
discharging 电池放电时电压下降搁置时间长又没及时补充电
快
③lack electrolyte 电池处于亏液 ②repeat charging 反复充
Salty electrode ③bulb early when charging 充电时状态，极群暴露时电法
③water wash 水洗疗法

12
极板硫酸盐化气泡产生早
间长
④voltage increase fast when ④replace with new
④electrolyte density too high 电解
charging 充电时电压上升快而高 battery 更换新电池
液密度过高
⑤electrode board with white
20
⑤electrolyte temperature too high

particle 极板表面有白色颗粒或
电解液温度过高
白斑
⑥impure electrolyte 电解液不纯
C-
①grid board crack 电池壳体串格

裂纹
①low voltage 电压低
②shock when moving 搬运时震动 ①fix the cover 修复更换
JA
Electrolyte ②electrolyte fluent in grids 相应贯

③shock when driving 车辆行驶时壳体
misplace 电解通的单格倾斜时电解液流动
液串格
震动 ②replace with new
③boil when discharging 放电时有 battery 更换新电池
④inner explosion when ignition 打
沸腾现象
火内爆
⑤abnormal heat sealing 热封不严
① 电池底部有过多沉淀物 too ①regulator setup too high 汽车电

active material much deposit in battery bottom 路调节器设定值高 ①clean the deposit with
loss 活性物质 water and charge 用水洗
②low battery capacity 电池容量偏 ②charging current and time
过量脱落
低 excessive 充电电流大且时间长法清洗沉淀物，充电再用
③brown red grid board and ③discharging too much and long ②replace with new
working valve 单格壁和工作栓有放电量大且时间长 battery 更换新电池
永久性红褐色
④long time driving and high
④brown red electrolyte 电解液呈 temperature 车辆长时间行驶温度
红褐色高且时间长
⑤soft grid board and explosive ⑤unqualified electrode board 制

active material on negative 电解液造极板不合格
微红且极板活性物质泥状脱落，
隔板呈软化状态，负极板活性物
质软化膨胀
⑥massive loss 块状脱落
①full discharge the
42
battery 将充反极性的电
池电量放完
①negative voltage valve 电压呈负
值 ①opposite connection when ②charge with low current
charging and normal charge after
charging 充电时正负极性连接错
26
oppositely ②opposite color on poles 正负端柱
误 grid react 先小电流充电，
色泽相反
充反极性各单格反应后再正常充
③opposite color on electrode board 电
12
极板色泽相反
③replace with new
battery 严重的更换新电
池
20
①improper installation 安装不当 ①install tightly 紧固安装

①ignition pin 端柱打火
②aged circuit 线路陈旧、线路细 ②replace circuit 更换线
②damaged positive circuit 正极线
③generator fault 发电机故障运行路
C-
路破损
④outer fire flash 外界火花介入 ③fix the generator 排除
battery ③crack on cover and bottom 壳、盖发电机故障
explosion 部位有孔或裂纹 ⑤false welding pin 端柱虚焊
④keep the battery away
⑥inner cut off 汇流排断
JA
电池爆裂 from heat 电池远离热源

⑦board drop 掉板 ⑤keep vent work 经常保
⑧neutral electrode broken 中间极持排气孔畅通
柱断 ⑥replace with new
⑨electrode board crack 极板断裂 battery 更换新电池
①bad connection 连接不实或线路

①abnormal starter 起动无力故障
②low voltage 电压值低 ②exceed quality period 超保管期 ①check circuit 认真检查
low capacity
③slow reaction 反应慢 ③bad positive 正极板钝化线路
初期容量低
④bad negative 负极板氧化 ②recharge 补充电
⑤grid board leakage 隔板轻微渗

透
□ Charging system troubleshooting 充电系统故障诊断
Symptom Analysis Solution
故障症状故障诊断故障处理
①replace bulb 装上新灯泡

Indicator not ①bulb failure 灯泡故障。
illuminate ②clean and tighten all the plug 清洁和拧紧蓄
②generator or battery plug loose 发电机或蓄
when ignition 电池或发电机电缆线，涂上防酸油脂。检查地
42
电池接头松开或氧化，地线连接不好
ON 点火开关线接头，需要时清洁和拧紧
在 ON 档位置 ③voltage regulator fault 电压调节器，转子或
③fix the open circuit 消除电路开路
时充电指示灯电刷电路出现故障
④replace new ignition switch 装上新的点火开
26
不亮 ④ignition switch fault 点火开关故障
关
Charging
①drive belt loose 驱动皮带松弛
indicator don’t
12
①tighten the belt 重新张紧驱动皮带
turn off ②generator plug loose 发电机接头松弛或氧
properly when 化，地线连接不好 ②clean and tighten all plugs 清洁并拧紧接头
generator work
③generator inner component failure 电刷不能 ③fix or replace the generator 检查电刷接头，
20
当发动机运转
接触转子环、在传导方向卡住、磨损、损坏、需要时清洁/松开电刷，装上新的电压调节器
时，充电指示
油污等。轴承、滑环磨损，电压调节器或整或更换发电机
灯不能正确地
流器总成出现故障
熄灭
C-
①drive belt loose 驱动皮带松弛

①重新张紧驱动皮带 tighten the belt
②generator plug failure 发电机上接头焊点有
Lack charging 缺陷 ②fix or replace the adapter or generator 必要
JA
充电不足时，装上新的电压调节器或更换发电机
③ground wire between adapter and generator
with bad contact 调压器和发电机壳体间地线 ③clean and tighten all plugs 清洁并紧固接头
连接不好
Over charging ①fix or replace the adapter 必要时，装上新的

①adapter failure 调压器故障
充电过量调压器或更换发电机
①bearing wear 轴承磨损 ①replace with new generator 装上新的发电机

Noise when ②tighten the belt, if bearing worn, replace
②loos belt 皮带轮松弛
working generator 拧紧皮带轮至规定扭矩。如轴损坏，
③worn belt 皮带磨损则更换发电机
运转时有噪音
③replace with new belt 装上新皮带
2、Light system 灯光系统
Troubleshooting procedure when light do not illuminate 当出现灯光不亮时，请参考电路图，按以下顺

序检查：
Step Item Measure

步骤检查内容方法
Check if the fuse blow 检查保险丝是否 If yes, replace the fuse; if not, go to next step 若保险丝熔断，在查
1
熔断清故障原因后更换保险丝；若未熔断，继续向下检查
42
Turn on the light switch, check if the relay work by hearing or
Check the light relay work or not 检查
2 multimeter 打开灯光开关，检查灯继电器是否有吸动，或用万用
灯光继电器是否正常动作
表检查继电器接线端是否正常接通
26
If bulb is normal, go to next 通过上述较为简单的检查后，若正常，
3 Check the bulb 检查灯泡是否损坏
请检查灯泡是否损坏；若完好，请继续下一步检查
12
Check all plugs 检查各接线插头是否 Check if there any plug loose 按线路图所示，检查灯光线路各接线
4
可靠端是否插接牢靠
Check the combination switch work or

20
Check the other functions of the combination switch, normal or not

5 not 检查组合开关（灯光开关）是否损
检查组合开关上的灯光开关部分是否能够正常开启
坏
C-
3、Combination instrument 组合仪表

JA
Symptom 主要故障 Reason 产生原因 Solution 排除方法
Check the voltage of instrument plug power

Whole instrument failure ①open circuit 电路未接通 pin 检查组合仪表接插件电源端子电压是
否正常，是否接通
整个仪表不工作 ②circuit damage 仪表电路损坏
replace instrument 调换仪表
Check all related circuit conduction 检查有

①open circuit 电路未接通
关线路、接插件是否接通
Indicator and background
②control signal failure 控制信号故障
light do not illuminate 指 Check whether there power signal 检查有关
示灯、照明灯不亮 ③instrument circuit damaged 仪表电路损开关信号是否有
坏
Replace instrument 调换仪表
Error indicator or ①system fault 系统故障 Check all related sensor, circuit and plug
disfunction 指示仪表误 ②instrument circuit damaged 仪表电路损 conduction 检查相关传感器输出是否正常，
差或不工作，里程液晶坏线路、接插件是否接通
不工作
Replace instrument 调换仪表
LCD mileage number

Instrument circuit damaged 仪表电路损坏 Replace instrument 调换仪表
error 里程液晶缺笔画
□ Whole instrument do not work 整个仪表不工作
42
Step Measure Yes No
步骤主要故障是否
26
To step 至步 To step 至步
1 Check whether the fuse blow 检查电器盒保险丝是否熔断
骤2 骤3
Replace the fuse and confirm if problem solved 排除因其他线路造成的故 To step 至步

12
2
障后，更换保险丝，故障是否排除骤3
Check voltage between the instrument power plug and ground 检查仪表插 To step 至步 To step 至步
3
骤5 骤4
20
头电源端子与接地之间电压是否正常
Fix the power circuit to check whether problem solved 根据配电线路图，修 To step 至步
4
理或者更换仪表的供电线路，故障是否排除骤5
C-
Check the conduction between plug ground pin and ground wire 检查仪表插 To step 至步 To step 至步
5
头接地端子与接地之间线路是否导通骤7 骤6
JA
Fix or replace the instrument plug ground pin and ground wire 修理或者更 To step 至步
6
换仪表插头接地端子与接地之间的线路，故障是否排除骤7
7 Replace the instrument 更换组合仪表
□ Indicator and light do not illuminate 指示灯、照明灯不亮
Step Measure Yes No

Check the conduction between the light and instrument 检查相关指示灯、照 To step 至步 To step 至步
1
明灯本身与仪表的连接线路是否导通骤3 骤2
Fix or replace the circuit 修理后者更换相关指示灯与照明灯的连接线路， To step 至步
2
故障是否排除骤3
Confirm the light and indicator work 排除相关指示灯、照明灯本身控制线 To step 至步

3
路或者原件故障后，故障是否排除骤4
□ Indicator error or not work,mileage indicator do not work 指示仪表误差或不工作，里程液晶不工
42
作
Step Measure Yes No
26
Check sensor work, and the circuit conduction 检查相关传感器元件是 To step 至步骤 To step 至步骤
1
12
否正常，线路是否导通 3 2
Replace the sensor and fix the circuit, check whether problem solved 更 To step 至步骤
2
换相关传感器，修理或者更换相关线路后故障是否排除 3
20

C-
□ LCD mileage indicator error 里程液晶缺笔画

JA
Step Measure
步骤措施
4、Loudspeaker system 音响系统
Symptom 症状 Reason 故障原因 Solution 排除方法
（1）power fuse blow 电源保险丝烧坏 Replace with new fuse 重新换上新的同规格保险管

Can not turn on
不能开机（2）power output plug and socket lose plug again or replace the output plug 将电源输出插头
contact 电源输出插头与主机插座松动或重新插入主机电源输出插座或更换输出插头
接触不良
Sound on and
off 声音有时断 Power connection fault 电源连接不正确 Check the circuit 检查电线连接情况
续
（1）volume control minimum position 音

Adjust volume control 将音量调节到适中的水平
量控制钮调在最小位置
No sound 扬声
器中无声
Check the conduction of circuit wire 检查电线与连接
（2）improper connection 不正确的连接
情况
42
Antenna socket and cable fault 天线插座及 Check the socket and cable 检查天线插座及天线电缆
Auto setup can 天线电缆连接异常连接是否正常
not operation 自
26
动预置不能操 Change to manual adjustment and change vehicle
作如常 Weak signal 电台信号弱 location 改用手动调节或移至障碍物少的地方再搜
台
12
Check the owner’s manual for right right format 请参
Wrong file format 非本机支持的文件格式
USD disable 不照说明书检查文件格式
能播放 USB
Bad connection 存储设备未连接好 Check the connection 检查是否连接正常
20
5、Cigarette lighter troubleshooting 点烟器故障诊断

C-
□ System check sheet 点烟器系统检查表

JA
Step Abnormal
Measure 措施 Normal 正常结果
步骤异常结果
Pull the lighter to the socket till hearing click When negative conducted,lighter will pop Lighter do not
1 sound 将点烟器按到点烟器座中直到听到咔 out 当负极通电时，点烟器将跳到点烟器座 work 点烟器
哒声为止的边沿不工作
□ Lighter do not work 点烟器不工作检查表
Step Measure Yes No

步骤措施是否
To step 至 To step 至步
1 Check if the fuse blow 检查保险丝是否烧断
步骤 4 骤2
Check the power in the socket with a test bulb 用一个测试灯连接点烟器的正 To step 至 To step 至步
2
负两端看是否有电，测试灯亮吗步骤 5 骤3
To step 至 To step 至步
3 Lighter indicator illuminate?点烟器灯亮吗
步骤 6 骤7
To system
4 Replace the fuse 更换保险丝 — check sheet 至
42
“系统检查”
To system
5 Replace the lighter 更换点烟器 — check sheet 至
26
“系统检查”
To system
6 Replace the lighter bulb 更换点烟器灯泡 — check sheet 至
12
“系统检查”
To system
7 Fix the circuit with bad conduction 修理接触不良的连接 — check sheet 至
20
“系统检查”
C-
6、Horn 喇叭
□ Horn check sheet 喇叭检查表

JA
Step
Measure 措施 Normal 正常结果 Abnormal 异常结果
步骤
Horn do not work 喇

Horn make sound when press and stop when 叭不能工作
Press and release the horn switch 按
1 release 当按下喇叭按钮的时候，喇叭发出声音。
当松开喇叭按钮的时候，喇叭停止发出声音。 Abnormal noise 喇
压并松开喇叭按钮
叭－声音异常
□ Horn do not work 喇叭不能工作
Step Measure 措施 Yes 是 No 否
步骤
To step To step
1 Check whether the horn fuse blow 检查喇叭保险丝是否熔断
至步骤 3 至步骤 2
①unplug the horn plug 拔出喇叭总成接插件。
②check with test bulb 用测试灯搭接喇叭总成接插件处。 To step To step

2
③press the switch to see if the bulb work 按下喇叭按钮的同时观察测试灯。至步骤 4 至步骤 5
测试灯是否点亮？
42
Replace the horn fuse to see the problem solved or not 排除因其它线路原因造成的 To step
3
故障后，更换喇叭保险丝故障是否排除至步骤 2
4 Replace the horn 更换喇叭总成
26
①connect the horn 重新连接喇叭。
②disconnection the horn relay 断开喇叭继电器。

12
To step To step
5 ③connect the relay with the test bulb, whether the horn work 用测试灯搭接继电至步骤 8 至步骤 6
器。
喇叭是否发声？
20
Check the circuit between horn and relay and ground.检查喇叭与继电器、接地之 To step To step
6
间的连接线路是否正常至步骤 4 至步骤 7
C-
Fix or replace the circuit and check whether the problem solved 修理或者更换喇叭 To step
7
与继电器、接地之间的连接线路，故障是否排除至步骤 4
①install the horn relay 装回喇叭继电器。

JA
②remove the horn switch wire form the steering wheel 从方向盘上拆卸喇叭开关
导线。 To step To step
8
③test the horn switch with the bulb, check whether the horn work 用测试灯搭接喇至步骤 9 至步骤 10
叭按钮的接头之间。
喇叭是否发声？
9 Replace the horn switch 更换喇叭按钮
Check the circuit conduction of horn switch and relay and ground 检查喇叭按钮与 To step To step
10
喇叭继电器、接地之间的连接线路是否正常至步骤 12 至步骤 11
Fix or replace the circuit problem 修理或者更换喇叭按钮与喇叭继电器、接地之 To step

11
间的连接线路，故障是否排除至步骤 12
12 Replace the horn relay 更换喇叭继电器
□ Abnormal noise 喇叭声音异常
（1）Confirm the noise first 操作喇叭以确认喇叭的异常工作情况。
（2）If significantly abnormal, process with follow procedure如喇叭声音异常现象明显，执行下列

例行检验：
42
①check and fix the plug contact 检查端子是否接触不良；修理发现的任何不良接触。
②check and fix the ground contact 检查接地连接。如显然有接触不良，修理不良接触。
26
③ make sure horn assembly fixing bolts fixed properly确保喇叭总成固定螺栓紧固适当。
④make sure horn do not contact with anything else, if contacted, remove it or bend the bracket to
12
avoid contact.确保喇叭总成与任何其它物体没有接触；如果有接触，重新确定其它物体的正确位置，
或者如有必要弯曲喇叭总成支架。
20
（3）Press the switch to check whether problem solved, if pending, then confirm the noise type操作
喇叭以确定该情况是否仍然存在。如果该情况仍然明显存在，请确定喇叭产生音质的类型：音调低
沉或音调尖弱
C-
①if the noise is deep and low,then the current is too high and circuit need to be checked, replace the
horn if finding no problem with circuit 如果明显为音调低沉，则表明电流太高而必须检查线路，线路
JA
正常时应更换喇叭总成。。
②if the noise is sharp and weak, check the horn if there is foreign matter如果明显为音调尖弱，喇叭
可能含有粘附的异物，拆卸喇叭总成并检查是否存在外来物质。
③remove the foreign matter, install the horn again去除任何粘附的异物，并且重新安装喇叭总成。
④if finding no foreign matter, replace the horn如果未发现任何粘附的异物，或者如果不能去除该

物质，更换喇叭总成。
（4）Press the switch again to check whether the problem solved操作喇叭确认已修复所关注事

项。
7、Wiper and washer system 雨刮洗涤器系统
□ Fault symptom：Fault symptom: wiper and washer don’t work regardless of modes
故障模式：不管雨刮器开关处于哪个档位，雨刮器和洗涤器不工作
Step 处理方法 Measure Yes No

步骤
至步骤至步骤
1 Check the wiper fuse 检查雨刮保险丝，保险丝是否损坏？
42
To Step 3 To Step 2
Remove the wiper switch, check whether ablative or cracked, check wire 至步骤至步骤 To
harness conduction, check the connector and wiper switch voltage, normal Step 4
To Step 5
26
2 voltage or not 拆下雨刮器开关，检查开关内是否存在烧蚀、断裂等异常，
使用数字万用表来测量导线通断，测量连接器和雨刮器开关端的电压，看
电压是否正常？
12
至步骤
3 Replace the damaged fuse 更换受损保险丝。
To Step 2
Check wire harness between fuse and wiper switch in the dashboard, fix if
20
至步骤
4 necessary
To Step 5
请检查从保险丝到雨刮器开关的仪表板导线线束，如果有必要请修理。
C-
Make sure the conduction between wiper switch and connector 至步骤
Separate wire harness with wiper motor, check wire harness between wiper To Step 6
switch and fuse to wiper motor, fix if necessary
5
JA
确信雨刮器开关以及导线线束连接器接触良好？
将导线线束与雨刮器马达分离，根据线路图检查从雨刮器开关和保险丝到
雨刮器电机的仪表板线束，线束如有必要加以修理。
Check wiper motor, fix if necessary. Check contact between wiper motor and 至步骤 —
connector after confirm
6 To Step 7
检查雨刮器电机，如必要加以修理。确信雨刮器电机没有问题。确认雨刮
器电机与连接器接触良好。
Check the ground wire of wiper motor, fix if necessary 请检查仪表板导线线至步骤
7
束处雨刮器电机的接地线, 如有必要加以维修。 To Step 8
8 Check whether issue solved 系统完好?
□ Fault symptom：stop working at high speed mode
故障现象：高速档位下不工作

步骤
1 Separate wire harness with wiper motor from the connector. Check the voltage of 至步骤至步骤
plug pins normal or not.请将导线线束连接器从雨刮器电机上分隔开。利用数
42
To Step 2 To Step 3
字万用表来测量导线线束侧针脚的电压，电压是否正常？
2 Check the wiper motor, fix if necessary 检查雨刮器电机的内部结构，如必要加

以更换或者修理。
26
3 Remove the wiper switch and check. Check the wire harness between wiper
switch and wiper motor in dashboard, fix if necessary 拆下雨刮器开关并且进行
12
检查；确信它没有问题。检查从雨刮器开关至雨刮器电机的仪表板线束，如
必要修理仪表板线束。
20
□ Fault symptom：Stop working at low speed mode

C-
故障现象：低速档位下不工作

JA
步骤
1 Separate wire harness with wiper motor from the connector. Check the voltage of 至步骤至步骤
plug pins normal or not with multimeter.请将导线线束连接器从雨刮器电机上
To Step 2 To Step 3
分隔开。利用数字万用表来测量导线线束侧针脚的电压，电压是否正常？
2 Check the wiper motor, fix if necessary 检查雨刮器电机的内部结构，如必要加

以更换或者修理。
3 Remove and check the wiper switch; Fix if necessary 拆下雨刮器开关并且进行至步骤
检查；如有必要进行更换或修理，确认雨刮开关没有问题。 To Step 4
4 Check the wire harness between wiper switch and wiper motor in dashboard, fix
if necessary 检查从雨刮器开关到雨刮器电机的仪表板线束；如必要修理仪表
板线束。
□ Fault symptom：Stop working at INT mode
故障模式：只有间隙档不工作
Step 处理方法 Measure Yes

No
步骤
Remove wiper relay, switch ignition to ON, switch wiper switch to INT mode.
Check the plug pin voltage normal or not 拆下雨刮器继电器，将点火装置拔到至步骤至步骤
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1
打开位置，将雨刮器开关拔到间隙档位置。利用数字万用表来测量继电器 To Step 4 To Step 2
针脚的电压，电压是否正常？
Check the wiper motor, fix if necessary 拆下雨刮器开关并且进行检查，确认它至步骤
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2
没有问题；否则如必要加以更换或者修理。 To Step 3
Check the wire harness between wiper switch and wiper relay in dashboard, fix if 至步骤
3 necessary 请检查从雨刮器开关到雨刮器继电器的仪表板线束，如必要加以修
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To Step 7
理。
至步骤至步骤
4 Check the replay ground wire 请检查继电器处的接地线，该线是否接地良好？ To Step 6
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To Step 5
5 Check the ground wire normal or not 请修理接地线，确认它接地良好。

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Check the wire replay to make sure the system working 请更换导线继电器，系
6
统是否完好？
Check the wire harness between wiper switch and wiper relay in dashboard, make 至步骤至步骤
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7 sure it working 请检查从雨刮器开关至继电器的仪表板线束，确信它没有问 To Step 8

To Step 10
题。
Remove the new wiper relay, check the relay voltage normal or not 拆下新雨刮至步骤
8
器继电器，使用数字万用表测量继电器上的电压，电压是否正常？ To Step 10
Check the dashboard circuit, fix if necessary 请检查仪表板线束，如必要加以修至步骤

9
理；确认它没有问题。 To Step 10
Check the wire harness between wiper switch and wiper relay in dashboard, fix if
10 necessary; Make sure the system working 请检查从继电器到雨刮器电机的仪表
板导线线束，如必要修理仪表板；确认它没有问题。系统是否完好？
□ Fault symptom：Wiper blade cannot reset

故障模式：雨刮器刮片不能正常复位

步骤
1 Remove and check the wiper motor, fix if necessary 拆下雨刮器开关，检查雨刮至步骤
器开关的内部结构。如必要加以修理或者更换，确信它没有问题。 To Step 2
2 Disconnect the wiper motor connector,断开雨刮器电机连接器；使用数字万用至步骤至步骤

表来测量导线线束侧针的电压，电压是否正常？ To Step 4 To Step 3
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3 Check the wire harness between fuse and wiper motor 根据电路图检查保险丝到至步骤
雨刮器电机仪表板线束；确认它没有问题。 To Step 4
26
4 Remove and check the wiper motor, fix if necessary. Confirm the system working
拆下雨刮器电机，检查结构；如必要加以修理或者更换。系统完好。 12
□ Fault symptom：wiper keep working
故障模式：雨刮器一直打开
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步骤
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1 至步骤至步骤
Check the fuse 检查保险丝，是否完好？ To Step 2
To Step 3
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2 至步骤
Replace the damaged fuse 更换受损保险丝。
To Step 3
3 Remove the wiper switch, check the switch voltage with multimeter 拆下雨刮器至步骤至步骤
开关，使用数字万用表测量开关上的电压，电压是否正常？ To Step 5 To Step 4
4 Check the wire harness between wiper switch and fuse, fix if necessary 请检查从至步骤至步骤
保险丝到雨刮器开关的仪表板导线线束，如必要加以修理。 To Step 5 To Step 6
5 Check the wiper switch, fix if necessary; Make sure it working and confirm the
至步骤
system again 请检查雨刮器开关的内部结构，如必要加以更换或者修理。
To Step 10
确信它没有问题。系统是否完好？
6 Disconnect the connector from wiper motor, switch ignition to ON, switch the 至步骤
wiper switch to high speed mode, test the connector pin voltage, normal or not 请至步骤 To Step 10
将连接器从雨刮器马达上分开，将点火开关拔到“打开”位置，将雨刮器开
To Step 7
关拔到高档，利用数字万用表测量(导线线束侧)连接器处针的电压，电压是
否正常？
7 Check the wire harness between wiper switch and relay 请检查从雨刮器开关到
至步骤至步骤
继电器的仪表板线束。
To Step 8 To Step 9
确信它没有问题。
8 Check the ground wire with multimeter 请利用数字万用表确认接地线是否接地

良好？
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9 Remove and check the wiper motor, fix if necessary 拆下雨刮器马达，对其进行至步骤
更换或者修理。系统完好。 To Step 10
26
10 Check the wire harness between wiper motor and wiper switch, fix if necessary 根
据电路图检查从雨刮器开关到雨刮器马达的仪表板导线线束；如必要加以修
理，确认它没有问题。系统是否完好？
12
□ Fault symptom：Washer stop working
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故障模式：洗涤器不工作

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步骤
1 Remove the wiper/washer switch, switch ignition to ON

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Check the plug pin voltage normal or not 拆下雨刮器/洗涤器开关；将点火开关至步骤至步骤
拔到“打开”位置； To Step 3 To Step 2
使用数字万用表测量开关原位处针的电压，电压是否正常？
2 Check the wire harness between fuse and wiper switch, fix if necessary 请检查从
保险丝到雨刮器/洗涤器开关的仪表板线束，至步骤
To Step 3
如必要加以修理。确认它没有问题。
3 Check the wiper switch, fix if necessary 请检查雨刮器开关的内部结构。如必要

至步骤
加以修理或者更换，
To Step 4
确信它没有问题。系统是否完好？
4 Install wiper/washer switch, separate the wiper motor connector, switch 至步骤
至步骤
wiper/washer to WASH, check the connector pin voltage normal or not 安装雨刮 To Step 6
器/洗涤器开关；将洗涤器电机马达连接器分开，将刮水器/洗涤器开关拔到 To Step 5
“洗涤”位置。利用数字万用表来测量洗涤器马达连接器处(导线线束侧)针
的电压，电压是否正常？
5 Check the wire harness between wiper/washer and washer motor 根据电路图检至步骤
查并且修理从雨刮器/洗涤器到洗涤器马达的线束。 To Step 6
6 Check the wire harness between wiper/washer switch to wiper motor 请根据电路
至步骤
图检查从雨刮器电机马达到雨刮器/洗涤器开关的仪表板导线线束。是否完
To Step 7
好？
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7 Replace the wiper motor, confirm the system working 请更换洗涤器电机。系统
是否完好？
26
12
20
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Chapter III A/C system
第三章空调系统
I. Introduction 简述
N721 series A/C system consists of cooling system and heating system.
N721 车型空调系统分制冷循环和制暖循环。
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Cooling system consists of compressor, condenser, air inlet pipe, air outlet pipe, fluid pipe,
evaporator, expansion valve, and IP controller. Cooling theory: Compressor sucks the low temperature
(LT) and low pressure (LP) refrigerant gas in, and compress it into high temperature (HT) and high
26
pressure (HP) refrigerant gas and transport to condenser to release the heat; After this, refrigerant will turn
into HP and normal temperature liquid, transported to reservoir, where the impurities and water will be
12
filtered from refrigerant, and go through the HP pipe to expansion valve, to lower the pressure till the
refrigerant turns into LP and LT liquid-gas mixture, then goes to evaporator to absorb the heat in the
vehicle, evaporate to overheated gas then goes to the compressor, when the next cooling loop will start.
20
Air in vehicle will release heat to evaporate and turns into cool air, since the surface temperature of the
evaporator is lower than air dew point, vapor in air will turns into water and outlet from the pipe to reduce
the humility and temperature in vehicle.
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制冷循环系统主要由压缩机、冷凝器、吸气管、排气管、液体管、蒸发器、膨胀阀和空调控制
面板等组成。制冷原理：压缩机吸入低温低压制冷剂气体，并对低温低压制冷剂气体进行压缩，变
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成高温高压制冷剂气体，高温高压制冷剂气体通过高压软管被送到冷凝器冷凝；向经过冷凝器的空
气放热，被冷凝成高压中温的液体，流向储液器；在储液器中制冷剂被过滤杂质、脱去水分后，通
过高压软管流至膨胀阀，经膨胀阀节流降压，变成低压低温液气混合物，进入蒸发器；低压低温液
气混合制冷剂在蒸发器中蒸发，从经过蒸发器的车内空气吸热，蒸发为过热的气体，进入压缩机并
开始下一个制冷循环，周而复始的进行。经过蒸发器的车内空气向蒸发器放热，变为冷空气，同时
由于蒸发器表面的温度低于空气露点，空气中的水汽冷凝成为露水排出车外，从而降低了车内空气
的温度和湿度。
膨胀阀：允许制冷剂迅
速膨胀成低温低压液体蒸发器：从周围环境吸 Evaporator ： Absorb
Expansion valve: 收热量使制冷剂变为气 the heat from
turn refrigerant to 体（同时环境被冷却） environment and turn
LP and LT liquid 鼓风机：给蒸发 refrigerant to gas,
器加压，向车内 Blower 外部或内部循环空气
鼓风机 Inter and outer cycling air reducing the
提供冷空气
Blower: increase
pressure to
evaporator,and
provide cool air 压缩机：由发动机通过v型皮 Compressor: powered by
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to cabin 带驱动，将由蒸发器传出的制 engine and turn refrigerant
Reservoir/Drying 储液/干燥罐：清冷剂转变成高压高温气体，并 to HP and HT air, to
Chamber: filter the 除制冷剂中的水提供给冷凝器，装有电磁离合 transport to condenser
water and impuritie 汽和灰尘杂质并器以便压缩机停止运转
26
s in coolant 保持制冷剂充足
冷凝器：装在散热器前面， Condenser:cool down
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冷却高温高压制冷剂，在这 the HT and HP

a
里制冷剂被风扇和车辆行驶 refrigerant, turn it into

e
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形成的风冷却成高压液体 LT and HP liquid
空调制冷原理图
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Heating system consist of blower, engine, pump, reservoir, hot air pipe. Heating theory: water pump
transport cool liquid from engine to heater, and release heat to cabin, then transport back to reservoir.
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制暖循环系统主要由暖风机、发动机、水泵、水箱、暖风管路等组成。制暖原理：利用水泵将
发动机的热冷却液泵入暖风芯体，通过暖风芯体进行热交换，向车内空气放热，之后回到水箱进入
下一个制暖循环。
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Radiator
Heater
Engine
water cover
Pump
空调制暖原理图
A/C system parameter 空调系统主要参数如下表所示。
Part name 部件名称 Parameter 参数 Vehicle mode

车型型号
A/C system main part Blower capacity Heating capacity Voltage
冷暖主机图号制风量制热量电压
8126001LD010 4600W±10% 4700W±10% 12V *
8126001LD060 4600W±10% 4700W±10% 12V
8126001LE190 4600W 4100W 12V
8126001LE050 4600W 4100W 24V
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Part name 部件名称 Parameter 参数
Vehicle mode
26
Condensing capacity 冷 Blower capacity 风
Condenser 冷凝器图号 Voltage 电压车型型号
凝器散热能力量
8105001LD010 ≥9KW 12V *

12
8105001LE190 8.1KW 12V ≥1000 m3/h
8105001LE050 7.6KW 24V ≥660 m3/h

20
Part name 部件名称 Parameter 参数

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Vehicle model
Compressor Bore size*travel range Voltage Emission per round 车型型号
压缩机图号缸径×行程电压每转排量
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8103010LD010 Φ29.5mm×20.92mm 12V 143cm3/r *
8103001LE310 Φ36mm×24mm 24V 147cm3/r
8103001LE190 Φ36mm×24mm 12V 147cm3/r
Accessories 辅材名称 Model 型号 Filling quantity 加注量
Refer to<Intro and Maintenance Manual>

Refrigerant 冷媒 R134a
参考《概述与保养分册》
PAG46 or Equivalent Refer to<Intro and Maintenance Manual>

Lubrication Oil 冷冻油
PAG46 或同类油参考《概述与保养分册》
II. Part position and exploded view 位置图及爆炸图
1、 Part position 位置图
A/C system main parts position 空调系统在整车中的位置如图所示：
42
26
12
20
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2、 Exploded view 主要部件爆炸图

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□ A/C main parts exploded view 冷暖主机总成
1 air condition unit 空调加热制冷单元
2 blast blower assembly（12V) 送风机总成
3 Bolt, spring washer and plain washer assembly 螺栓弹垫平垫组合件
4 Hex flange face bolt 六角法兰面螺栓
42
5 Nut 螺母
6 self-drilling screw 组合自攻钉
26
□ Condenser and bracket 冷凝器及支架总成
12
20
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1 condenser assembly 冷凝器总成
2 Condenser left bracket 冷凝器左支架
3 condenser right bracket unit 冷凝器右支架总成
4 Six angle bolt 六角法兰螺栓
5 hexagon flange nuts 六角法兰面螺母
□ Compressor 压缩机装置
42
26
1 air-conditioning compressor assembly 压缩机总成

12
2 Inner hexagonal screw 内六角圆柱头螺钉

20
4 spring washer 弹簧垫圈
□ A/C controller 空调控制器

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1 controller assembly unit 控制器总成
2 Instrument station crew area shield installed snaps 仪表台乘员区下护板安装卡扣
3 self-drilling screw 组合自攻钉
□ Bottom air blower 地脚风道装置
42
1 pipeline middle 地角风中间风道
2 pipeline left 地角风左风道
26
3 pipeline right 地角风右风道
4 Button(1) 地角风道安装卡扣㈠
12
5 Button(2) 地角风道安装卡扣㈡
□ Cooling pipe 制冷管路装置

20
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1 hexagon flange bolts 六角法兰面螺栓
2 compressor inspiration pipe assembly 压缩机吸气管总成
3 condenser outlet fluid pipe assembly 冷凝器出液管
4 pipe clip 管夹
5 hexagon nuts with flange 六角法兰面螺母
6 pipe clip 管夹
7 Heater pipes clip I 暖风管夹 I
8 Hexagon flange bolts 六角法兰面螺栓
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11 clip 管夹
26
13 protected pipe clip 带保护管卡

12
14 clip 管夹
15 compressor exhaust pipe assembly 压缩机排气管总成

20
16 fuel pipe bracket 燃油管支架
17 bracket 支架
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□ Heating pipe 制暖管路

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1 warm bellows water outlet pipe 暖风箱出水管
2 warm bellows water inlet pipe 暖风箱进水管
3 warm bellows steel pipe assembly 暖风钢管总成
4 engine outlet pipe 发动机出水管
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5 engine inlet pipe 发动机进水管
6 bracket 暖风水管支架 A
26
7 Heater pipes clip I 暖风管夹 I
8 clip Ⅱ 暖风管夹Ⅱ
12
9 two hole clips 两孔管夹
10 Hexagon flange bolts 六角法兰面螺栓

20

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Remark: Pictures above are for typical parts, not including slight difference parts between different models.
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III. Assembling/ Disassembling and adjustment 拆装与调整
1、Attention 注意事项
□ Please follow notices below when checking and maintaining A/C, otherwise it may cause vehicle
damage or personal injury.
检查和维修空调系统时必须遵守必要注意事项，否则可能造成车辆损坏和人身伤害。
□ Maintain A/C system attention, A/C system detection and method of fill refrigerant, refer to
42
“Overview and maintenance”.
维修空调注意事项、空调检查及加注制冷剂方法，详见《概述与保养分册》。
26
□ Recycle refrigerant when disassembling A/C system.
拆卸空调系统时，应先回收制冷剂。
12
2、Disassemble and assemble cold and warm controller unit assembly 拆装冷暖主机单元总成
20
□ Disassemble cold and warm controller unit assembly,

disassembly sequence is recycle, negative pole,
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instrument desk, air duct of feet blowing，cold and warm

controller unit assembly，framework of instrument desk,
ground and fixed bolt& connector of airblower.
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拆解冷暖主机单元总成，拆解顺序为回收制冷剂、蓄
电池负极、仪表台、地脚风道、冷暖主机单元总成与
仪表台骨架、地板、鼓风机的固定螺栓和接插件
□ Disconnect the negative pole of battery
断开蓄电池负极
□ Disassemble instrument desk （ Please refer to

disassembly instrument desk ）
拆卸仪表台；【参考仪表台的拆卸】
□ Disassemble air duct of feet blowing : remove the
fixed clip of the air duct, remove the air duct from cold
and warm controller unit assembly
拆卸地脚风道：断开地脚风道固定卡扣，从冷暖主机
单元上取下地脚风道
□ Remove the fixed bolts of framework of instrument
42
desk, ground and fixed bolt of airblower.
拆卸冷暖主机单元总成与仪表台骨架、地板、鼓风机
26
的固定螺栓
12
20
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□ Disconnect the connector, remove cold and warm
controller unit assembly
断开连接插头，取出冷暖主机单元总成
Assembling: opposite sequence of disassembly
42
26
3、Disassemble evaporator assembly 拆解蒸发器总成
12
□ Disassemble evaporator, disassembly sequence: remove
the bolts and clips of up cover and bottom cover of cold
and warm controller unit assembly and temperature
20
sensor.
拆解蒸发器总成，拆解顺序为冷暖主机单元上下壳体
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与上壳体连接的螺钉和卡扣、温度传感器
□ Remove the screws and clips of up cover and bottom

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cover of cold and warm controller unit assembly.
拆卸冷暖主机单元上下壳体与上壳体连接的螺钉和
卡扣
□ Remove the temperature sensor.
取出温度传感器
□ Remove the evaporator assembly.
42
取出蒸发器总成
26
12
Assembling : opposite sequence of disassembly
20
4、Disassemble air blower assembly 拆解鼓风机总成

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□ Disassemble air blower assembly, disassembling

sequence: remove the bottom plate of instrument,
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disconnect the negative pole of battery , remove the

fixed bolt and connector.
拆解鼓风机总成，拆解顺序为蓄电池负极、仪表板下
护板总成、鼓风机固定螺栓和接插件
□ Remove the bottom plate of instrument (please refer to

remove the bottom plate of instrument)
拆卸仪表板下护板总成；【参考仪表下护板的拆卸】
□ Remove the fixed bolt of air blower.
42
断开鼓风机固定螺栓
26
12
20
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□ Disconnect cold and warm controller unit assembly and

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air blower assembly.
断开冷暖主机单元线束总成与鼓风机总成的接插件
□ Remove air blower
取出鼓风机总成
Assembling : opposite sequence of disassembling
42
26
5、Disassemble condenser (with fan) assembly 拆解冷凝器带风扇总成
12
□ Disassemble condenser (with fan) assembly,
disassembly sequence: recycle refrigerating medium,
negative pole of battery, pipe connecting, bolts and
20
connectors of Condenser and water tank
拆解冷凝器带风扇总成，拆解顺序为回收制冷剂、蓄
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电池负极、管路连接、冷凝器与水箱连接的螺栓和接
插件
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□ Disconnect negative pole of battery
□ Move the vehicle to maintenance trench，disconnect the
pipe
将车开到地沟，在地沟断开管路连接
□ Remove the bolt of Condenser and water tank
42
拆除冷凝器与水箱连接的螺栓
26
12
□ Disconnect the connector, remove the condenser.
20
断开接插件，取出冷凝器
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Assembly : opposite sequence of disassembly

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6、Disassemble compressor assembly 拆解压缩机总成
□ Disassemble compressor assembly, disassembly

sequence: recycle refrigerating medium, negative pole of
battery, switch harness of A/C clutch, high & low
pressure connector pipe, driving belt of compressor and
fixed bolts of compressor.
拆解压缩机总成，拆解顺序为回收制冷剂、蓄电池负
极、空调离合器开关线束、高低压连接管道、压缩机
驱动皮带、压缩机固定螺栓
42
26
□ Disconnect switch harness of A/C clutch.
断开空调离合器开关线束
12
20
□ Screw off the fixed bolt of pipe, disconnect the high &
C-
low pressure connector pipe
拧下管道固定螺栓，然后脱开高低压连接管道
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□ Loose the nut of tensioningwheel， loose the adjust bolt

of tensioningwheel, remove the driving belt of
compressor.
松开张紧轮固定螺母，然后旋松张紧轮调节螺栓，拆
下压缩机驱动皮带
□ Remove the fixed bolt of compressor, remove the
compressor.
拆下压缩机固定螺栓，取出压缩机
42
26
12
Assembly : opposite sequence of disassembly, pay attention to following items:
20
□ Before assembling, please add the compressor oil back into the compressor, and tighten up the oil
adding port bolt.
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安装前，将压缩机油重新注入压缩机内，并拧紧机油加注孔螺栓。
□ Require torque: require torque for compressor, please refer to maintenance manual.
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拧紧力矩：压缩机螺栓安装拧紧力矩，具体请参考《概述与保养分册》。
□ After assembly, please adjust the belt density: release 98N force to the center of the belt, the
deflection of the belt is 8mm~11mm.
安装后，请调整皮带张紧度，皮带中间位置垂直施加 98N 的力：皮带变形在：8mm～11mm。
□ After assembling and refrigerating medium adding, please check whether there is leakage or not.
安装后，重新加注制冷剂后，检查管路是否泄漏。
7、Disassemble the A/C control panel 拆解空调控制面板

□ Please refer to disassemble the A/C control panel
拆解空调控制面板，【参考空调控制面板的拆卸与安装】
8、Disassemble expansion valve 拆解膨胀阀总成
□ Disassemble expansion valve, disassembly sequence:

recycle refrigerating medium, negative pole of battery,
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fixed bolts of refrigerating pipe (include expansion
valve) and cold and warm controller unit assembly, gas
intake pipe of compressor, connecter of compressor
26
discharging pipe and refrigerating pipe (include
expansion valve), fixed bolt of refrigerating pipe
12
(include expansion valve) locates on the bottom of the
cab, fixed bolt of refrigerating pipe (include expansion
valve) locates on the front panel of the cab，connector of
20
engine harness and pressure switch, fixed bolts of

expansion valve assembly and refrigerating pipe.
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拆解膨胀阀总成，拆解顺序为回收制冷剂、蓄电池负
极、制冷管路带膨胀阀总成与冷暖主机单元连接的膨
胀阀固定螺栓、压缩机吸气管总成和压缩机排气管总
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成与制冷管路带膨胀阀总成的连接、制冷管路带膨胀
阀总成在驾驶室底部的固定螺栓、制冷管路带膨胀阀
总成在驾驶室前围的固定螺栓、发动机线束总成与压
力开关的接插件、膨胀阀总成与制冷管路固定螺栓
□ Disconnect the negative pole of battery.
□ Remove the fixed bolts of refrigerating pipe (include
42
expansion valve) and cold and warm controller unit
assembly
26
将制冷管路带膨胀阀总成与冷暖主机单元连接的膨
胀阀固定螺栓拆卸
12
□ Remove the gas intake pipe of compressor, remove the
connector of compressor discharging pipe and
20
refrigerating pipe (include expansion valve)
拆卸压缩机吸气管总成、压缩机排气管总成与制冷管
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路带膨胀阀总成的连接
□ Remove the fixed bolt of refrigerating pipe (include

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expansion valve) locates on the bottom of the cab
拆卸制冷管路带膨胀阀总成在驾驶室底部的固定螺
栓
□ Remove the fixed bolt of refrigerating pipe (include
expansion valve) locates on the bottom of the cab
拆卸制冷管路带膨胀阀总成在驾驶室前围的固定螺
栓
□ Disconnect the connector of engine harness and pressure
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switch
断开发动机线束总成与压力开关的接插件
26
12
□ Remove the fixed bolts of expansion valve assembly and
refrigerating pipe. Remove the expansion valve
20
assembly
拆卸膨胀阀总成与制冷管路固定螺栓，取下膨胀阀总
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成
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Assembling : opposite sequence of disassembling, pay attention to following items:
□ After refrigerating medium adding, please check whether there is leakage or not.
重新加注制冷剂后，检查管路是否泄漏。
IV. Faults diagnosing and solution 故障诊断与处理
□ Warm wind performance diagnosing 暖风性能诊断
Process 步骤 Operation 操作 YES 是 NO 否
diagnose the fault according to symptom? Or indicate from

Turn to process 2
1 other diagnosing form? —
转至步骤 2
是否根据“症状”或其它诊断表的指示来执行该诊断？
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①Start the engine 起动发动机。
②Engine idle running 使发动机怠速运转。 Turn to process 3 Turn to process 9

2
Is the engine working in a normal working temperature? 转至步骤 3 转至步骤 9
26
发动机是否到达了正常工作温度？
①Engine idle running 使发动机怠速运转。

12
②Select feet blow mode 选择“（地板送风）”模式。
③Select lowest speed of air blower 选择最小鼓风机转速。

Turn to process 7 Turn to process 4
④Select warmest temperature 选择最暖温度设置。
20
3
转至步骤 7 转至步骤 4
⑤Touch the inlet/outlet hoses of heater core 触摸感觉加热
器芯处的加热器进口和出口软管的温度。
Is the inlet hose warmer than outlet hose?是否感觉加热器进

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口软管比出口软管暖？
①Put thermometer on the center air outlet 将温度计置于中央

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出风口处。
②Put thermometer on outlet hose of heater core 将温度计固

定在加热器芯出口加热器软管上。
③Select the fastest speed of the blower 选择最大鼓风机转

速。
④Select the warmest temperature 选择最暖温度设置。 Turn to process 5 Turn to process 6

4
⑤record the temperature of following position:记录以下位
置的温度：
Center panel air outlet 中央仪表板出风口。
outlet hose of heater core 加热器芯出口加热器软管。
⑥Compare the temperature recorded 比较记录的温度。
Is the two value closed?两个温度读数是否接近？
①Check whether there is leakage in following parts 检查车
辆以下部位是否有冷气泄漏情况，并进行修理：
ventilation door of inner recycle 前罩板。内循环风门。 Turn to process

5 Warm wind, ventilate and A/C module cover 暖风、通风与空 10 —
调系统模块壳体。转至步骤 10
②maintenance 进行必要的维修。
Is the maintenance finish?修理是否完成？
①Check the working state of temperature ventilation door.检
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查温度风门的运行情况。 Turn to process
6 10 —
②maintenance 进行必要的维修。
转至步骤 10
26
①Turn off the engine 关闭发动机。
②Wash the heater core in opposite direction 反向冲洗加热

12
器芯。
③Start the engine 起动发动机。

Turn to process
④Select ground blowing mode 选择“（地板送风）”模式。 Turn to process 8 10
20
7 ⑤Select lowest blower speed.选择最小鼓风机转速。转至步骤 8

转至步骤 10
⑥Select warmest temperature.选择最暖温度设置。
⑦Touch the inlet/outlet hoses of heater core 触摸感觉加热

C-
器芯处的加热器进口和出口软管的温度。

JA
Turn to process
Replace the heater core 更换加热器芯。
8 10 —
转至步骤 10
Repair the fault of engine low temperature 修理发动机温度转至步骤 10

9 过低的故障。
Turn to process —
Is the maintenance finished?修理是否完成？ 10
Run the system, check the performance after the

maintenance.运行系统，检验修理效果。 Turn to process 2
10 normal 系统正常
转至步骤 2
Is the fault solved?是否发现并排除了故障？
□ Defrost inadequacy 除霜不充分
Diagnose the fault according to symptom? Or indicate from Turn to process 2

1 other diagnosing form?是否根据“症状”或其它诊断表的 —
指示来执行该诊断？转至步骤 2
②Select defrost mode 选择“DEFROST （除霜）”模式。 Turn to process

Turn to process 3
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2 10
③Select fastest blower speed.选择最大鼓风机转速。
转至步骤 3
转至步骤 10
whether there is enough air coming out from Defroster
outlet？是否有充足的空气从除霜器出口流出？
26
Detect the working temperature of engine 测量发动机运行
Turn to process
温度。 Turn to process 4 8
3
Is the engine at the normal working temperature?发动机是否转至步骤 4
12
转至步骤 8
达到了正常运行温度？
①Select the lowest blower speed.选择最小鼓风机转速。

20
②Select the warmest temperature.选择最高温度设置。

Turn to process Turn to process
4 ③Touch the inlet/outlet hoses of heater core 触摸感觉加热 11 5
器芯进口和出口软管温度。
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Detect the working state of A/C compressor.测试空调压缩转至步骤 6

转至步骤 7
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5 机的运行情况。
Turn to process
Turn to process 7
Is the compressor working?空调压缩机是否工作？ 6
Turn to process
Replace A/C compressor 更换空调压缩机。
6 14 —
Is the maintenance finished?修理是否完成？
转至步骤 14
Process A/C performance test 执行空调系统性能测试。 Turn to process Turn to process

7 14 12
Satisfy the requirement or not?空调系统运行情况是否符合
规定？转至步骤 9 转至步骤 12
Maintenance on engine low temperature 修理发动机温度过 Turn to process

8 低的故障。 14 —
Is the maintenance finished?修理是否完成？转至步骤 14
Check whether the inner recycle ventilationdoor works
normal or not 检查内循环风门是否正常工作。
9 14 13
inner recycle ventilationdoor works normal or not？内循环
风门是否工作正常？
Turn to process
Maintenance on blowing fault.修理关于出风的故障。
10 14 —
转至步骤 14
Turn to process
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Maintenance on warm wind fault.修理暖风故障。
11 14 —
转至步骤 14
26
Maintenance on A/C performance.修理关于空调性能的故 Turn to process
12 障。 14 —
12
Maintenance on inner recycle ventilationdoor fault.修理关于内 Turn to process
13 循环风门的故障。 14 —
20
Run the system, check the performance after the Turn to process
Normal
14 maintenance.运行系统，检验修理效果。 2
系统正常
Is the fault solved?是否发现并排除了故障？转至步骤 2
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□ Blower motor noise diagnose 鼓风机电机噪声诊断
diagnose the fault according to symptom? Or indicate from Turn to process 2

1 other diagnosing form?是否根据“症状”或其它诊断表的 —
指示来执行该诊断？转至步骤 2
Check whether there is chippings in air inlet grilling 检查进

Turn to process 8 Turn to process
2 风口格栅是否有碎屑。
转至步骤 8 3 转至步骤 3
Are there chippings?是否有碎屑存在
1. Sit in the vehicle 坐在车内。 Turn to process 4 Turn to process

3
2. Close the windows and doors.关闭车门和车窗。转至步骤 4 11
3. When the engine is turned off, turn the ignition lock to ON 转至步骤 11
position.在发动机关闭的情况下，将点火开关置于 ON 位
置。
4. Run the blower in every speed and mode to find the noise.
在所有转速和模式下运行鼓风机电机，以确定噪音在何
处、何时出现。
Is the noise obvious during blower running?鼓风机运行期间

的噪音是否明显？
Touch the blower cover, check whether there is vibration

Turn to process
42
during working.触摸鼓风机壳体，检查鼓风机电机在各个 Turn to process 6
4 5
转速下运行时是否振动。
转至步骤 6
转至步骤 5
Whether there is obvious vibration?是否存在过度振动？
26
Listen the sounds of motor in every speed 倾听各个转速下
鼓风机电机的声音。 Turn to process 9 Turn to process
5
Is there abnormal noise in the motor ?鼓风机电机是否发出转至步骤 9 11 转至步骤 11
12
吱吱声或者唧唧声等噪音 ?
1. Remove the blower motor.拆下鼓风机电机。
2. Check whether there is foreignmatter on motor impeller.检

20
查鼓风机电机叶轮是否有异物沉积。
6 3. Check whether there is foreignmatter on blower motor 检
查鼓风机电机是否有异物沉积。转至步骤 8 7 转至步骤 7
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Check whether there is foreignmatter on blower or blower

motor 是否在鼓风机电机或者鼓风机电机叶轮上发现异
物？
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check whether there are following states:检查鼓风机电机是

否存在以下状况：
Impeller craze 叶片开裂。

7 Fixed bolts got loose 叶轮固定件松动。
转至步骤 9 10 转至步骤 10
Incorrect position of the impeller 叶轮定位不正确。
Are there any failure mentioned above happened?是否发现

上述任何故障？
Turn to process
Clean the unnecessary stuff 清除异物。
8 10 —
Is the operation finished?是否完成操作？
转至步骤 10
9 Replace the blower motor.更换鼓风机电机。 Turn to process —

Is the maintenance finished?修理是否完成？ 11
转至步骤 11
Turn to process
Assemble the blower motor 安装鼓风机电机。
10 11 —
转至步骤 11
Run the system, check the performance after the maintenance

Normal Turn to process
11 运行系统，检验修理效果。
系统正常 2 转至步骤 2
Have the faults been solved?是否发现并排除了故障？
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□ Refrigerating system noise diagnose 制冷系统噪声诊断
Process 步骤
26
Operation 操作 YES 是 NO 否
12
diagnose the fault according to A/C fault symptom?
Or indicate from other diagnosing form?是否根据 Turn to process 2
1 —
“空调系统症状”或其它诊断表的指示来执行该诊转至步骤 2
断？
20
Check the driving belt and belt tensioner, find out

whether there are faults, and solve the faults.检查附 Turn to process 3
2 —
件传动皮带和传动皮带张紧器是否有任何故障，必转至步骤 3
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要时排除故障。
start the engine and check the noise of compressor 运

行发动机并检查压缩机是否有噪音： Turn to process 5 Turn to process 4
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3
Does the noise last more than 30 minutes?噪音是否转至步骤 5 转至步骤 4
持续 30 秒钟以上？
Liquid hammering noise

is a normal performance.
Run the engine for several minutes.使发动机运行几 Stop the system in high
分钟。 temperature environment
for long time, and
Stop the engine for 1minute.停机 1 分钟。 Turn to process 6
4 temperature decreased
Restart the engine 重新起动发动机。转至步骤 6 for one night, this will
cause the noise 出现液击
Is there noise in this progress?使用本程序是否检测
噪声是一种常见现象。
到噪音？
在较高环境温度下长时
间关闭系统，然后经过
一整夜，环境温度下降
时，就会发生这种情况。
Check whether the refrigerating medium adding

value is enough or not 检测系统制冷剂加注量是否
Turn to process 7 Turn to process 8 转至步
5 过低。
转至步骤 7 骤 8
is refrigerating medium enough?系统制冷剂是否足
够？
Check whether the expansion valve is stuck on the

Replace
close or open position.检查热膨胀阀是否卡在闭合 Turn to process 7 转至步
6 expansion valve
或打开位置。骤 7
42
更换膨胀阀
Is the valve stuck?热膨胀阀是否卡在打开位置？
Check if compressor bolt or A/C pipe scratching with

tighten up the
26
vehicle body.检查压缩机螺栓和/ 或空调管路是否
bolts or Turn to process 8 转至步
7 刮碰车身部件。
紧固螺栓和/或骤 8
Is there any bolts getting loose?是否有安装螺栓松
重设管路
12
动。
①Recycle the refrigerating medium and replace the

compressor 回收制冷剂并更换压缩机。
System check
20
②Add the refrigerating medium again.重新加注系 Turn to process 1

8 finish 系统检查
统。
完毕转至步骤 1
Check whether the gas pressure is in required range.
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气体压力是否在规定范围内。
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□ A/C actuator noise diagnosing 空调系统执行器噪声诊断

1 other diagnosing form?是否根据“症状”或其它诊断表的指 —
示来执行该诊断？转至步骤 2
②finish following sets:完成以下所有设置：

2 blower motor speed 鼓风机电机转速
warm, ventilate and A/C mode 暖风、通风与空调系统模式
temperature control set 温度控制设置
③confirm the noise type 确定噪音的类型：
“bang” or scraping sound 刮擦声，砰砰声滴答/ 咔嗒声、

sound “Tick tick”唧唧声或嘎吱声
“sound of wind”“whistling”呼呼风声/ 啸叫声
when selecting mode or temperature setting, is the “bang” or

scraping sound obvious?当选择模式或温度设置时，刮擦声
或者砰砰声是否明显？
When speed of blower motor gets slow down, is the sound

“Tick” exist but getting volume down?当鼓风机电机转速降 Turn to process 6 Turn to process 4
42
3
低时，滴答/ 咔嗒声、唧唧声, 吱吱声或刮擦声是否仍存转至步骤 6 转至步骤 4
在但声音减小？
Is the “sound of wind”“whistling” exist in every modes, but Turn to process 6 Turn to process 5
26
4 not all temperature sets.是否在所有模式下呼呼风声/ 啸叫
声都明显，但并非所有温度设置下都如此？转至步骤 6 转至步骤 5
Is the “sound of wind”“whistling” just exist in defrost or Turn to process 6 Turn to process 6
12
5 ground wing mode?是否仅在除霜或地板送风模式下有明
显的呼呼风声/ 啸叫声？转至步骤 6 转至步骤 6
Remove the instrument panel bracket 拆下仪表板托架。

20
①Check whether the ventilation door could work normally.

检查风门运行是否正常。
6 ②Check whether there is clocking or foreign matter in air
C-
hose.检查风管是否堵塞或有异物。
Is the mentioned situation happened?是否发现任何上述情

况？
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Check the ventilation door of modes or temperature and

Turn to process
sealing element been warped or crack.检查模式、温度风门和 Turn to process 8
7 10
密封件是否有翘曲或开裂。
转至步骤 8
转至步骤 10
is the ventilation door normal.风门是否处于正常状态？
Replace ventilation door or sealing element 更换相应的风门 Turn to process

8 和/ 或密封件。 10 —
Turn to process
Clean the foreign matters found 清除发现的堵塞物或异物。
9 10 —
转至步骤 10
Turn to process
Assembly the instrument panel bracket 安装仪表板托架。
10 11 —
转至步骤 11
Run the system, check the performance after the maintenance.

System normal Turn to process 2
11 运行系统，以检验修理效果。
系统正常转至步骤 2
Has the fault been solved?是否发现并排除了故障？
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□ Peculiarsmell diagnose 异味诊断
26
1 other diagnosing form?是否根据“症状”或其它诊断表的指 —
示来执行该诊断？转至步骤 2
12
①Stay in vehicle 坐在车内。
②Close the windows and doors.关闭所有车门和车窗。

20
③Start the engine 起动发动机。
④Make the engine working in idling speed and normal

temperature 让发动机在正常工作温度下怠速运转。
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2 ⑤Select the fastest speed of the blower 选择最大鼓风机转

速。转至步骤 3 转至步骤 8
⑥Select the coldest temperature set.选择最冷温度设置。

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⑦Run the blower in every speed and mode and temperature

to confirm the peculiar sell.( musty，smell of cooling liquid,
smell of oil)在所有鼓风机转速、模式以及温度下运行，确
定出现的是哪种气味（霉味、冷却液气味、机油味）。
Check whether there is chippings in filters of warm wind,

ventilate or A/C module or air intake grilling 检查暖风、通风 Turn to process 4 Turn to process 5
3 与空调系统模块总成滤清器和进风口格栅是否有碎屑。
Are there any chippings?是否有碎屑存在？
Turn to process
Clean the chippings 清除所有碎屑。
4 15 —
转至步骤 15
5 Check the carpet is wet or not.检查地毯是否潮湿。 Turn to process 6 Turn to process

Wet or not?地毯是否潮湿？转至步骤 6 14
转至步骤 14
check whether there is following situations.检查是否存在以

下情况：
water leakage appear around the front windshield 前风窗四周

Turn to process
漏水 Turn to process 7
6 14
drain pipe of warm wind, ventilation or A/C is blocked 暖风、转至步骤 7
通风与空调系统模块排水管堵塞转至步骤 14
42
door sealing element leakage 车门密封件四周泄漏
Is there any leakage?是否出现泄漏？
Turn to process
26
Make some necessary maintenance.必要时修理泄漏。
7 15 —
转至步骤 15
12
Turn to process
Is the peculiar smell contains the smell of cooling liquid?异 Turn to process 9
8 12
味是否有冷却液味？转至步骤 9
转至步骤 12
20
检查冷却系统是否有泄漏。 Is there any leakage in 转至步骤 10 转至步骤 12

9 refrigeration system?
是否出现泄漏？Is there any leakage? 10 12
C-
Check whether is coolant liquid leakage inner the vehicle.

Check whether there is film of liquid on front windshield.检 Turn to process Turn to process
10 查车内是否有冷却液泄漏或前风窗玻璃上是否积有一层 11 15
JA
膜。
Does the faults appear?故障是否出现？
Turn to process
Replace the heater core.更换加热器芯。
11 15 —
转至步骤 15

Does the peculiar smell contain the smell of oil?异味是否有 13 15
12
机油味？
①Is there a leakage in engine compartment?检查发动机舱是 Turn to process

13 否有泄漏。 15 —
②Maintenance on oil leakage.修理漏油故障。转至步骤 15
Musty smell could be caused by the mycete in evaporator,

heater core, warm wind , ventilate or A/C module 霉味可能 Turn to process
14 由积聚在蒸发器上、加热器芯或暖风、通风与空调系统模 15 —
块总成内部的霉菌导致。.
转至步骤 15

Normal Turn to process 2
42
Have the faults been solved?是否发现并排除了故障？
26
□ Blower motor failure diagnosing 鼓风机电机不工作诊断

12
①When engine is stopped, turn the ignition lock to ON.在发
动机关闭的情况下，将点火开关置于 ON 位置。
②Select every speed of blower。将鼓风机电机开关置于每 Turn to fault 8 Turn to process 2

1
20
个转速位置。转至“故障 8” 转至步骤 2

can the motor work in any speed?鼓风机电机是否在任何转
速位置都能工作？
C-
①Turn the ignition lock to OFF 将点火开关置于 OFF 位

置。
②Cut off the blower motor 断开鼓风机电机。

JA
③Connect a test light between blower motor battery voltage

circuit and motor control circuit.在鼓风机电机电源电压电
路和鼓风机电机控制电路之间连接一个测试灯。 Turn to process 9 Turn to process 3
2
④When the engine is stopped, turn the ignition lock to ON 在转至步骤 9 转至步骤 3
发动机关闭的情况下，将点火开关置于 ON 位置。
⑤Select every speed of the blower motor 将鼓风机电机开关

置于每个转速位置。
is the light work in every speed?测试灯是否在任何转速下

都点亮？
Detect the battery voltage circuit of the motor is open or Turn to process
Turn to process 4
3 resistance is too large.测试鼓风机电机电源电压电路是否开 15
转至步骤 4
路或电阻过大。转至步骤 15
Detect the circuit of motor circuit is open or resistance is too Turn to process
Turn to process 5
4 large.测试鼓风机电机电路是否开路或电阻过大。 15
转至步骤 5
Has the fault been solved?是否发现并排除了故障？转至步骤 15
①Turn the ignition lock to OFF 将点火开关置于 OFF 位

置。
②Connect the blower motor 连接鼓风机电机。
③Warm wind, ventilate and A/C control module.暖风、通风
42
与空调系统控制模块。 Turn to process
Turn to process 6
5 10
④When engine is stopped, turn the ignition lock to ON 在发
转至步骤 6
动机关闭的情况下，将点火开关置于 ON 位置。转至步骤 10
26
⑤Select every speed of the motor 将鼓风机电机开关置于每
个转速位置。
Can motor work in every speed?鼓风机电机是否在任何转

12
Check the serial data coding or fault 检查串行数据编码或故

6 障。
20
Is there any faults?是否发现故障？
Turn to process
Detect the circuit.测试线路。 Turn to process 8
15
C-
7
Is there any faults? Solved?是否发现并排除了故障？转至步骤 8
转至步骤 15
Detect the circuit of motor switch control circuit is open or

JA
resistance is too large.测试鼓风机电机开关控制电路是否开

8 15 11
路或电阻过大。
Is there any faults? Solved?是否发现并排除了故障？
check whether there is bad contact in blower motor 检查鼓风 Turn to process Turn to process
9 机电机是否接触不良. 15 12
Has the fault been solved?是否发现并排除了故障？转至步骤 15 转至步骤 12
Check whether there is bad contact in the warm wind,

ventilate and A/C control module 检查暖风、通风与空调系
10 15 13
统控制模块是否接触不良。
11 Check whether there is bad contact in media system.检查影 Turn to process Turn to process
音娱乐系统是否接触不良。 15 14
Turn to process
Replace the blower motor 更换鼓风机电机。
12 15
Has the replacing been done?是否完成更换？
转至步骤 15
Replace the warm wind, ventilate and A/C control module 更 Turn to process
13 换暖风、通风与空调系统控制模块。 15
Has the replacing been done?是否完成更换？转至步骤 15
42
Turn to process
Replace the blower switch 更换鼓风机开关。
14 15
Has the replacing been done?是否完成更换？
26
转至步骤 15

12
Has the fault been solved?故障是否已排除？
20
□ Blower motor fault diagnosing 鼓风机电机故障诊断
process 步骤 Operation 操作 YES 是 NO 否

C-
①When the engine is turned off, turn the ignition lock to ON

置。
JA

1 ②Select every speed of the blower motor 将鼓风机电机开关
置于每个转速位置。转至步骤 3 转至步骤 2
is there failure in some speed?是否有鼓风机转速位置不起

作用？
Replace the fuse

Check the ruse of blower motor is fusing or not 检查鼓风机 with same Turn to process 3
2 电机保险丝是否熔断。 specification 用相
转至步骤 3
Is the fuse fusing?保险丝是否熔断? 同电流规格的保
险丝将其更换。
Check the power of the blower 检查鼓风机电机的电源。

3 Though there is power, the motor doesn’t work 尽管有电压，
但是鼓风机电机不运行？
①Run the blower in every speed, run the blower in Integrated
radio control blower control position.在所有的转速下运行
鼓风机，在集成无线电控制鼓风机控制位置运行一次。 Turn to process 8 Turn to process 5
4
②There should be 20 active speeds.应该有 20 个鼓风机转转至步骤 8 转至步骤 5
速有效。
Are all speeds active?是否所有鼓风机转速都有效？
①Connect 2-pin connector in the back of the blower.在鼓风

机电机上向后插入 2 针连接器。
42
②Use Integrated radio control blower working in every
speed.使用集成无线电控制鼓风机，从最低转速开始，在
20 个鼓风机风扇转速位置各运行一次。 Turn to process 8 Turn to process 6
5
③Compare the voltage with the voltage shown in diagram 转至步骤 8 转至步骤 6
26
form 将电压与图示的电压相对比，参见“自动暖风、通风
与空调系统”中的“1.2.1.2 传感器电阻值表”。
Is the voltage closed to the voltage shown in diagram form.电

12
压是否与图示的电压相接近？
Execute the
connect the diagnose tool. Turn to composite test, input switch function,
20
device. Use the diagnose tool to select all 20 speeds.连接故 Integrated radio Turn to process 7
6 障诊断仪。转至复合测试，开关数据。用故障诊断仪增大 control test 执行
/减小软按键选择全部的 20 个鼓风机风扇转速鼓风机开关功能转至步骤 7
Are all speeds active?是否所有转速都有效？的集成无线电控

C-
制测试。
Replace warm wind, ventilate and A/C control module 更换

Turn to process 8
7 暖风、通风与空调系统控制模块。
JA
转至步骤 8
Has the fault been solved?是否发现并排除了故障

□ 空调系统制冷效果差诊断 A/C bad refrigeration diagnosing
Turn to process 2
1 check the gas mix ventilationdoor to find out whether there is replace the
blocking or crack.检查空气混合风门的运行情况以确定其 actuator 更换执转至步骤 2
没有堵塞或破裂。行器
whether there is blocking or crack. on gas mix ventilationdoor

空气混合风门是否破裂或堵塞？
①When the engine is stopped, turn the ignition lock to ON.

在发动机关闭的情况下，将点火开关置于 ON 位置。
②Select every speeds of the blower motor.将鼓风机电机开 Turn to process 3 Turn to fault 7
2
关置于每个转速位置。转至步骤 3 转至“故障 7”
does the motor work in every speeds?鼓风机电机是否在任
何转速位置都能工作？
42
Is the blower motor working in homologous speed?鼓风机电 Turn to process 4 Turn to fault 8
3
机是否在相应的转速下运转？转至步骤 4 转至“故障 8”
26
Turn to “inner
②Select the face wind mode 将模式开关置于面部送风位 recycle fault” of
“auto warm,
12
置。
③Turn the inner recycle switch to ON position.将内循环开 ventilation and
关置于“ON （接通）”位置。 A/C”转至“自动

Turn to process 5 暖
4 ④Check the inner recycle ventilationdoor 观察内循环风门。
20
转至步骤 5 风、通风与空调
⑤Turn the inner recycle switch to OFF position.将内循环开
关置于“OFF （关闭）”位置。系统”中的“空
is the inner recycle ventilationdoor recycling the air through 气内循环故障诊

C-
inner recycle to air exchange position?内循环风门是否从内断帮助”。

循环位置转移到换气位置？

JA
②Clean the fault code in warm, ventilation and A/C module 用

故障诊断仪清除所有储存在暖风、通风与空调系统
控制模块中的故障诊断码。
③Select the coldest temperature on the left A/C switch 将左 replace the
Turn to process 6
5 侧空气温度开关置于最冷位置。 compressor
转至步骤 6
④Select the double air supply position 将模式开关置于双层更换压缩机
送风位置。
⑤Select the fastest speed of the blower motor 将鼓风机电机

开关置于高速位置。
Does the A/C compressor work?空调压缩机是否工作？
6 Execute the A/C performance test.执行空调系统性能测试。 Turn to process 9 Turn to process 7
Assembly a thermometer near the temperature sensor in the

vehicle.在车内空气温度传感器附近安装一只温度计。 Turn to process 9 Turn to process 8
7
Is the thermometer within 3°C(5°F) ?温度计温度是否在转至步骤 9 转至步骤 8
3°C(5°F) 以内？
Check whether there is leakage or blocking in air intake pipe.

Turn to process 9
8 检查吸气管是否漏气或堵塞。 —
转至步骤 9
42
系统正常 Turn to process 1
System normal 转至步骤 1
□ Lack of warm wind diagnosing 暖风不足诊断 26

12
20
Check the working situation of air mix ventilationdoor to

confirm whether there is block or crack.检查空气混合风门 replace the
Turn to process 2
1 的运行情况以确定其没有堵塞或破裂。 actuator
转至步骤 2
Is there block or crack in air mix ventilation door?空气混合
C-
更换执行器
风门是否破裂或堵塞？
Select every speed of the blower motor 将鼓风机电机开关置

JA
于每个转速位置。 Turn to process 3 转至“故障 7”

2
Can blower motor work normally in every speeds?鼓风机电转至步骤 3 Turn to fault7
机是否在任何转速位置都能工作？
Does the motor works in homologous speed.鼓风机电机是否 Turn to process 4 Turn to fault 7
3
在相应的转速下运转？转至步骤 4 转至“故障 8”
①Start the engine 起动发动机。 Turn to “inner

recycle fault” of
②Select the face wind mode 将模式开关置于面部送风位
“auto warm,
置。 Turn to process 5
4 ventilation and
③Turn the inner recycle to ON position 将内循环开关置于转至步骤 5 A/C”转至“自动
“ON （接通）”位置。暖
④Check the inner recycle ventilationdoor 观察内循环风门。风、通风与空调
⑤Turn the inner recycle switch to OFF position.将内循环开系统”中的“空
关置于“OFF （关闭）”位置。
气内循环故障诊
is the inner recycle ventilationdoor recycling the air through
断帮助”。
inner recycle to air exchange position?内循环风门是否从内
循环位置转移到换气位置？
Turn the temperature switch to OFF position 将温度开关置

于“OFF （关闭）”位置。
5 When requiring warm or defrost, is there situation that it’s too
cold in the vehicle?当要求暖风或除霜时，是否出现车内太
42
冷的情况?

replace the Turn to process 8
②Close the warm wind, ventilation and A/C control system.
26
6 compressor 更换
关闭暖风、通风与空调控制系统。
压缩机转至步骤 8
Does the A/C compressor work?空调压缩机是否工作？
12
check whether there is the following situation 检查冷却系
统是否存在以下情况：
liquidlevel of cooling liquid is too low 冷却液液位过低。

20
Driving belt is loose or worn 附件传动皮带松动或磨损。
Leakage on heater hose or radiator hose 散热器软管或加热

Turn to process
器软管泄漏。 Turn to process 8
7 10
C-
Radiator hose or heater hose is tangledup 散热器软管或加热转至步骤 8

转至步骤 10
器软管扭结。
Sealing element of radiator cover is lost 散热器盖压力密封

JA
件缺失。
Leakage on radiator 散热器盖泄漏。
①Select the face wind 将模式开关置于面部送风位置。
②When engine is stopped, turn the ignition lock to ON

position 在发动机关闭的情况下，将点火开关置于 ON 位
置。 Turn to process
Turn to process 9
8 ③Select the fastest speed of the blower motor.将鼓风机电机 10
开关置于最大转速位置。④Cover a piece of 5cm paper on 转至步骤 9
转至步骤 10
the air inlet of sensor, check whether there is air flow through
vehicle temperature sensor.将一张 5 厘米（2 英寸）见方
的纸片盖在传感器进风口上，检查是否有气流通过车内空
气温度传感器。
Does the paper stay in its original location?纸是否停留在原
位？
Check whether there is leakage or block in aspirator pipe.检 Turn to process

9 查吸气器的管道是否漏气或堵塞。 10 —
Has the fault been solved?是否发现并排除了故障？转至步骤 10

42
□ Air outlet failure diagnosing 出风不良
26

12
②Turn the mode switch to OFF position.将模式开关置于 Turn to process 2 Turn to process 2
1 OFF 位置。
Does the blower motor stop working?鼓风机电机是否停止
20
运转？
①Turn the mode switch to ventilation position 将模式开关

C-
置于通风位置。
②Select every speeds of the blower speed.将鼓风机电机开 Turn to process 4 Turn to fault 7
2
关置于每个转速位置。转至步骤 4 转至“故障 7”
can blower work in every speed?鼓风机电机是否在任何转
JA
Does the blower motor work in homologous speed?鼓风机电 Turn to process 4 Turn to fault 8
3
机是否在相应的转速下运转？转至步骤 4 转至“故障 8”
check whether the mode ventilationdoor is damage/ block or

Change mode
not 检查模式风门是否破损或堵塞 Turn to process 5
4 ventilation
whether the mode ventilationdoor is damage/ block or not 模转至步骤 5
更换模式风门
式风门是否破损或堵塞。

Is the fault been solved?故障是否已排除？
□ Inner recycle fault diagnosing 内外循环故障诊断
①When engine is stopped, turn the ignition lock to ON

置。
②Select fastest speed of blower motor.将鼓风机电机开关置
42
于最大转速位置。
③Select the double air supply mode.将模式开关置于双层送

风位置。 Turn to process 2 Turn to process 2
1
26
④Turn the inner recycle switch to air exchange position 将内转至步骤 2 转至步骤 2
循环开关置于换气位置。
⑤Turn the inner recycle switch to inner recycle position 将内

12
循环开关置于内循环位置。
is there sound of air flow when the inner recycle switch is

turned to inner recycle position 当内循环开关置于内循环位
置时，是否听到气流的声音发生变化？
20
①Turn the inner recycle switch to air exchange position 将内

循环开关置于换气位置。
C-
②观察内循环执行器的驱动轴。
2 ③Turn the inner recycle switch to inner recycle position 将内
循环开关置于内循环位置。
Check and confirm if the drive axle of the inner recycle is

JA
working .内循环执行器的驱动轴是否转动？
①Check the drive axle of the inner recycle 观察内循环执行

器的驱动轴。
②Use diagnose tool to make the inner recycle actuator turned Turn to process
Turn to process 4
3 to inner recycle position and air exchange position.使用故障 11
转至步骤 4
诊断仪，指令内循环执行器转到内循环位置和换气位置。转至步骤 11
Check the drive axle of inner recycle actuator working or not.
内循环执行器的驱动轴是否转动？
①Turn the ignition lock to OFF position 将点火开关置于

Turn to process
OFF 位置。 Turn to process 5
4 12
②Cut off the inner recycling actuator 断开内循环执行器。转至步骤 5
转至步骤 12
③When engine is stopped, turn the ignition lock to ON
置。
④Use the test light which has a good grounding to detect the
ignition 3 voltage circuit of inner recycle actuator.使用连接
至良好搭铁的测试灯，探测内循环执行器的点火 3 电压电
路。
Does the test light work?测试灯是否点亮？
①Connect a test light between control circuit A of inner

recycling actuator ventilation door and voltage circuit of
42
ignition lock 3.在内循环执行器的风门控制 A 电路和点火
3 电压电路之间连接一个测试灯。
5 ②Use diagnose tool to make the inner recycle actuator turn to
inner recycle position and air exchange position.使用故障诊转至步骤 6 转至步骤 7
26
断仪，指令内循环执行器转到内循环位置和换气位置。
Does the test light lighten after the diagnose tool’s operation?
执行任一指令时测试灯是否点亮？
12
①Connect a test light between control circuit B of inner
recycle actuatorventilationdoor and voltage circuit of ignition
lock 3.在内循环执行器的风门控制 B 电路和点火 3 电压
20
电路之间连接一个测试灯。②Use diagnose tool to make the

6 inner recycle actuator turn to inner recycle position and air
exchange position.使用故障诊断仪，指令内循环执行器转转至步骤 9 转至步骤 8
到内循环位置和换气位置。
C-
Does the test light lighten after the diagnose tool’s operation?
执行任一指令时测试灯是否点亮？
Test the control circuit of inner recycle actuator, to find out

JA
that whether the circuit is open/ Resistance is too large, Short

circuit to ground, short to voltage or not 测试内循环执行器
7 15 11
的控制电路是否开路、电阻过大、对搭铁短路或对电压短
路。转至步骤 15 转至步骤 11
Test the control circuit B of inner recycle actuator, to find out

that whether the circuit is open/ Resistance is too large, Short
circuit to ground, short to voltage or not 测试内循环执行器
8 15 11
的控制 B 电路是否开路、电阻过大、对搭铁短路或对电
压短路。转至步骤 15 转至步骤 11
9 check the inner recycling ventilation door and inner recycling

actuator to confirm the following situation:检查内循环风门
和内循环执行器是否存在以下状况： 15 10
malposition of recycling actuator 循环执行器错位。转至步骤 15 转至步骤 10
linkmechanism damage or block 连杆机构断裂或卡滞。
Inner recycle ventilation door damage or block 内循环风门断

裂或卡滞。
There is foreign matter block the inner recycle ventilation

door in the whole active range.有障碍物阻碍内循环风门在
整个活动范围内移动。
Sealing element of inner recycle ventilationdoor lost 内循环
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风门密封件缺失。
Sealing element of inner recycle ventilationdoormalposition

内循环风门密封件错位。
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Check whether there is bad contact in harness connector of

inner recycle actuator 检查内循环执行器的线束连接器处是
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10 15 13
否接触不良。
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Is there bad contact in harness connector of warm wind,

ventilate or A/C control module 检查暖风、通风与空调系统
11 15 14
控制模块线束连接器处是否接触不良。
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Maintenance on ignition voltage circuit of inner recycle Turn to process

12 actuator 修理内循环执行器的点火电压电路。 15 —
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is the maintenance finished?是否完成修理？转至步骤 15
Turn to process
Replace the inner recycle actuator 更换内循环执行器。
13 15 —
Is the replacement finished?是否完成更换？
转至步骤 15
Replace the warm wind, ventilate or A/C control module 更换 Turn to process
14 暖风、通风与空调系统控制模块。 15 —
Is the replacement finished?是否完成更换？转至步骤 15
Run system,check maintenance effect.运行系统，检验修理效

15 果。
Is fault eliminated?故障是否已排除？
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Compiling 编制 Penny.Wang 王海艳

Audit 审核 Youwang.Zhang 张有旺
Approve 批准
WORKSHOP MANUAL
维修手册
HFC1121P70K1E1- LG016
Chassis
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底盘分册
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Chassis 底盘分册
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contents in this Manual. This Manual shall be
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本手册用于帮助 JAC 授权的专业维修技术人员， Chassis

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对江淮汽车提供有效正确的保养及维修。为确保江淮底盘分册
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江淮汽车部门：客户服务部
All rights reserved, without the written consent of JAC, it may not be translated all or a part
of this manual.
Tel：0086-0551-2296644
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Fax：0086-0551-2296633
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ChapterⅠClutch
第一章离合
I Overview 概述
Clutch is located in the flywheel housing between engine and transmission, Fixing clutch assembly
on the surface of fly wheel with screw and the clutch output shaft is the transmission input shaft. In the
process of driving, the operator can press or release the clutch pedal, to let the engine and transmission
temporarily detached and gradually engaged, so as to cut or pass the input power through engine to
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transmission.
离合器位于发动机和变速箱之间的飞轮壳内，用螺钉将离合器总成固定在飞轮的后平面上，离
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合器的输出轴就是变速箱的输入轴。在汽车行驶过程中，驾驶员可根据需要踩下或松开离合器踏板，
使发动机与变速箱暂时分离和逐渐接合，以切断或传递发动机向变速器输入的动力。
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Clutch is the common parts in the mechanical transmission, which could make the drive system be
detached or engaged. The basic requirements are: engage smoothly, disengage quickly and thoroughly;
adjust and repair conveniently; small dimensions; light weight; good ability in wearing and sufficient
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cooling capacity; easy and convenient to operate.
离合器是机械传动中的常用部件，可将传动系统随时分离或接合。对其基本要求有：接合平稳，
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分离迅速而彻底；调节和修理方便；外廓尺寸小；质量小；耐磨性好和有足够的散热能力；操作方
便省力。
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The clutch important parameters
离合系统重要参数
Project 项目 Date 参数
Pressure plate static torque

465.3N
压盘静传递扭矩
Moment of inertia of the clutch assembly

0.137kg.mm
离合器总成转动惯量
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Maximum separation form
11mm
最大分离形成
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The clutch pedal free stroke
10-15mm
离合器踏板自由行程
The clutch pedal work Angle

33°
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离合器踏板工作角度
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II Location map and exploded 位置图及爆炸图
1、 Location map 位置图
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2、 Exploded figures 爆炸图
□ Clutch assembly 离合器总成
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S/N 序号 Spare parts name description 备件名称
01 brake oil pipe perforation bolt 变速器总成
02 braking oil pipe joint washer 离合器从动盘
03 hexagon flange bolts 分离套筒
04 oil storage boat 分离拨叉
05 hexagon nuts with flange 导向轴承
□ The clutch circuit 离合管路
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01 brake oil pipe perforation bolt 制动油管穿孔螺栓

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02 braking oil pipe joint washer 制动油管接头垫圈
六角法兰面螺栓
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03 hexagon flange bolts
04 oil storage boat 储油壶总成
07 clutch master cylinder inlet pipe assembly 离合器总泵进油管总成
08 double steel wire ring hoop 双钢丝环箍
09 clip 管夹
10 clutch master cylinder tubing assembly 离合器总泵出油管总成
11 clutch hose assembly 离合软管总成
13 clutch tube bracket 离合器管固定支架
15 clip 管夹（φ6）
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17 clutch tube assembly 离合器管总成
18 clutch tube bracket 离合器管支架
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hexagon flange bolts
hexagon flange nuts 27 六角法兰面螺栓
六角法兰面螺母
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21 clutch hose assembly 离合器软管总成
22 clutch tube bracket 离合器管支架

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23 clutch tube bracket (I) 离合器管支架(I)
24 clutch booster oil inlet pipe assembly 离合助力器进油管总成

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25 brake oil pipe perforation joint 制动油管穿孔接头
26 cylinder booster assembly 离合助力器总成

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27 cylinder booster bracket assembly 离合助力器支架总成
28 clutch pedal and bracket assembly 离合踏板支架总成
29 clutch master cylinder 离合器总泵总成
30 pipe clip I 管夹 I
□ Clutch pedal 离合器踏板
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01 connecting bracket 连接支架
02 bolt 六角螺栓
03 nut 六角螺母
04 flat washer 平垫圈
□ Driven plate of clutch pressure plate 离合器压盘从动盘
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01 Clutch pressure plate assembly 离合器压盘总成
02 Clutch 离合器从动盘总成
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03 Hexagonal bolt and spring washer Combination 六角螺栓和弹簧垫圈组合件
Note: The above picture is the typical part pictures, there is a slight difference in some type vehicles, here is no
longer remark.
备注：上述图片为典型部件图片，部分车型存在细微区别，此处不再标识
III Remove, install and adjust 拆装与调整
1、 Precautions 注意事项
□ When disassemble transmission assembly, please use a hoist to prevent the damage to the parts and
people
拆解变速箱总成时需用吊具，防止造成人员与零部件的损伤
□ Pay attention to collect abandoned clutch hydraulic oil, prevent environmental pollution
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注意收集废弃离合器液压油，防止污染环境
□ Clean the clutch friction plate please use the vacuum cleaner, do not use compressed air to clean
up
清洁离合器摩擦片请使用吸尘器，切勿使用压缩空气清理
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2、 Disassembly of clutch control assembly 离合器控制总成拆解
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□ Before disassembling, vehicle front and rear wheels need

mask wood will cover, to prevent the slide
拆装前，需用掩木将车辆前后轮掩实，防止溜车
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□ Before disassembling, vehicle front and rear wheels need

mask wood will cover, to prevent the slide
拆装前，拧开离合器放油螺塞，将离合器液放尽
□ Disassemble clutch control assembly and disassembly

sequence: Clutch Oil jug, clutch lines, clutch master
cylinder, clutch pedal.
拆解离合器控制总成，拆解顺序为：离合器储油壶、
离合器链接管路、离合总泵、离合踏板
□ The disassemble oil spout mounting bolts and Lines Link
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nuts and remove oil jug
拆解储油壶固定螺栓及管路链接螺母，取下储油壶
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□ Disassemble clutch master cylinder mounting bolts and
the clutch lines link nuts and remove the clutch master
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cylinder
拆解离合总泵固定螺栓以及离合管路链接螺母，取下
离合总泵
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□ Disassemble the clutch pedal and bracket nuts, remove

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the clutch pedal
拆解离合踏板与支架固定螺母，取下离合踏板
Assembly: operate in accordance with the removal procedure in reverse order, and note the
following matters
装配：按照拆解相反步骤开展，并注意以下事项
□ Assembling the clutch pedal attaching bolts is critical

operations, and specific torque please see the overview
and maintenance sub-register
装配离合器踏板连接螺栓为关键工序，具体拧紧力矩
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请参见《概述与保养分册》
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□ When assembling the clutch pipe mounting bolts, please
put leak-proof plastic,and refers to the overview and
maintenance sub-register about the specific model
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number
装配离合器管路固定螺栓时需涂防漏胶，具体型号请
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参见《概述与保养分册》
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3、 The removal and installation of clutch circuit 离合管路拆装
□ Disassemble clutch circuit, disassemble order: clutch

tubes and hoses, clutch pedal, clutch pedal and bracket
assembly, clutch switch or stop bolt, spring, and
clutch-pump, along the clutch line toward a case-by-case
basis disassemble the parts
拆解离合管路，拆解顺序为：离合器管和软管、离合
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器踏板、离合器踏板和支架总成、离合器开关或限位
螺栓、弹簧、离合器分泵，沿着离合管路走向逐次拆
解各部件
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Assembly: operate in accordance with the removal procedure in reverse order.
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4、Clutch removal 离合器拆装
□ Disassemble the clutch and remove order:

transmission, clutch pressure plate, clutch driven disc,
split sleeve, split fork, pilot bearing
拆解离合器，拆解顺序为：变速箱、离合器压盘、
离合器从动盘、分离套筒、分离拨叉、导向轴承
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□ Disassemble transmission and engine, frame, the
driving shaft link bolts and remove transmission
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assembly
拆解变速箱与发动机、车价、传动轴链接螺栓，取
下变速箱总成
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□ Disassemble clutch pressure plate retaining bolts and
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remove clutch pressure plate.
拆解离合器压盘固定螺栓，取下离合器压盘
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□ Disassemble clutch driven plate retaining bolts and

remove clutch pressure plate. Prevent driven disc
assembly free fall with a guide shaft. Mark on the
flywheel and pressure plate block, and when re-install,
make sure that the marks are aligned.
拆解离合器从动盘固定螺栓，取下离合器从动盘用
一个导向轴来阻止从动盘总成自由滑落。在飞轮和
压盘块上做标记，在复装时，用标记对齐。
□ Disassemble the socket assembly together with the

split sleeve and return spring.
拆解离合器分离套筒总成，把分离套筒和回位弹簧
一起拆下
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Assembly: operate in accordance with the removal procedure in reverse order, and note the
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following matters:
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□ Visually check the clutch cover for wear, cracks and
damage. Clutch cover with excessive wear, cracks and
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other damage must be replaced.
目视检查整个离合器盖的磨损、裂纹和其他损坏。有
过度磨损、裂纹和其他损坏的离合器盖必须更换。
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□ Pilot shaft goes through splined hub. Pilot shaft must be

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kept in a straight.Depth measurement platen rivet.If the

measured value exceeds limits, should be replaced
driven disc assembly
在花键毂内插入导向轴。导向轴必须保持很平直，测
量从动盘铆钉深度，如果测量值超出极限值，应更换
从动盘总成
IV Fault diagnosis and solutions 故障诊断与处理
1、 Clutch drag (gear with gear grinding teeth) 离合器拖滞（换挡时伴随齿轮磨齿声）
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2、 Clutch slip 离合器打滑
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3、 Clutch vibration (partial clutch engaged make the body vibrations)
离合器振动（离合器部分啮合起动时，使本体发生振动）
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4、 Clutch noise (engage and disengage the clutch to check if clutch has noise, and thus determine what
caused the noise)
离合器噪音（啮合和脱开离合器时检查是否离合器发出的噪音，从而确定引起噪音的原因
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ChapterⅡ Front axle
第二章前桥
I Overview 概述
Front axle is usually located in the front of the car, which is an important assembly part. Mainly
includes front axle, bend arm, direct arm, knuckle, kingpin and other parts. There are two main functions
for the front axle in the car, one is to withstand part of the payload of the vehicle, the other is for the
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steering of the vehicle, therefore, also known as steering axle. Front axle connects with frame through
suspension to withstand the vertical load between ground and frame, also bear braking force and lateral
force, as well as the forces that constitute the torque and to ensure that the rotating wheel move correctly.
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During the use of vehicle, the forcing condition of steering axle is comparatively complex, and therefore
should have sufficient strength. To ensure that steering wheel the correct positioning to manipulate light
and reduce tire wear, so steering axle is also expected to have sufficient rigidity. In addition, it should also
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be possible to minimize steering axle weight. In sum, when driving, the front axle is under the poor
working environment, with complex performance, the bearing load mostly is alternating load which make
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the parts much more easier to be fatigue cracks and even broken. This requires that the structural design,
there must be with sufficient strength, stiffness and fatigue resistance capacity to destroy.
前桥一般位于汽车的前部，是汽车上一个重要的总成件。主要包括前轴、弯臂、直臂、转向
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节、转向主销等零部件。前桥在整车上主要有两个功能，其一是承受整车的部分载荷，其二就是
实现车辆的转向，所以也称转向桥。前桥通过悬架与车架相连，用以承受地面与车架之间的垂直
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载荷外，还承受制动力和侧向力以及这些力所构成的力矩，并保证转向轮作正确的运动。在汽车
使用中，转向桥的受力状况比较复杂，因此应具有足够的强度。为保证转向车轮的正确定位角
度，使操纵轻便并减轻轮胎的磨耗，转向桥也应有足够的刚度。此外，还应尽量减轻转向桥的重
量。总之，由于在汽车的行驶过程中，前桥所处的工作环境恶劣，工况复杂，其承受的载荷也多
为交变载荷，从而其零部件易出现疲劳裂纹甚至断裂现象。这就要求其在结构设计上必须有足够
的强度、刚度和抗疲劳破坏的能力。
Front axle important parameters
前桥重要参数
The front wheel camber Angle

Empty 空载：0°30′ Full 满载：0°15′
前轮外倾角
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Kingpin caster Angle
Empty 空载：0° Full 满载：2°45′
主销后倾角
Kingpin inclination
主销内倾角
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Empty 空载：11°45′ Full 满载：12°
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Axial load
Common 出厂：10-25N Maintenance 保养：5-20N
轴向负荷
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Steering knuckle and front axle surface gap

≤0.1mm
转向节与前轴面间隙
前束
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Oblique tire 斜交胎 4mm-6mm Meridian tire 子午线胎-2mm-2mm

Front beam
车轮最大内转角
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33°
Front wheel maximum amount of corner
1、 Location Map 位置图
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2、 Exploded diagrams 爆炸图
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S/N 序号 Spare Parts Name
27 备件名称
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00 front axle assembly 前轴总成
01 wheel hub cover 轮毂罩

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02 nut (L) 轮胎外螺母（左）
03 left&front wheel huband brake drum assy 左轮毂带制动鼓总成

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04 right&front wheel huband brake drum assy 右轮毂带制动鼓总成
05 nut (R) 轮胎外螺母（右）

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06 front axle 前轴
07 nut 转向节螺母
08 lock plate 锁片
09 wheel hub-outer bearing 轴承
10 wheel hub-inner bearing 轴承
11 oil seal 油封
12 oil seal seat 油封座
13 oil retainer plate 挡油盘

14 right steering knuckle with jacket unit 右转向节带衬套总成
14 left steering knuckle with jacket unit 左转向节带衬套总成
15 keen pin dustproof cover 主销防尘罩
16 keen pin 主销
17 bolt 制动器底板螺栓
18 bolt 转向限位螺栓
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19 plug 螺塞
20 nut 螺母
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22
keen pin cover
lock bolt,king pin 27 主销盖
主销锁栓
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23 steering knuckle-crank arm 转向弯臂
24 tie rod assy 横拉杆总成

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25 Thrust bearings 止推轴承
26 steering straight arm 转向直臂

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27 hexagon bolt 六角头螺栓
28 flat washer 平垫圈

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30 hex nut 六角头螺母
31 hexagon nut 六角螺母
32 spring washer 弹性垫圈
33 cotter pin 开口销
longer remark.
1、 Remove front axle assembly 前桥总成拆卸
□ Before Remove and Install, make sure front and rear

wheels with a mask to prevent it from rolling
拆装前，需用掩木将车辆前后轮掩实，防止溜车
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□ Lift the vehicle to safety height with jack
用千斤顶将车辆举升至安全高度
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□ Remove the tyre retaining bolt and remove the front

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wheel vehicles
拆卸轮胎固定螺栓，拆下车辆前轮
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□ Remove joint nut of steering lever(and power steering

machine
拆卸转向直拉杆与动力转向器连接螺母
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□ Remove the front saddle bolts. Remove the front
bumper blocks
拆卸前骑马螺栓，拆下前缓冲块
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□ Remove the front brake and vehicle connect pneumatic
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tubing and remove the front axle assembly
拆卸前制动器与车辆连接气动管路并取下前桥总成
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2、 Decomposition front axle assembly 前桥总成分解
□ □ Remove the hub caps and remove the front wheel
拆下轮毂罩，拆卸前轮外螺母外螺母
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□ Remove the front wheel hub with brake drum assembly
卸下前轮毂带制动鼓总成
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□ Remove the sleeve and front brake mounting nut and
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remove the front brake assembly
卸下衬套与前制动器固定螺母，取下前制动器总成
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□ Remove the main pin cover
拆下主销盖
□ Remove the cotter pin and remove steering lever and

bend arm retaining nut and remove steering lever
取下开口销，卸下转向直拉杆与转向弯臂固定螺母，
取下转向直拉杆
□ Remove the cotter pin and remove joint nut of steering
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lever and steering arm
拆下开口销，拆卸转向横拉杆与转向直臂连接螺母
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□ Remove the joint nut of steering lever and steering arm,
and remove steering lever
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拆卸转向横拉杆与转向弯臂连接螺母，取下转向直拉
杆
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□ Remove fixing nut of steering arm and bushing , steering

bend arm and bushing mounting nuts and remove
steering straight arm and steering bend arm
分别拆卸转向直臂与衬套固定螺母、转向弯臂与衬套
固定螺母，拆下转向直臂与转向弯臂
□ Remove the main pin retaining nuts and remove thrust

bearing
拆卸主销固定螺母、取下止推轴承
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□ Remove the main pin and bushing
拆下主销、衬套
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3、 Front axle assembly 前桥装配
□ Multiple steps in contrast to th 复装的步骤与拆解顺序相反
□ Assembly considerations 装配注意事项
 Before assembly parts outside surface should be clean, no rust, burrs, cracks and other defects;
装配前各零部件外表面应清洁，无锈蚀、毛刺、裂纹和其他缺陷；
 Before assembly, front axle and steering knuckle, steering arm straight forgings convex mesa is
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convex, dept. of mark to use file file;
装配前，前轴、转向节、转向直臂等锻件凸台面上有凸起、磕痕处要用锉刀锉平；
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 Front axle assembly to make a comprehensive inspection, all nut must be tightened according to the
specified torque value, the assembly lubrication mouth parts should be injection lubrication, until
from a crack in the parts of extrusion, front axle and steering knuckle end clearance and wheel hub
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bearing looseness should carry on the sampling inspection;
前轴总成要进行综合检查，所有螺母必须按规定扭矩值拧紧，各装配润滑嘴部位应注入润滑脂，
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直至从零部件的缝隙中挤出为止，前轴与转向节端面间隙和轮毂轴承松紧度应进行抽样检查；
 Left and right steering knuckle, thrust bearing, type O sealing ring and adjusting shim, guarantee the
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steering knuckle and front axle end single side clearance is not greater than 0.1 mm; Unilateral
adjusting shim not more than 2 slices.
装左、右转向节、止推轴承、O 型密封圈及调整垫片，保证转向节与前轴端面单侧间隙不大

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于 0.1mm；要求单侧调整垫片不多于 2 片；
 Section will turn to dust cover in the steering knuckle (lower) king pin hole hole steps, a flat surface
rung up tight, along the circumferential and rivet rivet at three.
将转向节防尘盖放入转向节（下端）主销孔台阶孔内，将曲面敲平涨紧后，沿周向冲铆三点
铆紧。
 Both inside and outside the front wheel hub bearing race between roller and thoroughly lithium base
grease, fitting within the hub, two bearing between the inner surface, end face and hub bearing block
filling 190 + 10 g lithium grease (unilateral), fill inside hubcap;
在前轮毂内外轴承座圈和滚柱之间充分涂抹锂基润滑脂，合件轮毂内、两轴承挡内表面、端
面及轮毂轴承挡之间填充 190±10g 锂基润滑脂（单侧），轮毂罩内填充；
 Front wheel hub oil seal, use special tools by the oil seal pressure into the front wheel hub oil seal
seat inside the hole, the pressure of the oil seal pressure into the 2.94 x 106 n/m2, oil seal face shall
not be higher than that of wheel hub face;
装前轮毂油封，用专用工具经油封压入前轮毂内油封座孔内，油封压入的压力为
2.94×106N/m2，油封端面不得高出轮毂端面；
 From the steering knuckle small end into the oil seal seat, the wheel hub and brake drum and woolly
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steering knuckle petiole, in turn into the lock, nut, screw the nut, nut tightening torque: 147 ~ 176
N · m, to turn 50 ° ~ 80 ° make nut notches on the recent split pin hole, again into the split pin;
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从转向节小端套入油封座，将轮毂及制动鼓合件套转向节柄部，依次装入锁片、螺母、拧紧
螺母，螺母拧紧力矩：147～176 N·m，再回转 50°～80°使螺母槽口对准最近的开口销孔，再
装入开口销
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Requirements: brake drum can be moved freely, check its axial load is 10 ~ 25 n, but there is no
obvious axial channeling and oscillating phenomenon; Inspection method: use a spring balance hook
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outside the tire bolts of twisting the tangent direction of fine line, tension within the scope of the 10 ~ 25
n, brake drum assembly can free uniform rotation is unqualified, less than 10 n rotation for loose, greater
than 25 n turns too tight. Turn the brake drum assembly 10 ~ 20 times before inspection, make the bearing
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grease evenly distributed.；
要求：制动鼓能够自由转动，检查其轴向负荷为 10～25N,但不允许有明显的轴向窜动和摆动

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现象；检查方法：用弹簧秤钩挂在缠绕轮胎螺栓外圆切线方向的细线上，拉力在 10～25N 范围

内，制动鼓总成能够自由匀速转动为合格，小于 10N 转动为过松，大于 25N 才转动为过紧。检
查前转动制动鼓总成 10～20 圈，使轴承润滑脂均匀分布。
4、 Front Axle Adjustment 前桥调整
 Front wheel toe-in measurement and adjustment 前轮前束测量和调整
□ Let front wheel on a flat position
将前轮置于平坦的位置
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□ Mark in the middle of tire and tread , and place the
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equipment of toe-in measuring in the center of the wheel
用笔在轮胎轮距中心部位做标记，放置测量前束装置
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在车轮的中心位置
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□ In front of the vehicle measured center-to-center of tires

of the distance (A), push the vehicle to the rear or
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Forward to let each wheel rotate 180 degrees, in

accordance with the original mark measure the distance
between rear side tire center distance of front-wheel(B).
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The toe-in is equal to the B subtract A
在车辆前面测量轮胎中心线之间的距离(A)，把车辆
向后或向前推，将每个车轮转动 180°，按照原标记
测量前轮后侧的轮胎中心线之间的距离(B)。前束等于
B减A
□ If the toe-in does not match. Release clamp bolts of the

rod end. Use a wrench reverse link to adjust the front
harness
如果前束不符。松开连杆端头的夹紧螺栓。用扳手扭
转连杆以调整前束
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 Turn radius adjustment 转向半径调整
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□ Put the front wheels on a flat position and put
block under the rear wheels,and its thickness and
wooden
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measuring instruments thickness are the same. Put the
front wheel on the instruments, and to ensure it is in the
center of instruments. Turn the front wheels in clockwise
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and counter-clockwise separately to the maximum

position.
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将前轮置于平坦的位置在后轮下加木垫块，其厚度和
测量仪器的厚度相同。把前轮放置在仪器上，并保证
置于仪器的中央。分别以顺时针和逆时针方向转动前
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轮到最大位置。
□ Note: when turn the front wheels, depress the brake

pedal
注意：在转动前轮时，要踩下制动踏板
 The inner and outer wheels angle adjustment 内轮和外轮转角调整
□ The put the front wheels on a flat position loosen the

adjusting screw lock nut of the steering section and
adjust the screws height, till steering angle meeting
requirement and tighten the lock nut
将前轮置于平坦的位置拧松转向节上的调整螺栓的
锁紧螺母，调整螺栓的高度，知道转向角达到要求，
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拧紧锁紧螺母
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Front axle bearing anti-competitiveness in vertical direction surface from the ground, horizontal
direction braking force, inertial force, braking resistance and torque resulted from braking and so on. As
front axles long endure the serious impact load, following may occur:
前桥承受来自地面的垂直方向反力、水平方向制动力、惯性力、制动阻力和制动时引起的转矩
等。汽车前桥长期承受这些交变冲击载荷，可能发生以下故障：
1、 Front axle fatigue damage, cracks or broken fault
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前桥疲劳损伤、裂纹或断裂故障
 Fault symptom: Find front axle fatigue damage, cracks or broken fault
故障现象：发现前桥疲劳损伤、裂纹或断裂。
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 The failure repair: Parts should be replaced in a timely.
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故障维修：应及时更换新件。
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2、 The front axle happens bent failure in the vertical direction
前桥在垂直方向产生弯曲变形故障
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 Fault symptom: Find front axle happens bent failure in the vertical direction
故障现象：发现前桥在垂直方向上弯曲变形。
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 Fault cause: As front axle bear large anti-competitiveness in the vertical direction from the ground
and it is easy to cause bent, will change the pin pitch, outside of the wheel angle, the diesel vehicle
steering heavy, wheel hub bearing load increases, and reduce its life.
故障原因：前桥在垂直方向上承受来自地面的反力很大，易产生弯曲变形，会改变主销内倾角、
车轮外倾角，会使柴油车转向沉重，轮毂轴承负荷增大、降低使用寿命。
 The failure repair. There should be timely correction beams.
故障维修：应及时校正横梁。
3、 The front axle happens bent failure in the horizontal direction
前桥在水平方向产生弯曲变形故障
 Fault Symptom: Find front axle horizontal bent.
故障现象。发现前桥水平方向弯曲变形。
 Fault cause: Front axle bear the braking force in the horizontal direction from under
ground ,which is easy to cause bent, will change Front Wheel toe-in and increase tire wear.
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故障原因：前桥在水平方向承受来自地面的制动力易产生弯曲变形，会改变前轮前束，增大轮
胎磨损。
 The failure repair: There should be timely correction front beams.
故障维修：应及时校正前横梁。
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4、 The front axle has distorted fault
前桥产生扭曲变形故障
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 Fault symptom: Find front axle has a reverse deformation.
故障现象:发现前桥产生扭转变形。
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 Fault cause: Front axle with a reverse deformation will change the caster angle, and impact
front-wheel driving stability.
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故障原因:前桥产生扭转变形会改变主销后倾角，影响前轮行驶稳定性。
 The failure repair: Adapter, replace the front beam or to correct repair.
故障维修：适情更换前横梁或进行校正修理。
5、 The front axle shaft with Thermal fault
前桥轴头发热故障
 Fault symptom: The front axle shaft with Thermal fault when driving
故障现象:行驶中发现前桥轴头发热。
 Fault cause: Shaft hair hot typically occurs after maintenance, and often resulted from bearing
pre-pressure too tight to seat bearings with too tight when assembly wheel hub. Wheel hub bearing
damage or pitting will not only result in heat but also with some noise. Wheel hub bearing lacking oil
can also cause shaft thermal failure.
故障原因：轴头发热一般发生在修理保养之后，往往是在装配轮毂时，轴承预压过紧使轴承配
合过紧所致。轮毂轴承损坏或点蚀不仅会发热而且还会有噪声。轮毂轴承缺油也会造成轴头发
热的故障。
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 The failure repair: Check the bearings for tightness and wheel hub bearings for the oil
故障维修：检查轴承配合松紧和轮毂轴承是否缺油。
6、 The front axle brake drums heat failure

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前桥制动鼓发热故障
 Fault symptom: The front axle shaft with Thermal fault when driving
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故障现象:行驶中发现前桥制动鼓发热
 Fault cause: the main reason of brake drum heat is air brake chamber diaphragm do not return to
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the original place or return too slow; brake shoe return spring broken or weak will cause brake drum
heat.
故障原因:制动鼓发热的主要原因是气制动室膜片不回位或回位太缓慢所致；制动蹄回位弹簧
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断裂或弹力不足也会造成制动鼓发热。
 The failure repair: There is no gap between brake shoes and brake drum, which will obviously cause
brake drum heat. At this time except check adjust clearance, should check the problem of air chamber
diaphragm without returning, and when the brake air chamber diaphragm does not return, the air
problem should check and check whether the brake camshaft stocked.
故障维修:制动蹄片与制动鼓没有间隙，显然也会造成制动鼓发热。此时除检查调整间隙外应
检查气室膜片不回位的问题，制动气室膜片不回位除检查气路故障外应检查制动凸轮轴是否
发卡。
7、 The master pin bushing, main pin, Thrust Bearing Wear-out failure
主销衬套、主销、止推轴承磨损故障
 Fault symptom: Heavy direction, manipulation is unstable.
故障现象:方向沉重，操纵不稳。
 Fault cause: The pin bushing, the main pin, thrust bearings are worn, the absenteeism, will affect the
wheel alignment, lower the lever stability.
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故障原因:主销衬套、主销、止推轴承磨损、松旷，会影响前轮定位，降低操纵杆稳定性。
 The failure repair: Replace worn parts and re-front wheel alignment.
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故障维修:应更换磨损件并重新进行前轮定位。
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8、 Step brake lightly with the front wheels failure
轻踩制动时前轮发摆故障
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 Fault symptom: when the brakes are applied in full load, front axle work normally, often rock when
brake step lightly.
故障现象:汽车在全负荷制动时，前桥工作正常，往往在轻踩制动时前轮发摆。
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 Fault cause: This is mainly caused by the drum round error value, while the two front wheels in
part-load when the brakes are applied, since the brake force is a little, the two front wheels have a
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braking effect are not in sync, and some times in the left brake, and sometimes in right brake
resulting front wheel wiggle.
故障原因:这主要是制动鼓圆度误差超值所致，当两前轮在部分负荷制动时，由于制动力小，
两前轮产生制动效果不同步，时而左刹、时而右刹从而造成前轮摆动。
 The failure repair: Removal brake drum checks and makes the cut. Tire rims deformed sometimes
will also cause this problem.
故障维修:此时应将制动鼓拆卸检查并进行光削修理。轮胎钢圈变形有时也会产生这种故障。
9、 The steering failure
转向沉重故障
 Fault cause: Front Axle Steering System mechanical failure; steering hydraulic power system failure.
故障原因:前桥转向系统机械部分故障；转向液压动力系统的故障。
 The failure repair: Steering heavily owing to the mechanical portion of the burden is mainly due to
the steering joint pin lacking of the oil. Long-term without maintenance, not apply grease to steering
joint pin, which cause the pin-to-Bushing dry friction, not only increase steering resistance heavily,
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and can be as severe as the pin-to-Bushing sintered. Therefore, the service require apply grease to
steering joint pin, generally first, lift up the I frame of front axle ,apply oil with a grease gun to oil
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mouth which is installed on the camshaft holder until the beam with pin holes, the flat extruder oil.
故障维修:由于机械部分造成的转向沉重主要原因是转向节主销缺油。长期不保养，不向转向
节主销内加注润滑脂，造成主销与衬套干燥摩擦，不仅增加转向阻力，使转向沉重，而且严重
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时会造成主销与衬套烧结。因此，要求在保养中应向转向节主销中加润滑脂，一般先讲前桥工
字辆顶起，用黄油枪向安装在凸轮轴座上的黄油嘴注油，直到工字梁与销孔上、下平面挤出油
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为止。
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10、 The front brake drum rotor oil
前制动鼓甩油故障
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 Fault symptom: The front brake drum rotor oil when driving
故障现象:行驶中发现前制动鼓甩油。
 Fault cause: Front brake drum swings oil, which is clearly because of hub oil seal damage. Wheel
Hub Oil Seal Leak not only caused shaking oil, but will also enable brake failure.
故障原因:前制动鼓向外甩油显然是轮毂油封损坏所致。轮毂油封漏油不仅造成甩油，而且会
使刹车失灵。
 The failure repair: Replace it with a new oil seal to troubleshooting.
故障维修:更换新油封才能将故障排除。
11、 The front tire wear and tear are not normal fault
前轮胎磨损不正常故障
 Fault symptom: Driving found that front-wheel wear is not functioning properly.
故障现象:行驶中发现前轮磨损不正常。
 Fault cause: The reason of that front tire wear and tear are not are much complex, and toe-in value is
not right clearly will worn front tire, Steel ring deformation, shaft and the absenteeism, the beam is
deformed, the main pin clearance, and so on, all of which can cause wear front tire failure
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故障原因:前轮磨损不正常的因素较为复杂，前束值不对显然会磨损前轮胎，钢圈变形、轴头
松旷、工字梁变形、主销间隙过大等都会造成磨损前轮胎的故障。
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 The failure repair: Troubleshooting the issue is a complex work, it is necessary to take into account
the front wheel alignment of the parameters of the change, but also to take into account other factors.
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故障维修:排除此故障是一项复杂的工作，既要考虑到前轮定位各项参数的变化，又要考虑其
他方面因素的影响。
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12、 The front-wheel brake drift .

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前轮制动跑偏故障
 Fault symptom: Find front-wheel brake drift when driving.

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故障现象:行驶中发现前轮制动跑偏。
 Fault cause there are two reasons for front wheel brake deviation. The clearance difference between
left and right brake make the braking starting time is not synchronized; left and right brake shoes and
brake drum to contact different size or the oil causing contact friction torque of the differences, which
results in different brake torque to the brake run in deviation.
故障原因:前轮制动跑偏有两个方面的原因。左、右制动蹄片间隙不同，使开始投入的制动时
间不同步而造成的；左右制动蹄片与制动鼓接触面积不同或由于油污造成接触摩擦力矩的差
异，从而产生不同的制动力矩导致制动跑偏。
 The failure repair: When the vehicle's braking drift, by adjusting brake shoes clearance cannot be
excluded when it is, and should be remove brake drum inspection and the mill.
故障维修:当汽车制动跑偏、通过调整制动蹄片间隙不能排除故时，应拆卸制动鼓进行检查和
光磨。
13、 The brake failure doesn't work .
制动不灵故障
 Fault symptom: Driving found that brake does not work.
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故障现象:行驶中发现制动不灵。
 Fault cause: Brake inefficiency is the problem of braking drum and braking shoe except the reason of
braking control system. In the actual repair, Check brake effection often using the brake drum and
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brake shoes contact area, and the general requirements for brake shoes and brake drum contact area
should be more than 70 per cent. From the practical experience, two end-engaged of the brake shoes
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are much more productive than the median engage.
故障原因:制动不灵除制动控制系统原因外，就是制动鼓与制动蹄片的问题。在实际维修中，
往往用制动鼓与制动蹄片接触面积来检查制动效果，一般要求制动蹄片与制动鼓接触面积应在
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70%以上。从实践经验看来，制动蹄片两端啮合要比中间啮合效果好的多。
 The failure repair: In the mill foot-and-mouth, its diameter should be slightly larger than the diameter,
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in order to ensure that shoes engage both ends, in order to get the most recent braking effectiveness.
故障维修:在光磨蹄片时，其直径应略大于鼓的直径，以保证制动蹄片啮合两端，以便获得最
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近制动效果。
Chapter Ⅲ Transmission
第三章变速箱
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12
20
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一、技术参数：(Main Technical Data)
中心距
120mm
Center Distance
重量
120kg
Net Weight
操纵方式远距离操纵
Control Remote control
里程表传动比 12/ 4 、 1 1 / 4 、 1 3 / 5 等
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Speed Ratio 12/ 4 、 1 1 / 4 、 1 3 / 5etc.
润滑油牌号及油量 GL-4 80W/90（冬季）、85W/90（夏季）6L
Brand and capacity of lubricating oil. GL-4 80W/90 (winter ), 85W /90(summer ) 6L
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档位传动比：(Gear ratio)
额定输入扭
Ⅰ Ⅱ Ⅲ Ⅳ Ⅴ Ⅵ R 矩（N·m）
Input Torque
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6.012 3.292 2.004 1.367 1.000 0.789 5.395 700
档位示意图(Shift gear sketch)

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5 3 1
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6 4 2 R
二、变速器的润滑和保养：(Transmission lubrication and maintenance:)

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1、变速器的润滑(Transmission lubrication)：
严禁使用劣质润滑油，不同牌号的润滑油不应混合使用！
Forbid using lubricating oil of low quality, forbid using different brand lubricating oil mixed!
加注润滑油时，车辆应停放在水平路面上，应加到注油孔的下边缘。
When filling oil the vehicle must stop level road and oil level is just below the filling hole.
润滑脂必须使用符合 GB5671-85 标准要求的汽车通用锂基润滑脂。
Lubricating oil must accord with standard GB5671-85 vehicle general Li base lubricating
oil.
2、变速器的保养（maintenance）
行驶 3000 千米时应检查润滑油平面，油平面以加油口下缘为准，不足时添加。
The oil surface should be checked while driving 3000km. Fill oil if it is not enough.
行驶 5000 千米时，应更换变速器内润滑油，并用煤油清洗变速器。以后每行驶 24000
千米时更换润滑油。
While driving 5000km the oil in the transmission should be replaced and the inner of the
transmission cleaned. Replace lubricating oil after each 24,000km.
行驶 12000 千米时，还应对变速器分离轴承座加注润滑脂。润滑脂嘴装在变速器离合
器壳上，注入润滑脂不能过多，以免玷污离合器摩擦片。48000 千米时应检查变速器各轴承
工作情况，必要时更换。
Clutch release bearing should be lubricated with grease after 12000km driving. Grease could
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not be filled too much to avoid dirtying the friction disk. Check the state of bearings after
48000km. replace the failed.
通气塞的保养：通气塞应经常清理，清除脏物，保持畅通。
Maintenance of the vent plug: Vent plug should be often cleaned to get rid of the dirty and to
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keep air flowing.
四、变速器使用注意事项：(Pay for attention)

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1、 WLY6G120 变速器的各档均带有锁环式同步器，为了减轻齿轮和同步器的磨损，使同步
器和齿轮顺利脱开，防止打碎齿轮，换档动作要和缓。汽车只有在停稳后才能由前进档
换入倒档或由倒档换入前进档。 Since each position in WLY6G120 is with lock-ring
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synchronizer,in order to lessen the wear between gear and synchronizer,disengage the
synchronizer from the gear,the gear-shifting should be gentle to avoid breaking the gear.Only
after the truck parks completely ， can be the forward gear position change into the reverse
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position or the reverse into the forward.

2、应特别注意：变速器的六档为超速档，为避免超速齿轮损坏，在整车不超载，路面状况
较好，车速达到 50 公里/小时以上才能使用六档。在使用六档时，如遇某种情况致使整
车速度降到 50 公里/小时以下，此时应换入低档，如继续使用六档，极易使六档齿轮打
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碎。 Warn:Since the sixth gear position is overspeed,it should be engaged only under the
condition of good road, being not overload and speeding more than 50km/h.Otherwise the
gearwill be broken.If the speed is less than 50km/h,the lower position should be engaged and
the sixth position should not be used any more.
3、根据道路和车辆载重情况，采用Ⅰ档或Ⅱ档起步。According to condition of the road and
the load the vehicle gear shift starting is at 1st speed or 2nd speed.
4、换倒档时，离合器踏板应踩到底，平稳准确地移动变速杆到所需档位。When shifting
reverse speed , clutch pedal should be stepped to its bottom, then the gear-shift lever should
be moved to the required shift position smoothly and correctly.
5、变速器不应空档滑行，特别是下坡时禁止换入空挡，防止烧损同步器及各类型轴承。
When the vehicle running, the gearshift lever should not be located at the natural position, the
transmission is not allowed to coast at the free speed, especially to coast downhill.
6、换倒档时，必须先停车再挂档，以免损坏倒档齿轮、齿套及相关零件。When shifting
reverse speed, the vehicle must be stopped first and then to shift gear to avoid damaging the
reverse gear, sleeve and concern parts.
五、检查与维修 ( Check and Maintenance )
通过检查如发现零件磨损、损坏或其它故障时，应进行必要的修理或更换。肉眼检查：
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检查所有拆下零件的磨损、损坏或其它故障情况，具体要求如下：
Check the wear,break of the parts.Repair or change if necessary The requirements are as
following:
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12
20
1.换档拨块厚度（thickness of the shift 2 齿轮内孔与二轴间的间隙 mm

fork）mm (clearance between inner hole and mainshaft)
标准（standard）极限(limit) 标准（standard）极限(limit)
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1/2 12.0 11.0 0.04～0.08 0.2
3/4、5/6 8.0 7.0

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故障类型可能原因排除方法

Failure Possible Remedy
1、一二轴轴承损坏
Bearings of primary shaft or main shaft are
damaged. 1、更换轴承
2、齿面磕碰、有毛刺或齿面发生点蚀或接触不 Replace the bearing or the
良 assembly.
Gear face is bumped, and there are burrs or 2、修复或更换齿轮
噪声过大 corrosion pitting or poor contact on the teeth Repair or replace the gear
或响 faces. 3、检查、调整
Excessive 3、齿轮轴向位置和间隙不当造成齿轮与其他 Make inspection and
or 零件碰撞 investigation
abnormal Axial location and clearance of gear shaft is 4、加油至规定位置
noise not proper, resulting in contact with or Top up the oil to the
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bouncing against the other parts. specified level.
4、润滑油面太低，润滑不充分 5、更换为规定牌号润油
Oil level is too low and lubrication is not Change the lubricating oil
sufficient. same as stipulated
5、使用不合格质量要求的劣质润滑油
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Lube oil with a poor quality is used, which
does notcomply with the quality requirement.
1、加油过多，油面过高 1、拆注油螺栓检查油面
Oil is overfilled and oil level is too high. Unscrew the oil plug and
2、油封过量磨损或损坏 check the oil level.
渗油 3、密封胶涂抹不均或密封纸垫损坏
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Oil seal is worn out excessively or damaged. 2、更换油封
Removing and checking.
Oil Sealing glue is applied unevenly or the paper 3、重涂胶
leakage gasket is damaged. Make inspection and
4、通气塞堵塞 apply sealing glue.
4、更换
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Failure of breathing plug.
5、结合面磕碰、未及时修平 Replace it.
Bumping of joining faces and are not trimmed 5、检查、修平
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3.同步器齿环和结合齿间的间隙 mm 4 变速器二轴径向跳动 mm
（ clearance between gear ring and (radial jig of mainshaft)
engaging gear）极限(limit) 0.1
标准（standard）极限(limit)
1.3～1.7 0.5
六、变速器常见故障原因及排除（Common failures and troubleshooting for gearbox）

5
timely. Inspect and trim it.
1、离合器调整不当，分离不彻底
Clutch is not adjusted properly and 1、调整
挂档困难 disengagement is not thoroughly. Adjust it.
Difficult to 2、选档和换档拉杆调整不当或发生运动障碍 2、调整
get gear 或干涉 Make inspection and
engaged Improper adjustment of gearshift and gear adjustment.
selector pull-wire or movement is hindered. 3、更换
3、同步器齿环磨损严重近于失效 Make replacement.
Synchronizer gear ring is worn-out seriously
and almost failed.
1、滑动齿套与锥体结合齿倒锥面严重磨损 1、更换有关零件
掉档
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Meshing faces of sliding coupling and Make replacement of
Shifted relevant parts.
meshing teeth of synchronizer cone are
gear 2、调整
worn-out excessively.
disengage
2、拉杆调整不当 Make adjustment.
d
Improper adjustment of pull-wire
1、润滑油太脏 1、更换润滑油
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轴承非正 Lube oil is too dirty. Make replacement.
常损坏 2、润滑不充分或润滑油质量太差 2、检查、更换
Abnormal Insufficient lubrication or oil does not comply Make inspection and
damage of with requirements and oil quality is too poor. replacement.
bearings 3、使用不合格的轴承 3、更换
Unqualified bearing is used.
12 Make replacement.
七、保修原则（service principle）
1、对本公司产品在报废前有服务的义务。
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Our company is obligated to provide service before product is scrapped.
2、公司生产的 WLY6G120 系列变速器，在规定使用条件下和使用期限内，无偿为用
户更换或维修因产品设计、制造和材质等质量问题造成的零部件损坏，以确保公司
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产品正常使用。
In the prescribed running condition or Within the fixed time we will change or repair the
damaged part of our WLY6G120 family transmissions that it is caused by product design,
manufacturing or material to insure our company’s product running normally.
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3、通过服务可以直接了解本公司产品的质量状况和用户要求，并将信息及时反馈到质
量部门，以便采取改进措施提高产品质量和增加产品品种满足市场需求。
We will directly know quality of our company’s product and customer’s demand by
serving and we will take measures to improve quality of our company’s product and develop
new product to meet needs of market.
八、保修范围（service scope）
1、在保修期限内，由于产品质量原因引起零件损坏和使用性能改变，经鉴定确属我公司的
问题给予保修。
The trouble caused by the product quality in the warranty time limit will be in good repair by
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our company.
2、凡属下列情况之一的不予保修 we have not responsibility for the any situation listed below :
1）超出或无法确定保修期的产品；
The warranty time limit of the product is out or the purchase time could not be confirmed.
2）自行或委托他人改装过的产品；
The product has been refitted by oneself
3）自行拆卸修理造成零件的损坏；
The damaged part is caused by disassembling and repairing of oneself..
4）发现故障未及时排除而继续使用所引起的继发性故障和损坏；
Continual driving caused the parts destroyed as the discovered trouble had not been got rid
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of in time.
5）不按产品说明书规定进行操作或保养所引发的产品故障；
Trouble is caused by operation or maintenance that they are not in the manner described in
the service manual
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6）由于使用或操纵不当造成的产品故障；
Trouble caused by incorrect using or operating.
7）交通事故导致的产品故障或损坏；
Trouble or damage caused by traffic accident.
8）凡弄虚作假伪造事实者，我公司将追究其责任，并承担由此给我公司造成的各种损
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失。We keep the right for punishing the skullduggery during our service.
九、变速器零件图解（Spare Parts – Gearbox Housing Group）
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1、上盖总成（Transmission Upper Cover）
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27
12
序号数量
名称 Name
No Number
1 换档轴总成 1
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Selecting shaft
2 骨架油封 Oil seal 1
3 通气塞 air plug 1
4 顶盖 Top cover assembly 1
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倒档开关及增压器
5 Reverse light switch unit 1
总成
6 螺栓 Screw Stopper 1
六角头螺栓与锥型 Bolt & lock washer
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7 4
弹性垫圈组合件 assembly
8 六角头螺栓 Bolt 1
9 螺母 Nut 3
10 弹簧垫圈 Spring washer 1
11 平垫圈 Plain washer 3
12 选档臂总成 Outer select rocker arm 1
13 轴用弹性挡圈 Ring 1
14 平垫 Plain washer 1
15 骨架油封 Oil seal 1
16 圆柱销 Cylinder pin 1
17 碗形塞片 Stopper Slice 1
8
序号数量
名称 Name
No Number
18 自锁装置 Self-lock 1
19 弹簧 Spring 2
20 互锁套 Self-lock sleeve 1
21 换档拨头 Shift guild block 1
22 选档轴总成 Gear--select rocker arm 1
23 隔套 Bushing 1
24 垫片 Spring pad 1
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2．换档机构(Gear—Shift mechanism)
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12
20
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序号图号数量
名称 Name
No Code Number
五、六档换档档拉
1 6G120-6570 Pull-rod assembly 1
杆总成
2 三四档拉杆 6G120-6371 Pull-rod 1
一、二档换档档拉
3 6G120-6170 Pull-rod assembly 1
杆总成
4 弹性销 Q5280630 Elastic cylinder pin 3
5 倒档拨块 6G120-6875 Dialing block 1
五、六档拨叉及衬 th th
5 /6 shift fork and
6 6G120-6579 1
套总成 Bushing assembly
WTB10*21*8-
7 换档拨块 Dialing block 4
6G120
三、四档拨叉及衬 3rd/4th shift fork and
8 6G120-6379 1
套总成 Bushing assembly
9 一二档拨叉 6G120-6173 1st/2nd shift fork 1
10 换档拨块 WTB10*18*12-6G120 Dialing block 2
序号图号数量
名称 Name
No Code Number
11 弹性圆柱销 Q5280430 Elastic cylinder pin 3
12 倒档拨叉 6G120-6873 Reverse shift fork 1
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13 变速器叉轴 6G120-6071 Fork shaft 1
3、变速器总成与离合器壳总成（Housing and Clutch Housing）
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12
20
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10
序号数量
名称 Name
No Number
轴承
1 Bearing 1
(192309)-6G120
2 卡环 Ring 1
3 O 型密封圈 O-seal 1
4 里程表软轴接头 House Fitting 1
5 里程表从动齿轮 Speedometer driven gear 1
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弹簧垫圈 Spring washer 2
螺栓 Bolt 1
7 双头螺柱 Double end studs 12
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8 波形弹性垫圈 Cushioning plate washer 12
10 螺母 Nut 14
序号数量
名称
12 Name
No Number
11 二轴突缘 Flange 1
12 突缘螺栓(镀锌) Flange bolt 4
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13 突缘锁紧螺母 Nut 1
14 O 型密封圈 O-seal 1
15 油封 Oil seal 1
16 里程表主动齿轮 Speedometer driven worm 1
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17 二轴盖 Rear bearing cover 1

18 倒档增压器 Reverse supercharger 1
19 螺塞 Washer 1
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20 变速器外壳 Rear housing 1

23 倒档检查孔盖板 Cover plate 1
六角头螺栓和锥形 Bolt & lock washer
24 8
27 取力器孔盖板 Side cover 1
28 磁性放油螺塞 Oil drain plug 1
29 橡胶垫 Washer oil plug 2
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30 螺塞 Bolt 1
31 拨叉支撑销 Backing pin 6
32 波形垫圈 Cushioning plate washer 6
33 变速器前壳体 Front housing 1
六角头螺栓和锥形 Bolt & lock washer
34 20
35 轴承 Bearing 1
36 轴用弹性挡圈 External clip ring 1
37 第一轴 Input shaft 1
38 油封 Oil seal 1
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39 一轴盖 Input shaft cover 1
40 波形弹性垫圈 Cushioning plate washer 11
序号数量
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名称 Name
No Number
43 弹垫 Spring washer
12 2
Clutch vent cover board
44 离合器通风盖合件 1
assembly
调整垫片 Plain washer 1
45 调整垫片 Plain washer 1
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调整垫片 Plain washer 1
46 衬套 Bushing 2
分离叉轴及叉臂总 Clutch fork shaft & lever
47 1
成 assembly
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48 平键 Key 1
分离轴承润滑软管
49 Lubrication hose 1
总成
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50 离合器壳体 Clutch housing 1

53 分离叉 Clutch release fork 1
离合器分离轴承总
57 Bearing Cover assembly 1
成
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4、变速器第二轴及其附件（Transmission main shift and accessories）
28
27
12
20
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序号数量
名称 Name
No Number
13
1 轴用弹性压扁档圈 External clip ring 1

2 滚针轴承 Needle bearing 1
3 五档轴承座圈 External clip ring 1
轴用弹性挡圈 External clip ring 1
5 五档同步锥 th
5 synchronizer cone 2
th th th
3rd/4 /5 /6
6 三四五六档同步环 Synchronizer 4
cone-ring
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5th/6th synchronizer
7 五六档同步齿套 1
sleeve
5th/6th synchronizer
8 五六档同步齿座 1
hub
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9 同步器弹簧 Synchronizer spring 3
10 同步器滑块 Synchronizer block 3
二轴六档齿轮
12
12
Output shaft 6th gear 1
数量
序号名称 Name
Number
No
20
14 四档齿轮止推环 Thrust washer 1
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15 钢球 Steel ball 1
17 二轴四档齿轮 Output shaft 4th gear 1
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18 四档同步锥 Synchronizer cone 1

rd th
3 /4 Synchronizer
20 三四档同步齿座 1
hub
3rd/4th Synchronizer
21 三四档同步齿套 1
sleeve
22 三档同步锥 Synchronizer cone 1
23 二轴三档齿轮 Output shaft 3nd gear 1
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25 二轴倒档轴承座圈 External clip ring 1

26 二轴倒档齿轮 Output shaft rev. gear 1
Rev. Synchronizer
28 倒档同步齿座 1
cone
29 二轴一档齿轮合件 1st gear assy 1
st nd
1 /2 Synchronizer
31 一二档同步器内环 2
28
inside cone
一二档同步器中间 1st/2nd Synchronizer
32 2
环 middle cone
1st/2nd Synchronizer
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33 一二档同步器外环 2
outside cone
34 倒档同步器推块 Synchronizer block 3
Spring retainer,
35 倒档同步器定位块 3
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synchronzing
36 同步器弹簧 Synchronizer spring 3

序号数量
名称 Name
20
No Number
37 一二档同步器齿座 1
hub
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38 一二档滑动齿套 1
sleeve
39 二轴二档齿轮合件 2nd speed gear 1
二轴
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41 Mainshaft 1
15
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5、变速器中间轴及倒档轴（Transmission countershaft and reverse gear shaft）
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12
20
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序号数量
名称 Name
No Number
16

2 滚柱轴承 Needle bearing 1
3 中间轴五档齿轮 Count shaft drive gear 1
4 中间轴六档齿轮 Countershaft 6th gear 1
5 中间轴四档齿轮 Countershaft 4th gear 1
6 中间轴三档齿轮 rd
Countershaft 3 gear 1
7 中间轴 Countershaft 1
8 滚柱轴承 Needle bearing 1
9 倒档惰轮 Rev. idler gear 1
10 倒档轴 Rev. idler shaft 1
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27
12
20
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Chapter Ⅳ Drive shaft

第四章传动轴
I Overview
Drive shaft is an important component that transmits power in the automotive driveline. It functions
with gearbox and drive axle to transmit the power of engine to the wheels, making the vehicle generates
driving force.
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传动轴是汽车传动系中传递动力的重要部件，它的作用是与变速箱、驱动桥一起将发动机的动
力传递给车轮，使汽车产生驱动力。
The movable or rotatable circular parts that are connected or assembled to the drive shaft are usually
27
made of alloy-steeltube which is light and with good torsional resistance. For the front-engine rear-wheel
drive vehicle, drive shaft transfers the rotation of the transmission to the final drive shaft, which can be
12
made up of several sections and connected by universal joints. It is a rotating body with high rotating
speed and less support, which means the dynamic balance is of great importance. Generally, dynamic
balance test of drive shaft should be carried out before drive shaft leaves the factory, and adjustment of
20
drive shaft should be performed on the balance machine.
传动轴连接或装配各项配件，而又可移动或转动的圆形物体配件，一般均使用轻而抗扭性佳的
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合金钢管制成。对前置引擎后轮驱动的车来说是把变速器的转动传到主减速器的轴，它可以是好几
节由万向节连接。它是一个高转速、少支承的旋转体，因此它的动平衡是至关重要的。一般传动轴
在出厂前都要进行动平衡试验，并在平衡机上进行了调整。
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II Location plan and exploded view 位置图及爆炸图
1、 Location plan 位置图
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27
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2、 Exploded view 爆炸图
20
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S/N 序号 Spare Parts Name 备件名称
01 Drive shaft assembly 传动轴总成
02 Bracket on the drive shaft protection 传动轴保护上支架
03 Drive shaft protection under the bracket 传动轴保护下支架
04 Rear axle drive shaft bolt 后桥传动轴螺栓
05 spring washer 弹垫
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06 I type hex nuts Ⅰ型六角螺母
08
09
hexagon flange nuts
hexagon flangen bolts 27 六角法兰面螺母
六角法兰面螺栓
12
10 Hex head bolt, spring washer and plain washer assemblies 六角头螺栓、弹簧垫圈和平垫圈组合件
11 Drive shaft assembly 传动轴总成

20
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III Removal and Adjustment 拆装与调整
□ Protection should be taken in the process of removing and installing parts to avoid scratches
拆卸和安装部件过程中，应做好防护，以免出现划伤。
□ Check if there is poor lubrication of the parts when removing them, if necessary smear "Grease."
拆装某些部件时，检查部件是否润滑不良，如果有必要，进行润滑。
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□ Multi-man cooperation is required in the removing process because of the complexity of auto
parts.
27
由于汽车部件结构的复杂性，拆卸过程可能需多人配合进行。
□ Do not use excessive force when removing which may cause deformation of parts
12
拆卸时请勿用力过大，因此可能导致零部件变形过大。
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2、 Driveshaft Removal 传动轴拆装
□ When disassembling the drive shaft assembly, the

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disassembly order is differential end nut, middle

hanging, transmission end nut, drive shaft assembly.
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拆解传动轴总成，拆解顺序为差速端螺母、中间吊挂、
变速器端螺母、传动轴总成
□ Make the vehicle in a steady state to prevent it from

slipping before removal and installation. Flat cart
should be put at the bottom of vehicle to prevent the
falling damage of drive shaft.
拆装前，使车辆处于平衡稳定状态，防止溜车。拆解
前须将平板推车放入车底部，防止传动轴跌落损伤
□ Disassemble drive shaft and differential side coupling

nut.
拆解传动轴与差速器端连接螺母，拆解时需在螺母上
做好标记
□ Disassemble the middle hanging mounting nut
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拆解中间吊挂固定螺母
27
12
□ Disassemble drive shaft and transmission side coupling
nut.
20
拆解传动轴与变速器端连接螺母，拆解时需在螺母上
做好标记
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□ Remove the drive shaft, and disassemble the coupling

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nut of front and rear axle.
取下传动轴总成，拆解前轴与后轴连接螺母
Installation: Please note the following procedures and install in the reverse order of removal:
装配：按照拆解相反步骤开展,但是需注意一下事项
□ Caution: Make an assembling mark on the universal

joint when disassembling, because the drive shaft
requires a good balance performance.
注意：因为传动轴要求有良好的平衡性能,所以在拆
卸时，应在万向节上作好装配记号
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3、 Universal joint tear open outfit 万向节拆装
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□ When disassembling the universal joint, the disassembly
order is grease nipple of universal-joint pin, bearing
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retainer of universal joint, needle roller bearings,
universal-joint pin, and flange yoke.
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拆解万向节，拆解顺序为十字轴滑脂嘴、万向节轴承
挡圈、滚针轴承、十字轴、突缘叉
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□ Gently knock on the universal-joint pin, and then

disassemble the needle roller bearings. Disassemble
other bearings with the same method.
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轻轻敲击十字轴，拆下滚针轴承。用同样的方法将其
他轴承拆解
□ The flange yoke of drive shaft must be installed as the

picture shows: spline shaft and spline should be
assembled in alignment as the arrow shows.
传动轴的突缘叉必须如图所示安装，花键轴与花键叉
如箭所示对齐装配
□ Smear grease on the oil seal and needle roller bearings.
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Assemble the needle roller bearings into flange yoke
with the universal joint pin as a guider. During assembly,
please use a soft faced hammer to knock.
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把油封和滚针轴承涂上油脂。用十字轴做导向将滚针
轴承装进突缘叉中。装时用软面锤敲击
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□ Install grease nipple to universal joint pin by a specified
angle. Make sure that the grease nipple is upwards.
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安装润滑脂油嘴至十字轴规定角度。必须保证滑脂嘴
朝上
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4、 Removal of Center Bearing 中心轴承拆装
□ When disassembling the center bearing, the disasse mbly

order is intermediate rubber, center bearing, dustproof
cover, connecting fork, washers, and nuts.
拆解中心轴承，拆解顺序为中间橡胶、中心轴承、防
尘罩、连接叉、垫圈、螺母
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□ The seal lip and the center bearing should be coated with
bearing grease when in re-installation.
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复装时把油封唇和中心轴承涂上轴承油脂
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□ After the middle nut is tightened up, make a mark on the

nut and make two symmetric piling in the
circumferential direction.
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中间螺母上紧后在螺母上打标桩。在圆周方向对称打
两个
□ Check the diameter of universal joint pin, and replace it

if there is any abnormal wear.
检查十字轴销直径，如果异常磨损想要进行更换
□ Check spline backlash, and replace it if there is any

abnormal wear.
检查花键侧隙，如果异常磨损想要进行更换
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IV Trouble Diagnosis and Troubleshooting 故障诊断与处理
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Chapter Ⅴ Suspension
第五章悬架
I Interview 概述
The suspension system is the general term for all power transmission and connecting devices that
connected between the frame and axles or wheels. Its function is to transmit force and moment that
function between the wheels and the frame, cushion the impact coming from the uneven road and
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attenuate the vibration resulted from the impact, in order to ensure smooth running. Functions that
suspension system should have are to support the body and improve the driving feeling, for different
suspension settings make drivers get different driving experience. Deceptively simple as it looks, the
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suspension system integrates a variety of forces and determines the stability, comfort and safety of the
vehicle, becoming one of the crucial components of modern automobiles.
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悬架系统是汽车的车架与车桥或车轮之间的一切传力连接装置的总称，其功能是传递作用在车
轮和车架之间的力和力矩，并且缓冲由不平路面传给车架或车身的冲击力，并衰减由此引起的震动，
以保证汽车平顺行驶。悬挂系统应有的功能是支持车身，改善乘坐的感觉，不同的悬挂设置会使驾
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驶者有不同的驾驶感受。外表看似简单的悬挂系统综合多种作用力，决定着汽车的稳定性、舒适性
和安全性，是现代汽车十分关键的部件之一。
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Front suspension 前悬
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Rear suspension 后悬
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Front suspension 前悬
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01 nut 螺母
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02 Front leaf spring pin assembly 前板簧销总成
03 Front leaf spring bushing 前板簧衬套
04 Front left leaf spring assembly 前左钢板弹簧总成
05 Front right leaf spring assembly 前右钢板弹簧总成
06 Before the horse bolts 前骑马螺栓
07 Buffer block assembly 前缓冲块总成
08 iron mat 前板簧垫铁
09 nut 前骑马螺栓螺母
10 Front leaf springs hanging ear plate assembly 前板簧吊耳板总成
12 left upper bracket,front shock absorber 前减震器左上支架
13 right upper bracket,front shock absorber 前减震器右上支架
14 front shock absorber 前减震器总成
15 Front shock absorber rubber sleeve gasket (outer) 前减震器橡胶套垫圈（外）
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Front shock absorber rubber sleeve gasket
16 前减震器橡胶套垫圈（内）
(within)
17 down pin ,front shock absorber 前减震器下销
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19
hexagon flange bolts
I type hex nuts 27 六角法兰面螺栓
Ⅰ型六角螺母
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20 spring washer 弹垫
21 Hexagon head bolts - fine tooth 六角头螺栓-细牙

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Rear suspension 后悬
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01 nut 螺母
02 Front leaf spring pin assembly 前板簧销总成

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03 Front leaf spring bushing 前板簧衬套
04 Front left leaf spring assembly 前左钢板弹簧总成
05 Front right leaf spring assembly 前右钢板弹簧总成
06 Before the horse bolts 前骑马螺栓
07 Buffer block assembly 前缓冲块总成
08 iron mat 前板簧垫铁
09 nut 前骑马螺栓螺母
10 Front leaf springs hanging ear plate assembly 前板簧吊耳板总成
12 left upper bracket,front shock absorber 前减震器左上支架
13 right upper bracket,front shock absorber 前减震器右上支架
14 front shock absorber 前减震器总成

15 前减震器橡胶套垫圈（外）
(outer)
16 前减震器橡胶套垫圈（内）
(within)
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17 down pin ,front shock absorber 前减震器下销
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I type hex nuts
spring washer 27 Ⅰ型六角螺母
弹垫
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21 Hexagon head bolts - fine tooth 六角头螺栓-细牙
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1、 Front suspension removal 前悬拆装
□ When disassembling the front suspension, the

disassembly order is front shock absorber、U-bolt、 lug
pin、steady pin、leaf spring
拆解前悬，拆解顺序为前减振器、U 型螺栓、吊耳销、
固定销、钢板弹簧
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□ Preparations: fix rear –wheel, and jack the vehicle, then
27
jack front axle with lift equipment.
准备工作：先抵住后轮，顶起汽车，然后再用举升装
12
置顶起前轴
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□ Removal of U-bolt
拆解 U 形螺栓：
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 Loosen(not removing) U-bolt and nut
松开(不要拆下来)U 型螺栓和螺母
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 Raise the vehicle ,and support it with the chassis holder
将车辆升起并将它支承在底盘支架上
 Removal U-bolt and nut
拆下 U 型螺栓和螺母
□ Removal of front shock absorber
拆解前减震器
 Remove front shock absorber upper bracket and front

axle hold-down nut
拆解前减震器上支架与前轴固定螺母
 Remove front shock absorber lower bracket and front
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axle hold-down nut
拆解前减震器下支架固定螺母
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□ Remove of front axle assembly
拆解前桥总成
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 Removal of front leaf spring

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拆解前板簧
 Remove front leaf spring hold-down nut
拆解前板簧固定螺母
 Remove front leaf spring lug pin
拆解前板簧吊耳销
 Take down front leaf spring assembly
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取下前板簧总成
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Installation: Please note the following procedure and install in the reverse order of removal:
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□ Make a assembling mark on the leaf spring intersecting

surface before removal leaf spring
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拆卸钢板弹簧之前，要在钢板弹簧横面上做安装标记
□ Smear lubricating grease on two sides of leaf spring
在每个钢板弹簧两面上涂润滑脂。
□ Removed center bolt cannot be reused and should be

replaced with new one.
拆下的中心螺栓不要再使用，应更换新的中心螺
□ Use leaf spring with same sagitta ,when changing leaf

spring
更换钢板弹簧时，使用相同弧高的钢板弹簧
□ Check the clearance between leaf spring bushing and
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leaf spring pin. If the clearance is too big, leaf spring
bushing or leaf spring pin should be replaced.
查看板簧衬套与板簧销的间隙。如果间隙过大，应更
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换板簧衬套或板簧销
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□ Pay attention to filling lubricating oil (until the oil oozes
a little) when assemble lug pin.
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装配吊耳销时应注意加注润滑油，至有少许渗出为止
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□ Check the absorber leakage, and a little leakage is

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acceptable.
检查减振器的泄露，允许有少量渗漏。
□ Check the temperature of shock absorber rises or not,

after driving for some distance, if the temperature does
not rise, it indicates that the shock absorber is not
working and should be replaced.
车辆行使一段行程后，检查减振器的温度是否升高，
如果温度没有升高，说明减振器不工作，应予更换。
□ Stretch shock absorber, if there is no heavy resistance, it

indicates the absorber does not work and should be
replaced
拉伸减振器，如果感觉不到有较大阻力，说明减振器
不工作，应予更换。
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2、后悬拆装 Removal rear suspension
□ When
27 disassembling the rear suspension,

disassembly order is front shock absorber、U-bolt、lug
the
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pin、steady pin、leaf spring
拆解后悬，拆解顺序为后减振器、U 形螺栓、吊耳、
板簧销、钢板弹簧
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□ Fix rear –wheel, and jack automobile, then jack front

C-
axle with lift equipment.
先抵住前轮，顶起汽车，然后再用举升装置顶起后桥
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□ Removal U-bolt 拆解 U 形螺栓
 Loosen(not dismantle) U-bolt and nut
松开(不要拆下来)U 型螺栓和螺母
 Raise the vehicle ,and let it supports on the chassis

holder
将车辆升起并将它支承在底盘支架上
 Remove U-bolt and nut
拆下 U 型螺栓和螺母
□ Remove rear shock absorber
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拆解后减震器
 Remove rear shock absorber upper bracket and front
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axle hold-down nut
拆解后减震器上支架与前轴固定螺母
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 Remove front shock absorber lower bracket and front
axle hold-down nut
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拆解前减震器下支架固定螺母
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□ Remove rear axle assembly

JA
拆解后桥总成
□ Remove rear leaf spring
拆解后板簧
 Remove rear leaf spring hold-down nut
拆解后板簧固定螺母
 Remove front leaf spring lug pin, and take down front
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leaf spring assembly.
拆卸前板簧吊耳销，取下前板簧总成
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□ Make a assembling mark on the leaf spring surface,

before removal leaf spring
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拆卸钢板弹簧之前，要在钢板弹簧横面上做安装标记
□ Smear lubricating grease on two sides of leaf spring
在每个钢板弹簧两面上涂润滑脂。
□ Remove center bolt can’t be reused ,should use new one
拆下的中心螺栓不要再使用，应更换新的中心螺栓
□ Use the leaf spring with same sagitta , when changing

leaf spring.
更换钢板弹簧时，使用相同弧高的钢板弹簧
□ Check the clearance between leaf spring bushing and

leaf spring pin. If the clearance is too big, leaf spring
bushing or leaf spring pin should be replaced.
查看板簧衬套与板簧销的间隙。如果间隙过大，应更
换板簧衬套或板簧销
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□ Pay attention to fill lubricating oil(until the oil oozes a
little),when assembling lug pin.
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12 装配吊耳销时应注意加注润滑油，至有少许渗出为止
□ Check the absorber leakage, and a little leakage is

20
acceptable.
检查减振器的泄露，允许有少量渗漏。
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□ Check the temperature of shock absorber rises or not,

after driving for some distance, if the temperature does
JA
not rise, it indicates that the shock absorber is not

working and should be replaced.
车辆行使一段行程后，检查减振器的温度是否升高，
如果温度没有升高，说明减振器不工作，应予更换。
□ Stretch shock absorber, if feel no heavy resistance, it

indicates the absorber does not work and should be
replaced.
拉伸减振器，如果感觉不到有较大阻力，说明减振器
不工作，应予更换。
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Chapter Ⅵ Steering
第六章转向
I Description 概述
A series of devices used to change or keep the vehicle running or reversing are called automotive
steering systems .The function of steering system is to control of the driving direction in accordance with
the driver's will. Automobile steering system is critical to the driving safety, so auto steering system parts
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are called security pieces. Automotive steering systems and braking systems are two important systems in
auto safety that must be paid attention to.
用来改变或保持汽车行驶或倒退方向的一系列装置称为汽车转向系统。汽车转向系统的功能就
是按照驾驶员的意愿控制汽车的行驶方向。汽车转向系统对汽车的行驶安全至关重要，因此汽车转
向系统的零件都称为保安件。汽车转向系统和制动系统都是汽车安全必须要重视的两个系统。
27
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Steering important parameters
转向系统重要参数
For maximum front axle load

2000kg～3500kg
适用最大前轴负荷
Theory of maximum output torque

1965N.m
最大理论输出力矩
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Turning laps
≥5.1
转向圈数
27
Output Angle
44.5°-47.5°
输出角
Input spline (diameter x number of teeth)

Φ17.805×36
12
输入花键(外径×齿数)
Output spline (big end diameter x number of teeth)

Φ35×36
输出花键（大端外径×齿数）
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Oil pressure
10.3Mpa
工作油压
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Appropriate working temperature

-40℃～120℃
适用工作温度
Oil pump rated flow

JA
(9～11)L/min
油泵额定流量
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01 steering wheel 转向盘总成

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02 dustproof cover 防尘罩
03 steering gear adjust rack unit 转向可调支架总成

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04 steering column cover unit 转向柱护罩总成
05 steering shaft and driving universal joint 转向轴及传动万向节总成
06 steering gear assembly 转向器总成
07 nut, hexagon flange 六角法兰面螺母
08 Hexagon-headed bolt 六角法兰面螺栓
09 Hex bolt 六角法兰面螺栓
10 cross slotted screw and flat washer 十字槽盘头螺钉和平垫圈组合件
11 steering cover button 转向护罩卡扣
Hex head bolt spring washer and plain washer

12 六角头螺栓弹簧垫圈和平垫圈组合件
assemblies
13 Hex nut and taper washer 六角螺母和锥形弹性垫圈
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27
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01 power steering oil outlet pipe assembly 动力转向进油钢管总成
02 power steering oil inlet pipe assembly 动力转向出油钢管总成
03 hose clamp (φ10) 平管夹（φ10）
05 power steering hose assy 动力转向软管总成
06 oil pump outlet perforation bolt 油泵出油穿孔螺栓
07 combined seal washer 组合式密封垫圈
08 power steering pump assy 动力转向泵总成
09 Compressor bracket tightening bolt Ⅱ 压缩机支架紧固螺栓Ⅱ
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11 pipe clip 管夹
12 Worm drive type hose clamp B 型蜗杆传动式软管环箍
13
14
clip
hose clip 27 卡箍
软管夹
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16 power steering return pipe 动力转向回油软管

20
17 pump inlet hose 油泵进油软管
18 oil tank bracket 油罐支架总成

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19 power steering oil tank 动力转向油罐总成
20 steering oil reservoir cover 动转油罐盖

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□ In the process of disassembly and installation parts should be protection, lest appear scratches
拆卸和安装部件过程中，应做好防护，以免出现划伤。
□ Check if there is poor lubrication of the parts when removing them, if necessary smear "Grease."
拆装某些部件时，检查部件是否润滑不良，如果有必要，需进行润滑
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□ Multi-man cooperation is required in the removing process because of the complexity of auto parts
由于汽车部件结构的复杂性，拆卸过程可能需多人配合进行。
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□ Do not use excessive force when removing, because it may cause deformation of parts
拆卸时请勿用力过大，因为可能导致零件变形。
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2、 Steering System Removal 转向系统拆装
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□ When disassembling the steering system, the

disassembly order is steering wheel, combination switch,
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steering column, steering shaft, power steering gear,

dynamic steering oiler, steering lines
拆解转向系统，拆解顺序为方向盘、组合开关、转向
JA
管柱、转向轴、动力转向器、动转油壶、转向管路
□ Preparations: Make the vehicle in a steady state to

prevent it from slipping; The oil in the dynamic steering
oiler should be dumped before disassembling.
准备工作：使车辆处于平衡稳定状态，防止溜车。拆
解前需将动力转向油壶中的动转油放尽.
□ Turn the cab over and remove the coupling nut between
steering shaft and power steering gear. Pre-mark on the
steering shaft and mounting bolts of the power steering
gear to ensure the corresponding installation.
翻转驾驶室，拆解转向轴与动力转向器连接螺母拆卸
前预先在转向轴与动力转向器固定螺栓上做标记，安
装时确保标记对应
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□
□ Removal of steering wheel
27
拆解方向盘
□ Remove the steering wheel cover with both hands, and

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remove the retaining nut that fixing the steering wheel
with sleeve.
c
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双手扣下方向盘上盖，并用套筒拆解下方向盘固定螺
母
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□ Unscrewed the retaining nut, and disassemble the upper

cover of the steering column.
JA
拧下固定螺母，拆解转向管柱上护罩
□ Remove the retaining nut, and unplug the connectors,

then disassemble combination switch assembly.
拆下固定螺母，拔下接插件，拆解组合开关总成
□ Remove the lower cover assembly of steering column.
取下转向管柱下护罩总成
□ Remove the instrument panel (consult the cab
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disassembling section).Disassemble the adjustable
steering bracket and steering column assembly
27
拆解仪表台（参见拆装驾驶室章节）。拆解转向可调
支架与转向管柱总成
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□ Disconnect steering fluid pipe and steering gear coupling
nut
20
断开转向液钢管与转向器连接螺母
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□ Remove the coupling nut between steering gear and

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steering drag link.
拆解转向器与转向直拉杆连接螺母
□ Remove the retaining nut between steering gear and

frame and remove steering gear assembly.
拆解转向器与车架固定螺母，拆下转向器总成
□ Remove the connection clamps between power steering
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oil tank and oil in-and-back software
拆解动力转向油罐与进回油软件连接卡箍
27
12
□ Disassemble the coupling nut that connect the power
steering oil tank and the frame, then remove the tank.
20
Remove the power steering pump and power steering

hose steel pipe
拆解动力转向油罐与车架连接螺母，拆下油罐。拆解
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动力转向泵及动力转向钢管软管
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□ Power steering oil refueling 动力转向油的加注
Refueling process: First fill up the tank, then start the engine and make the drive pump running in
low speed to fill the hydraulic system. During engine operation, the oil in the tank will continue to decline,
refueling must be continued so as to avoid air inflow. Meanwhile turn the steering wheel to the both ends
of the limit position of the left and right respectively, and repeat it several times until the oil in the tank no
longer decreases.
加油过程：先将油罐加满，起动发动机，低速运行驱动油泵，使油液充满液压系统。在发动机
运转过程中，油罐的油面会不断下降，必须不断加油，以免油泵吸入空气。同时分别向左右打方向
盘至两端极限位置,反复几次,至油罐中油液不再下降为止.
Oil change process: Jack up the front axle, and open the tank cover and fuel returning port of
steering gear. Then start the engine in less than 15 seconds, and turn the steering wheel in both directions
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consecutively to each extreme position to drain the oil .Then refuel according to the refueling procedures.
换油过程：顶起前轴，打开油罐盖，将转向器回油口打开，短时间起动发动机，不超过 15 秒，
连续两个方向转动方向盘至两极限位置，将油液全部排出。然后再按加油程序进行加油。
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Exhaust process: Jack up the front axle (or remove drag link) and make the engine idling, turn the
steering wheel to the limit position of the left and right respectively, repeat it several times so as to
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exhaust air and vaporized fluid. With the bubble discharging, the oil in the tank will fall. At this time oil
should be added continuously until the oil surface keep placid, which completes the exhaust process.
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排气过程：顶起前轴（也可卸去直拉杆）发动机怠速，左、右转动方向盘至极限位置，反复转
动数次，让空气和汽化的油液排出。随着汽泡的排出，油罐油面将下降，这时要不断补充油液，直
到油面稳定，这就完成了排气过程。
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Precautions 注意事项：
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 Oil with inconsistent model is forbidden to mix.
禁止型号不一致的油液混用。
 Filter screen that on the oil tank must be used when filling the oil.
加注油液时必须经过转向系统油罐上的过滤网过滤。
 The volume of oil filling must be between two scale marks specified by the tank gauge (Keep the
engine start in 3min-5mins after oil filling, check if the oil filling volume is between the scale marks.
If too much oil, oil spilling is tend to occur after the engine is started；If too less oil, Ablation of vane
pump of the steering system is tend to occur.
油量加注必须在油罐标尺规定的两刻线之间（油量加注后启动发动机 3min-5min,检查补加油量
至规定标尺刻度线间。过多，发动机启动后易造成油液溢出；过少，易造成转向叶片泵烧蚀）。
 When regularly change the oil, the tank and the tank filter should be cleaned at the same time, not
allowing any debris mixed with the oil. Pay special attention to that do not use cotton fiber materials
(such as cotton yarn, emery cloth, etc.) to clean parts, which is to avoid their entry into the system
and causing malfunction.
定期换油时，应同时清洗油罐和油罐中的滤芯，不允许有任何杂物混入油内。特别注意不能用
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棉织纤维物品（如棉纱、砂布等）擦试零件，以免带入系统内，造成故障。
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□ When assemble the new steering gear, make sure that
there is no foreign material or damage in the steering
gear and steering column joint.
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装配新转向器时要确保转向器与转向管柱接头处无
异物，无损伤
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□ The steel pipe of power steering fluid and steering gear

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should be coated with leak-proof glue when assembling.

Specific brands and smear standard, please consult
"Overview and maintenance manual "
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装配动力转向液钢管与转向器是需要涂防漏胶。具体
品牌与涂抹标准请参见《概述与保养分册》
□ When reinstallation is carried out, make sure that the

steering wheel is in the middle position under the
condition of straight driving, or start from the steering
wheel when removal or installation.
复装必须保证车辆处于直线行驶状态下方向盘处于
中间位置进行，或在拆装钱预先在方向盘
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Chapter Ⅶ Rear axle
第七章后桥
I Overview 概述
This series drive axle is for two-wheel drive, rear suspension is not single suspension construct. it
comprises reducer、bevel gear differential and drive axle housing and some of other parts. It is the last stage
reducing speed mechanism in automotive driving system.
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Final reduction can enlarge torque and reduce rev, at the same time change the direction.It is
composed of driving gear and driven gear. Driving gear, in which side there is spine, connects with coupling
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assembly of driving axle by driving gear’s flange. It is sustained by two cone bearings, which is reverse
assembled, in its middle for supporting axial force and radial force. The axle neck on small end of driving
gear, bearing radial force, is assembled columnar bearing. Driven gear is fastened to left housing of
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differential of some bolts.
Differential, which can make the right and left wheel’s rev different, consists of the housing of
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differential, spider, four spider gears, and two side gears and some of other parts.
Drive axle’s half-shaft is connected with half-shaft gear by spine in one side, and with hub by some
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bolts in flange in another side.
该系列后桥是两轮驱动汽车驱动桥，后悬挂是非独立悬挂结构。由主减速器、差速器及桥壳等
部分组成，是汽车传动系中末级减速传动机构。主减速器即能改变传动方向，又能降低转速、增大
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扭矩。它由主动齿轮和从动齿轮组成，主动齿轮有花键的一端通过主齿凸缘与传动轴万向节总成联
接，中间支撑在两个安装方向相反的圆锥轴承上，以承受轴向力和切向力。主动齿轮小端面颈则安
装在圆柱滚子轴承上，仅承受径向力。从动齿轮用螺栓紧固在差速器左壳上。
差速器是使左、右车轮可产生不同转速，它由差速器左右壳、十字轴、二/四个行星齿轮、两
个半轴齿轮等零件组成。
后桥半轴的一端用花键与半轴齿轮联接，另一端凸缘用螺栓与轮毂带制动鼓总成联接。
Rear axle important parameters
后桥重要参数
后桥型号
2400000LG012A
Rear axle model
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Gear oil model
（GL-4)85W / 90
齿轮油型号
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Gear oil filling quantity
6.5L
齿轮油加注量 12
The main reduction ratio
4.875
主减速比
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1、 Location Map 位置图
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2、 Exploded diagrams 爆炸图
□ Rear axle assembly 后桥总成
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00 Rear axle with brake assembly 后桥带制动器总成
01 hex bolt 六角头螺栓
03 bolt 六角头螺栓
04 spring washer 重型弹簧垫圈
05 shaft 半轴
06 oil seal 半轴油封
07 lock washer 锁止垫圈
08 nut 轴承螺母
09 bolt 制动底板螺栓
10 hexagon nut 六角螺母
12 hex fine bolt 六角头细牙螺栓（预涂胶）
13 stud bolt 双头螺栓（桥壳）
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14 nut 螺母
15 plug coke 六角头磁性螺塞
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17
plug coke
VENTILATE PLUG 27 放油塞密封垫圈
通气塞
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18 plug cock 加油塞
19 plug coke 加油塞密封垫圈

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20 Rear wheel hub with brake drum assembly (left) 后轮毂带制动鼓总成（左）
21 Rear wheel hub with brake drum assembly (right) 后轮毂带制动鼓总成（右）

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22 Rear brake assembly (left) 后制动器总成（左）
23 Rear brake assembly (right) 后制动器总成（右）

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24 Rear axle housing assembly 后桥壳总成
25 Main reducer assembly 主减速器总成
□ Drum assembly 轮毂总成
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S/N 序号 Spare Parts Name
27 备件名称
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00 Rear drum oil seal 后轮鼓内油封
01 Rear brake drum 后制动鼓

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02 inner bearing 后轮毂内轴承
03 rear hub 后轮毂

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04 outer bearing 后轮毂外轴承
05 Tire bolt assembly (right) 轮胎螺栓组件（右）

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06 gear ring 齿圈
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□ Main reducer assembly 主减速器总成

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00 Drive gear assembly 主动齿轮总成
01 oil seal O 形圈-主动齿轮轴承座

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02 shim 主齿轴承座调整垫片
六角螺母
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03 nut
05 spring sprag 导向轴承弹簧挡圈
06 guided bering 主动齿轮导向轴承
07 stopping plate assy 导向轴承挡板总成
08 Final drive housing assembly 主减速器壳总成
09 differential unit 差速器总成
10 bolt 螺栓-从动齿轮
11 bolt 轴承座螺栓
□ Differential assembly 差速器总成
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00 bearing 差速器轴承
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01 Differential case 差速器壳总成
02 thrust plate 半轴齿轮止推垫片

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03 side gear combination 侧卫齿组件
04 spinder 行星齿轮轴
longer remark.
1、 Matters needing attention 注意事项
□ Check the parts with special inspection implement or tool
应使用专门的测量仪器或工具来检查零件。
Decide whether one part can reuse or not according to maintenance standard table. Broke part must
be repaired or replaced. If one of partner parts wore, leading to B/L out of set standard, we must
change the partner parts whole.
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根据指定维修标准表来断定零件是否能继续使用。损坏零件按要求进行修理和更换。如果在
配对零件中有一个被磨损，使间隙超出了规定的间隙，按有关要求更换此零件以及其他配件
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□ Some repairing parts which still in limited tolerance must be change according to pre-maintenance
opinion.
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从预防保养的观点出发，某些仍在修理或磨损极限内的零件，在超出极限之前就应更换。
□ All rubber parts, such as O loop, oil seal, shim etc., can not be reused after disassembly.
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所有的橡胶件，如O形圈、油封、垫片等在拆下之后应抛弃，不准在使用。
□ When there have noise or shake in transmission system, check the total B/L of rear axle firstly then
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decide whether to disassembly differential carrier assy’.
传动系统产生异响或震动时，先测量后桥的总游隙，决定是否需要拆卸主减速器总成。
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□ Stop the truck on flat ground, push the transmission or transfer into empty speed position, rise the
truck after braking with hand brake rod, turn the flange clockwise to bottom, mark matching sign on
dust cover & carrier, then turn the flange counterclockwise to bottom, measure the mark moving
distance. The limit windage is 6mm，if measured date is bigger then the limit, we must disassembly
rear axle and adjust it.
将车辆放在水平地面上，将变速器及分动箱置于空档位置，拉上驻车制动杆后将车辆顶起。顺
时针方向旋转凸缘到底，并在凸缘防尘罩和减壳上做匹配标记，再反时针方向将凸缘旋转到底，
测量两匹配标记所移动的距离，极限游隙为6mm，游隙大于极限，说明后桥的齿轮间隙过大，
必须拆卸后加以调整。
□ Abnormal noise, which belong to noise, such as clash or harshness etc. abnormal sound under
different condition, some can die away after normal wear, some change much bigger, and the main
reason is adjustment N/G, we can solve them through adjusting the assembly B/L if all parts are good.
异响属噪音的一种，主要表现为在不同的使用条件下（如车速、路况）会产生撞击声或刺耳的
尖叫声等非正常声响，有些声响会通过磨合逐渐消失，有些声响会不断加大；主要是因为装配
调整不当造成的，在零件合格的前提下，其解决方法大多可通过调整零件装配间隙解决。
2、 Remove rear axle assembly 后桥总成拆卸
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□ Before Remove and Install, make sure front and rear
wheels with a mask to prevent it from rolling
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12 拆装前，需用掩木将车辆前后轮掩实，防止溜车
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□ Lift the vehicle to safety height with jack
用千斤顶将车辆举升至安全高度
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□ Remove the tyre retaining bolt and remove the rear

wheel vehicles
拆卸轮胎固定螺栓，拆下车辆后轮
□ Disassembly the link between transmission shaft and

differential carrier assembly.
分解传动轴与主减速器的连接
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□ Remove the front saddle bolts. Remove the front
bumper blocks
拆卸前骑马螺栓，拆下前缓冲块
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□ Remove the Rear brake and vehicle Connect pneumatic
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tubing and remove the front axle assembly
拆卸后制动器与车辆连接液力制动管路并取下前桥
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总成。
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3、 Decomposition rear axle assembly 后桥总成分解
□ Disassembly shaft
拆卸半轴
 Loose shaft nuts
松开半轴螺母
 Disassembly shaft. if difficult, strike the shaft slightly

with copper hammer until it loose
拆下半轴。如果半轴卸不下，用铜锤轻轻的敲击半轴
法兰，直到半轴松动。
□ Disassembly hub
分解轮毂
 Disassembly the lock plate
拆下锁止垫圈
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□ Disassembly the lock nut hub B/R
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卸下轮毂轴承锁紧螺母
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□ Disassembly the hub assembly

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拆下轮毂总成
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□ Disassembly oil seal bush and inner B/R loop
同内轴承内圈一起，拆下油封衬套
□ Disassembly the brake drum
拆除制动鼓
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□ Disassembly differential carrier assembly
分解主减速器总成
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 Check and record the B/L of pinion & ring gear before
disassembly
在分解之前，测量和记录主被动齿轮的齿侧间隙；
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 Note: check the mesh condition of gears after adjust
注意：调整后，检查齿轮啮合情况
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□ Disassembly lock plate

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拆除锁片
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□ Mark matching sign on the B/R cover & carrier
在轴承盖和壳体上，做上装配标记
□ loose bolt of B/R cover, then disassembly adjust nut

with differential wrench
拧松轴承盖的固定螺栓，利用差速器扳手，拆下调整
螺母；
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□ Disassembly B/R cover & bolt
拆下轴承盖和螺栓；
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□ Disassembly the differential case assembly
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拆下差速器总成
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□ Disassembly the pinion gear assembly with special

disassembly implement, and disassembly the shim
利用拆卸器拆下主动齿轮总成，同时拆下调整垫片
□ Disassembly differential case assembly
分解差速器总成
 Disassembly right case
拆下差速器右壳
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□ Disassembly shaft gear & shim
拆下半轴齿轮和支承垫圈
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□ Inspection and record the backlash of planet gear
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测量和记录行星齿轮的齿侧间隙
 Note: locking the cross shaft when check backlash

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注意：测量齿侧间隙时，要压住行星齿轮十字轴
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□ Disassembly the cross shaft & planet gear assembly

then take out the planet gear and washer
拆除行星齿轮十字轴总成，再从十字轴上拆下行星齿
轮和支承垫圈；
□ Take out shaft gear and shim
拿出半轴齿轮和半轴齿轮的止推垫圈
 Remove the ring gear
拆下从动齿轮
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□ Disassembly differential case B/R
从差速器壳上拆下差速器轴承
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□ Disassembly of pinion gear
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主动齿轮的拆卸
 Disassembly the nut of pinion gear flange

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拆除主齿凸缘螺母
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□ Disassembly spring loop and take out the roller B/R
拆除轴用弹性挡圈和取下主动齿轮导向轴承
□ push out the pinion gear
从轴承座上压出主动齿轮
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□ Disassembly adjust shim and distance washer
拆除调整垫圈和轴承隔套
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□ Disassembly B/R from pinion gear
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从主动齿轮上拆下轴承
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4、 Rear axle assembly and adjustment 后桥装配及调整
□ The assembly of differential carrier assembly is reverse with disassembly.All parts need to be cleaned
before assembly, no oil, iron and other impurities, which are coated with oil lubrication assembly, the
10th and adjusted according to the requirements of the following
主减速器总成装配按以上拆卸逆过程装配，装配前所有零件许保持清洁，无油污、铁屑等杂物
存在，涂以 10 号机油润滑装配，并按以下要求进行调整：
 Preload of pinion fear inner & outer B/R
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主动齿轮内外轴承预紧
The taper B/R must preload when assembly differential carrier assy’, that is on the basis of removing
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B/L of B/R, press somewhat preload more, the aim is to decrease pinion gear axis movement in
transmission. But the preload can not press too much, or the B/R will be worn rapidly.
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装配主减速器时，圆锥滚子轴承应有一定的装配预紧度，即在消除轴承间隙的基础上，再给予
一定的预紧力。其目的是为了减少在锥齿轮传动过程中产生的轴向力引起的轴向位移，以提高
轴的支承刚度，保证锥齿轮副的正常啮合。但也不能过紧，若过紧则传动效率低，且加速轴承
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磨损。
 Adjustment of pinion gear preload: after tight pinion nut, assembly pinion oil seal and adjust the
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preload(without ring gear) through remove or add shim between inner and outer B/R. adding shim,
preload also add and remove shim, it will be decrease.
主动齿轮轴承预紧力调整：在主齿凸缘螺母拧紧力矩的条件下，装上主齿油封，主动齿轮未与
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从动齿轮啮合，保证主齿轴承预紧力矩。预紧度的调整在主齿内外轴承之间增加或减少主齿轴
承调整垫圈。调整垫片减少，预紧力矩增加；调整垫片增多，则预紧力矩减少。
□ Adjustment of differential case B/R preload.
□ 差速器轴承预紧调整
 Adjust of differential B/R : differential B/R should have suitable preload, make two side
over0.01-0.02mm. the B/R start torque is 0.686-1.586 N.m when lubricating the B/R with gear oil
under pinion & ring gear non-match condition. It can get through tight side nut. Tight cover bolt,
then adjust preload. After adjustment, the lock slot should align to lock plate and ring gear have no
axis movement.
差速器轴承的调整：差速器轴承应调整使其具有预紧力，使其两侧得到 0.01-0.02 的过盈,在主
从动齿轮未啮合条件下在轴承转动部分加注齿轮油,起动摩擦力矩为 0.686-1.586N.m。差速器轴
承预紧力调整是借拧紧差速器轴承螺母调整来进行的，调整时应先将轴盖自由地盖上，待调整
环拧动自如时，再将轴承盖螺栓拧紧，然后再调整预紧力。调整后的调整螺母上的锁槽应对准
锁片位置。调整后被动齿轮应无轴向窜动。
 Adjust B/L of differential case gear
差速器齿轮间隙调整
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Measuring planet gear B/L with gauge. Note: check more then 3 point, standard:0-0.15mm;
用百分表在行星齿轮上测量差速器齿轮啮合间隙。注意：测量三个以上点，标准值：0～0.15mm；
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极限值：0.3mm。
□ Adjust of pinion & ring gear B/L and pattern

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主被动齿轮齿侧间隙、啮和印迹的调整
 Adjust B/L
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齿侧间隙的调整
The standard B/L and vary (according to table 5), should check it along ring gear edge 4 points, and
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the gauge head should be perpendicularity to check point
主、从动齿轮正常啮合间隙及侧隙变动量见表 5，调整齿侧间隙时，应在从动齿轮沿圆周大致
均布的四个位置上进行测量，所用千分表的测量头应垂直与被测点表面。
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 Adjust pattern
主被动齿轮啮印迹调整
Applying red paint on the ring gear tooth, turning the ring gear come-and-go, then checking the print
of tooth’s both side. If the print lie in medium and near to small side, total to 60% of whole tooth
surface, we can decide the pattern is good(according to attached picture1). We can get the pattern
through adjusting the pinion gear housing shim(table 6) and adjusting differential case B/R nut.
先在主动齿轮轮齿上涂红丹粉，然后用手使主从动齿轮反复转动，于是从动齿轮的两侧工作面
上出现红色印迹，若从动齿轮正转和反转工作面上的印迹位于齿高的中间偏于小端，并占齿面
的 60%以上，为正确啮合。见附图。正确啮合的印迹位置通过主齿轴承座调整垫片及差速器轴
承调整螺母来调整的。
One B/R nut out circle should equal to another side nut in circle, thus the preload of side B/R will not
change. Recheck B/L and lock the lock plate.
为保持已调整好的差速器轴承预紧度不变，一端调整螺母拧入的圈数应等于另一端螺母拧出的
圈数。再确认间隙后，锁紧锁片。
□ The rear wheel hub with brake drum assembly according to remove the inverse process of assembly,
assembly time adjustment is as follows
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后轮毂带制动鼓总成装配按拆卸逆过程装配，装配时调整如下：
 The rear wheel hub bearing clearance adjustment
 后轮毂轴承游隙调整
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Tighten bearing nut to brake drum is not moving or rotating heavy, slightly loose bearing nut 1/6-1/8,
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and then turn the brake drum, without any contact with the brake drum brake friction disc, should be
able to rotate freely.
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将轴承螺母拧紧至制动鼓不动或转动沉重，然后稍松轴承螺母 1/6-1/8 圈，转动制动鼓，制动

摩擦片不与制动鼓接触情况下，应能转动自如。
□ The rear brake clearance adjustment

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后制动器制动间隙调整
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 Bidirectional balance brake according to the direction arrow on bottom plate adjustment hole, first
pump adjustment tooth pulled move two points respectively, brake drum and the friction plate die,
and then adjust the cylinder gear, respectively, and virtually back to 5 ~ 9 after the tooth, the brake
drum to flexible rotation.
双向平衡式制动器按底板调整孔处的箭头方向，先分别拔动两个分泵调整齿，使制动鼓与摩擦
片贴死，然后将分泵调整齿分别跋回 5~9 齿后，使制动鼓能灵活转动。
□ Adjustment of backlash
齿轮啮合间隙调整方法图
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A、gear contact zone adjustment
Adjustment ways:
Passive work gear tooth surface contact Reason
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B、gear side clearance adjustment
1、Driven gear moves away from

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main gear
Main gear is too far 2、Main moves to the driven
from the driven gear gear to get the right clearance

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Partial gear top
(Add gasket）
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1、Driven gear moves to main
gear
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2、 Main moves away from the
driven gear to get the right

Partial gear roof Main gear is too near
clearance
from the driven gear
(Reduce gasket）
1、Driven gear moves away from
main gear
The driven gear is too 2、Main moves away from the
near from Main gear driven gear to get the right

Partial gear little side
clearance
(Reduce gasket）
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1、Driven gear moves to main
gear
2、Main moves to the driven gear
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The driven gear is too
far from Main gear to get the right clearance

Partial gear big side
(Add gasket）
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Gear depth
Gear length
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Failures 故障 Causes 原因 Action 措施
preload is big adjust preload
轮毂轴承预紧力大调整预紧力
Problem of wheel hub

lack lubrication or misusing add lubrication or change
bearing
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轴承缺乏润滑或润滑脂不正确加注或更换润滑脂
轮毂轴承滞涩
bearing is contaminated with dust clean and add lubrication
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轴承沾灰尘清洗并加注润滑脂
camshaft may not be well lubricated or adjusting add lubrication or rectify failure part
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arm can not get back to the original position
加润滑脂或校正有故障部件
problem of wheel
凸轮轴润滑不良或调整臂不回位
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车轮发涩
brake shoe or spring is broken or fatigued exchange the failure part
制动蹄或气室回位弹簧折断或疲劳更换有故障部件
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the gap of differential gear is not right exchange washer or gear

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差速器齿轮间隙不当更换垫片或齿轮
preload of drive gear bearing is too small adjust preload diff pinion
abnormal noise 主动齿轮轴承预紧力过小调整预紧力
传动非正常声音
lack lubrication add enough lubrication
油平面过低加足润滑油
problem of oil seal Replace the oil seal
油封磨损、松动或损伤更换油封
The main reduction fastening bolt loose or

Tighten bolts or recoat sealant
sealant damage
拧紧螺栓或重涂密封胶
主减紧固螺栓松或密封胶损坏
In accordance with the provisions,
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The bolt bearing loose.
torque screw down the bolt
轴承座紧固螺栓松
lubrication leak 按规定力矩拧紧螺栓
润滑油泄漏
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Oil drain screw loose or pad damage
Tighten the screw or replace the
gasket
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放油螺塞松或衬垫有损伤
拧紧螺塞或更换衬垫
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Correction or replacement of the

Due to the overload bridge shell deformation
bridge shell
由于超载使桥壳变形
校正或更换桥壳
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Air plug stuck or damage Clean or replace vent plug

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通气塞被堵或损伤清洁或更换通气塞
malfunction of camshaft check camshaft
凸轮轴旋转不灵检查凸轮轴工作情况
problem of brake
制动力不足 the stroke of pushing rod is not well adjusted adjust stroke
制动气室推杆行程调整不当调整行程
the problem of brake shoe lining exchange the brake shoe lining
摩擦片过热或变质更换摩擦片
the position of brake shoe lining is incorrect rectify the position
摩擦片贴合不当校正摩擦片贴合位置
problem of brake
water get into brake drum press pedal and drain the water
制动力不足
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制动鼓进水行驶中轻踩踏板，排干水
the contacting face of brake shoe lining or brake clear up the brake shoe lining or
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drum has grease exchange
摩擦片或制动鼓接触面上有油脂清除油脂或更换摩擦片
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Chapter Ⅷ Brake system
第八章制动系统
I Interview 概述
Brake system mainly consists of brakes, air reservoir, brake pipe, brake pedal and other components,
which is a series of specialized devices used to enable outside object (mainly the road) to apply a certain
force to some automotive parts (mainly the wheels), so that it can apply constraint braking force to the
vehicle. The function of Braking system role to make the running vehicle slow down or even stop
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mandatory in accordance with the willing of the driver; ensure the parking vehicle be stably parked under
various road conditions (including the ramp); make the downhill running vehicle remain a stable speed.
The vehicle braking action can only come from the apposite direction external force while the magnitude
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of these external forces are random, uncontrollable, so a series special devices need to be installed on the
vehicle to achieve the above functions.
制动系统主要包含制动器、储气筒、制动管路、制动踏板等零部件，是汽车上用以使外界（主
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要是路面）在汽车某些部分（主要是车轮）施加一定的力，从而对其进行一定程度的强制制动的一
系列专门装置。制动系统作用是：使行驶中的汽车按照驾驶员的要求进行强制减速甚至停车；使已
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停驶的汽车在各种道路条件下（包括在坡道上）稳定驻车；使下坡行驶的汽车速度保持稳定。对汽
车起制动作用的只能是作用在汽车上且方向与汽车行驶方向相反的外力，而这些外力的大小都是随
机的、不可控制的，因此汽车上必须装设一系列专门装置以实现上述功能。
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II Location drawing and exploded view 位置图及爆炸图
1、 Schematic Diagram 原理图
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Exploded view 爆炸图
□ Front Brake 前制动器
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00 Return spring-brake shoe 回位弹簧-制动蹄

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01 Assembly of brake shoe with friction plate (lower) 制动蹄带摩擦片总成
02 Assembly of front brake shoe with friction plate (upper) 前制动蹄带摩擦片总成
03 Assembly of front brake bottom board(R) 前制动器底板总成

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04 Shaft of front brake shoe 前制动蹄片轴
05 Front brake cam(R) 前制动凸轮
06 Hex nut 六角螺母
07 Assembly of front brake chamber assembly(R) 前制动器室支架总成
08 Assembly of front brake chamber assembly(R) 前制动气室总成
09 Front brake adjustable arm assembly 前制动间隙调整臂
10 Hex nut 六角螺栓
11 Dust proof cover of front brake 前制动器防尘罩
□ Rear Brake 后制动器
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00 Dust proof cover 防尘罩
01 Assembly of brake shoe with friction plate (lower) 制动蹄带摩擦片总成（下）

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02 Return spring-brake shoe 回位弹簧-制动蹄
03 Assembly of brake shoe with friction plate (upper) 制动蹄带摩擦片总成（上）
左制动器底板
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04 Assembly of left brake bottom board(R)
05 Shoe pin 蹄销
06 Rear left brake cam 后左制动凸轮

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□ Brake Pipe 制动管路
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00 brake valve push rod 制动阀推杆

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01 transmission fork 传力叉
02 Air outlet hose unit I on the upper chamber of brake valve 制动阀上腔出气尼龙管总成Ⅰ
03 air inlet hose unit II on the upper chamber of brake valve 制动阀上腔进气尼龙管总成Ⅱ
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04 air inlet hose unit II on the lower chamber of brake valve 制动阀下腔进气尼龙管总成Ⅱ
05 connecting hose unit 连接软管总成
06 air outlet hose unit on the upper chamber of brake valve 制动阀上腔出气尼龙管总成Ⅱ
07 air outlet hose unit on the lower chamber of brake valve 制动阀下腔出气尼龙管总成
08 seal board unit of air outlet hose,brake valve 制动阀出气密封板总成
09 air inlet hose unit of front quick-release valve 前快放阀进气软管总成
10 brake pedal and driving gear assembly 制动踏板及传动机构总成
11 air inlet hose unit I on the upper chamber of brake valve 制动阀上腔进气尼龙管总成Ⅰ
12 bracket of brake pipe 制动管支架
13 air inlet hose unit I on the lower chamber of brake valve 制动阀下腔进气尼龙管总成Ⅰ
14 seal board unit of air inlet hose,brake valve 制动阀进气密封板总成
15 brake valve assembly 制动阀总成
16 exhaust hose of brake valve 制动阀排气管
17 inlet hose unit of front brake chamber 前气室进气软管总成
18 hex nut 六角薄螺母
19 Serrated lock washer 外锯齿锁紧垫圈
20 inlet hose of front brake chamber（R) 前气室进气尼龙管总成（右）
21 front quick-release valve and bracket assembly 前快放阀带支架总成
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22 inlet hose of front brake chamber(L) 前气室进气尼龙管总成（左）
23 hose joint 管接头
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25 brake pipe unit 制动尼龙管总成
26 seal washer 密封垫圈
六角薄螺母
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27 hex nut
28 air pump outlet elbow 打气泵出气弯头
29 air compressor outlet steel pipe unit 空压机出气钢管总成

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31 air compressor outlet hose unit 压缩机出气软管总成
32 bracket 支架
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33 hex flange bolts 六角法兰面螺栓
34 hex nut 六角薄螺母
35 washer 垫圈
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36 hex flange nuts 六角法兰面螺母
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00 Air compressor outlet steel pipe unit(Ⅱ) 压缩机出气钢管总成(Ⅱ)
01 Air compressor outlet pipe bracket unit (Ⅱ) 压缩机出气钢管支架(Ⅱ)

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03 rubber pipe clip 橡胶管夹
05 clip(Ф4-Ф12) 管夹(Ф4-Ф12)
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07 air compressor outlet pipe bracket unit (Ⅲ) 压缩机出气钢管支架(Ⅲ)
09 air reservoir model 储气筒模块
10 inlet hose unit of air reservoir(Ⅱ) 储气筒进气尼龙管总成(Ⅱ)
11 inlet hose unit of air reservoir(Ⅰ) 储气筒进气尼龙管总成(Ⅰ)
12 inlet hose unit of air reservoir(Ⅲ) 储气筒进气尼龙管总成(Ⅲ)
13 inlet hose of unit air reservoir(Ⅳ) 储气筒进气尼龙管总成(Ⅳ)
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00 pipe clip 带保护管卡

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02 pipe bracket 尼龙管支架

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06 air inlet hose unit of rear brake chamber 后气室进气软管总成
07 relay valve with quick-release valve assembly 后继动阀带快放阀总成
08 air inlet hose unit of rear brake chamber 后气室进气软管总成
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S/N 序号
00
Spare Parts Name
Manual control valve bracket 27 备件名称
制动阀推杆
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01 hex flange nuts 传力叉
02 manual control valve assembly 手控阀支架
03 spring washer 六角法兰面螺母

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04 cross recessed screws 手控阀总成
05 hand brake valve outlet hose assembly I 弹簧垫圈

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06 hand brake valve inlet hose assembly II 十字槽盘头螺钉
07 card 手制动阀出气尼龙管总成 I
08 connecting hose unit 手制动阀进气尼龙管总成 II

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09 hand brake valve inlet hose assembly 卡片
10 hand brake valve outlet hose assembly II 连接软管总成
11 air inlet hose unit of front quick-release valve 手制动阀进气尼龙管总成
12 hex flange bolts 手制动阀出气尼龙管总成 II
13 air inlet hose unit of front quick-release valve 前快放阀进气软管总成
14 quick-release valve assembly 六角法兰面螺栓
15 hex flange nuts 前快放阀进气软管总成
Remarks: The above pictures are typical component pictures, there is subtle difference between
some models and we didn’t mark them here
1、 Cautions 注意事项
□ Good protection should be conducted to avoid scratches in removing and installing components
process
拆卸和安装部件过程中，应做好防护，以免出现划伤；
□ When remove and install some parts, check the lubrication of parts. If necessary, smear "Grease";
拆装某些部件时，检查部件是否润滑不良，如果有必要，涂抹“润滑脂”；
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□ Several persons may be required to cooperate in removing and installing because of the complexity
of the structure of vehicle parts.
由于汽车部件结构的复杂性，拆卸过程可能需多人配合进行；
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□ Do not use excessive force when removing, because it may cause deformation of parts.
拆卸时请勿用力过大，因为可能导致零件变形。
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Removal and Installation of air reservoir 储气筒拆装
□ Remove air reservoir, removal order: brake pipe,

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dual-circuit protection valve, air reservoir fixing bolts;
拆解储气筒，拆解顺序为：制动管路、双回路保护阀、
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储气筒固定螺栓
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□ Preparation: pull the clip ring of air release hole of air

reservoir until the air is released clearly.
准备工作：用手拉住储气筒放气孔卡环，直至空气放
完为止
□ Remove the connecting nuts between brake pipe and air
reservoir.
拆解制动管路与储气筒链接螺母
□ Remove the connecting nuts between dual-circuit

protection valve and air reservoir.
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拆解双回路保护阀与储气筒链接螺母
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□ Remove the fixing nuts between air reservoir and
ground.
拆解储气筒与地盘固定螺母
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Installation: Install according to the opposite order of removal and please be noted with the
following items:
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□ Please smear leakage-proof glue when installing the

connecting bolts of brake pipe, dual-circuit protection
valve and air reservoir.
装配制动管路、双回路保护阀与储气筒链接螺栓时需
要涂防漏胶。
Removal and Installation of brake pipe 制动管路拆装
□ Remove brake pipe: remove the brake pipe one by one

along with pipe alignment.
拆解制动管路，沿着制动管路走向逐一拆解各段制动
管路
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准备工作：用手拉住储气筒放水孔卡环，直至空气放
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完为止
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Installation: Install according to the opposite order of removal
4、Removal and Installation of brakes 制动器拆装

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□ Remove brakes, removal order: brake chamber, brake

chamber bracket, brake shoe with friction plate
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assembly.(Please refer to Front axle and Rear axle for

the removal of brakes assembly from front and rear
axle )
拆解制动器，拆解顺序为：制动器室、制动器室支架、
制动蹄带蹄片总成（制动器总成从前轴、后桥拆解
下的步骤请参见《前桥》、《后桥》章节）
□ Remove the connecting bolts between brake chamber
and brake chamber bracket, take off brake chamber
拆解制动器室与前制动器室支架链接螺栓，取下制动
器室
□ Remove the fixing bolts between brake chamber and

dust-proof cover, take off brake chamber bracket.
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拆解制动器室支架与防尘罩固定螺栓，拆下制动器室
支架
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□ Remove the fixing bolts of brake shoe shaft, take off
brake shoe shaft and return spring and take off brake
shoe
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拆解制动蹄片轴固定螺栓，取下制动蹄片轴与回位弹
簧，拆下制动蹄片
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□ Remove brake camshaft
拆解制动凸轮轴
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following items:
□ Adjust brake clearance
调整制动间隙
□ It’s required to adjust brake clearance when re-installing:

first press down the lock of brake adjustment arm, then
rotate adjustment bolts to adjust brake clearance. Rotate
clockwise to narrow the clearance. Rotate anti-clockwise
to increase the clearance.
复装时必须调整制动间隙：先压下制动调整臂上的锁
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止套，然后旋转调整螺栓调整制动间隙。顺时针旋转
减少间隙。逆时针旋转增加间隙。
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5、Brake lever removal of parking brake 驻车制动制动手柄拆装
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□ Remove the fixing nuts, take off brake lever.
拆解固定螺母，拆下驻车手柄
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following items

准备工作：用手拉住储气筒放水孔卡环，直至空气放
完为止
6、制动踏板拆装
□ Removal the bolts and replace the brake pedal
拆解制动踏板固定螺母，取下制动踏板
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following items:
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IV Diagnosis and treatment 故障诊断与处理
1、 Brake block
制动不灵
□ Fault phenomenon: when the car brake, driving people feel inadequate deceleration; When the car
emergency braking, braking distance is too long.
故障现象：汽车制动时，驾驶人感到减速度不足；汽车紧急制动时，制动距离太长。
□ The cause of the problem
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故障原因：
 The poor work of air compressor results in the low-pressure or no air within air reservoir. The reasons
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may be the loose or broken of air compressor belt, leakage of exhaust valve, the spring of exhaust
valve being too soft or broken, leakage of piston or piston ring.
空气压缩机工作不良，而使贮气筒内气压低或无气。可能是空气压缩机皮带过松或折断，空气
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压缩机排气阀漏气，空气压缩机排气阀弹簧过软或折断，活塞或活塞环漏气。
 Pipe cracks or connections loosen

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气管破裂或接头松动。
 Brake diaphragm or brake chamber diaphragm cracks
制动阀膜或制动气室膜片破裂。
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 The stroke of brake pedal is too large
制动踏板自由行程过大。
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 Improperly adjustment of brake arm worm makes the brake chamber push rod outstretch too long
制动臂蜗杆调整不当，使制动气室推杆伸出过多。
 The clearance between friction plate and brake drum is too big or there is oil spill on the friction plate
摩擦片与制动鼓间隙过大或摩擦片有油污。
□ Diagnosis and Trouble clearing
诊断与排除：
 If the barometer indicates the number "0", please depress the brake pedal, if there is a sound of
deflating when lift the pedal, it means the barometer is broken and please replace it. If there is no
sound of deflating, please check the air compressor belt and the pipes between air compressor and air
reservoir.
如压表指示数为“0”可踏下制动踏板，松起时如有放气声，即说明气压表有故障，应更换气压
表。如无放气声，则检查空气压缩机皮带和由空气压缩机至贮气筒一段气管的情况。
 After the above inspection, if the barometer indicates a low pressure level, it means there are faults
within air compressor. Please check the exhaust valve and inner cylinder and clear the trouble.
经上述检查，情况良好，如气压表指示数很低，则故障在空气压缩机，应检查排气阀或汽缸内
部技术状况，予以修复。
 If barometer indicates a normal pressure level, then depress the brake pedal and check whether there
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is leakage among brake valve and each wheel. If there is no leakage, please check the stroke of brake
pedal and adjust the clearance between brake friction plate and brake drum
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如气压表指示压力数值合乎标准，可踏下踏板，检查由制动阀至各车轮间有无漏气之处。如无
漏气处，则检查踏板自由行程和调整制动蹄摩擦片与制动鼓的间隙。
Made brake bite

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制动发咬
□ Phenomenon: when lifting the brake pedal, the exhaust brake valve exhausts slow or does not exhaust,
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resulting in no release of brake immediately; Or the exhaust valve exhausts normally, but there is still
a left braking effect that causes the car running hard or weakness. Original car:
现象：抬起制动踏板后，制动阀排气缓慢或不排气，不能立即解除制动，或排气虽快，但仍有
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制动作用，致使汽车起步困难或行车无力。原车：
 No free stroke of brake pedal

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制动踏板无自由行程
 Brake exhaust valve adjustment pads is too thin, the return spring is too soft or broken or Rubber seat
is aging
制动阀的排气阀调整垫片过薄，其回位弹簧过软、折断或橡胶阀座老化发胀。
 Brake valve lever rusts

制动阀挺杆锈蚀
 The transmission parts between the brake pedal and brake valve arm get stuck
制动踏板至制动阀位臂之间传动件发卡。
 Brake camshaft and brackets bushings rust and get stuck
制动凸轮轴与支架衬套锈蚀发卡
 The clearance between brake drum and brake friction plate is too small
制动鼓与摩擦蹄片间隙过小
 Brake shoe pins rust or the return spring is too soft or broken.
制动蹄支销锈污或回位弹簧过软、折断
 The match section between axle tube and its rear axle housing or wheel bearings wear, resulting in
loosening
半轴套管与其后桥壳或轮毂轴承配合处磨损造成松动
 Brake chamber diaphragm is deformed and aged, single-layer film ruptured or a brake hose is aged,
28
the air flow is not smooth.
制动气室膜片老化变形，单层胶膜破裂鼓起或制动软管老化，气流不畅
27
□ Diagnosis
诊断
12
 The exhaust brake valve exhausts slow or does not exhaust when lifting the brake pedal, it is the
brake valve fault in most cases and the symptom is that all the brake drums get hot.
抬起制动踏板时制动阀排气缓慢或不排气，多属制动阀故障，表现为各轮制动鼓均发热。若排
20
气声怯或继续排气而制动发咬，一般为个别轮制动发咬，摸试各轮制动鼓温度高者即为有故障
之轮。
 If it’s confirmed that its fault of brake valve, please the free stroke of brake pedal first. If the free
C-
stroke is too small, please adjust it. If the free stroke is normal, please loosen the exhaust valve to test.
If the situation gets better, then the fault is the exhaust valve adjustment pads is too thin. If the
situation remains bad, please check whether the exhaust valve return spring and film are fine, if yes,
JA
please check the whether the brake lever rusts or not and brake passing rod is flexible or not.
若确定制动阀有故障，应先检查制动踏板自由行程。若自由行程太小或没有，应予以调整。若
自由行程正常，可旋松排气阀试验。如有好转，则为排气阀调整垫片过薄。仍无好转，可检查
排气阀回位弹簧及胶座以上均正常，则应检查制动挺杆是否锈污及制动传递杆件是否活动灵
活。
 Individual gears bite. Please observe the brake chamber push rod returning situation when lifting the
brake pedal. If it returns slowly or does not return, please check whether there is no lubrication
between the brake camshaft and its bracket cover or too large angle of different axles that causes
stuck. If the clearance is found normal when lifting the wheel, but the clearance changes when
putting down the wheel, then it means the wheel bearing loosens or the match of axle tube and its rear
axle housing loosens. If the clearance remains normal, please check whether there are problems with
brake chamber diaphragm and return spring.
个别轮发咬，可在抬起制动踏板时，观察制动气室推杆回位情况。若其回位缓慢或不回位，应
检查制动凸轮轴与其支架套是否失去润滑或不同轴度过大而发卡。若架起车轮检查该间隙正
常，而落下车轮后间隙在变化，则系轮毂轴承松旷或半轴套管与后桥壳配合松动。若间隙正常，
可检查制动气室膜片及回位弹簧是否有问题。
Brake deviation (unilateral)

制动跑偏(单边)
□ Phenomenon: Two wheels can not brake concertedly when brake, the vehicle cannot stop along with
28
straight direction while deviate to one side
现象：制动时，同轴两车轮不能同时制动，汽车不能沿立脚点直行方向停车而偏向一侧。
□ Causes
原因
27
 The clearance of friction plate and brake drum of left and right side is different.
12
左右车轮摩擦片与制动鼓的间隙大小不均
 There are oil spill, hardening or rivet head exposed of some friction plate.
个别车轮摩擦片有油污、硬化或铆钉头露出
20
The friction plate material of left and right side is inconsistent or poor contact.
 左右车轮摩擦片材料不一致或接触不良
C-
 Camshaft stuck or brake chamber fault of some wheels

个别车轮凸轮轴发卡或制动气室有问题
JA
 The brake drum of some wheels goes out of roundness or the surface of the drum gets grooves of
some wheels
 个别轮制动鼓失圆度过大或鼓壁磨出沟槽
 Two front leaf springs elastic is unequal

两前轮钢板弹簧的弹力不等
 Uneven front beam

有负前束
 Horizontal connecting rod pin loosens or vertical arm loosens.

横、直接杆球头销或垂臂松旷
□ Diagnosis
诊断
 First, please conduct road test. If the vehicle deviates to left side when braking, it means that the right
brake is not effective. If the vehicle deviates to right side it means the left brake is not effective. After
parking, please check the grinding crack of left and right wheels on the ground. The brake of the side
is not effective if its grinding crack is short and light. Referring to the exclusion of the above reasons,
if it’s the problem of friction plate, please repair, replace, adjust, tighten and so on. There are many
similarities of brake deviation of air brake and hydraulic brake, please refer to each other.
首先进行路试。制动时，汽车向左偏斜即为右边车轮制动不灵，向右边偏斜好为左边车轮制动
28
不灵。停车后察看左右两边车轮在地面上的拖痕，拖痕短而轻的一边车轮制动不灵。参照上述
原因进行排除，如是摩擦片有问题，可进行修复、更换、调整、紧固等。气压制动跑偏与液压
27
制动跑偏有许多相同之处，可以互相参考
12
20
C-
JA
28
27
12
20
C-
JA
Compiling 编制 King.wang 汪国君
Audit 审核 Youwang.zhang 张有旺

Approve 批准
标记处数分区更改文件号签名日期
4000002LG016
Power distribution配电 Meter仪表 Diagnosis诊断 EC BC ABS

B2 PD05 B/W 3.0 B2 B2 B2 B2 B2 B2 B2 B2
B2
B1
B1
ACC
PD06 B/R 3.0
IC06 R/Y 3.0

B1
ACC
B1
ACC
B1
ACC
U B1
ACC
B1
ACC
B1
ACC
M B1
ACC
B1
ACC
ACC
IG1 IC07 G/B 2.0 IG1 IG1 IG1 IG1 IG1 IG1 IG1 IG1
IG1
IG2 IC09 G 3. 0 IG2 IG2 IG2 IG2 IG2 IG2 IG2 IG2
IG2
120Ω
10eY0.5
l 05
.
cab terminal resistance驾驶室终端电阻
20eB
AB
CA
CANH CANL
CA
AB S consta nt el ectric F4
1 8 SO
2 F3 ABS常电 10A
B05 M46 M46 N电
SBF2 SBF5 SBF6 F18 F3 1 F35 F20 F42 6 13 15A
F34 W/S05 F36 F38 F13 F10 F21 SBF10 F8
l 05
SBF1 F17 F4
10Y0.5
.
C I J K L M N
20B
50A 30A 40A 10A 5A 30A 5A 30A 20A
20A B A 10A 30A 10A 10A 10A 10A 60A 20A 7 10A
CA
CA
4 5 B09
1
MC01 MC01 B14 2 WW01a Bl/W 0.85
6
rB0.5
MC04
B13
CA10Y0.5
l 05
44aB
B14 4 WW06 Bl/G 0.85
.
4 6 2 6 1 9 4 1 5 12 6
CA20B
/ 5.0
EU
0.85
B01 B11 B07
04BR
8
l/W0.85
MC05 MC05 B02 B04 B02 B01 B10 B14
B11 3
IC03R12f
X16-86 B14 3 WW07 Br 0.85
GD30a B 0.5
/R5.0
X15-86 X9-86
l/W
Solenoid valv e PD09a G 0.5 PD09b G 0.5 X13-86 X32-86 X31-86
80
EU38aGY05
Y05
Y05
B14
Y0.5
01aB
PD
.
.
04W
11W
01B
Small lights relay High beam relay Low beam relay Front fog lamps Rear fog lamps
38bG
38dG
2
38cG
Rearview mirror B14 13
09G0.5
09G0.5
W
WW08 B/R 0.85
W
电磁阀
PD
IP14a B/Bl 0.5

PD
W
16R0.85
W
IP14B/Bl 0.85
r 0.5
PD15R3.0
D30aB0.5
EU
EU
IP15G/O0.5
B05
EU
小灯继电器远光灯继电器近光灯继电器 relay relay defrosting relay 4
PD
PD
87a 87 87a 87
PD08G
2 M19 Ignition switch 1 2 M21 Right combination switc RL01 R 0. 5
MR01 85 85
D40cB0.85
PD
.5
12R3.0
MC04 1 4 Starting protection relay 前雾灯继电器
13R30
PD14R12
后雾灯继电器后视镜除霜继电器 5
G
M19点火锁 1 2
.
W/S01 1 5 8 85 30 3 85 87a 87 85 87a 87 85 87a 87 hM21右组合开关
rB1.25
12
.5
RL01bR0.5
r0.85
terminal
起动保护继电器 3
PD
W12
OFF AC 0N ST
E F 2 2 Urea ta nk temperature 85 30 85 30 85 30 Unlocking relay
PD
底盘终端电阻
RL01aR0.5
MC05
G
RL01R0.5
3 1 MC01 B16 B11 B15 B13 B9 +2 +1 1 Locking relay
08aG
DU36G
resistance
PD05 B/W 3.0
DU35R
X11 X4
20
2 Solenoid valve 电磁阀RF 2 Solenoid valve 电磁阀LB 2 Solenoid valve 电磁阀RB
0Ω
B2 C60 sensor
+ R03 Front top light R04 Rear top light 2 Solenoid valve 电磁阀LF
.
C
6R
Coolant level SCR outlet temperature 开锁继电器
/ 50
1 Urea heatin g solenoi d val ve INT

D40B3.0
PD
.
M
闭锁继电器
IP15aG/O0.5
Chassis12
Low-speed High-speed
6
IC09 G 3. 0 SCR i nl et tem perature 尿素罐温度传感器
CAN line short-circuiter M42 Washing motor M
B
R
IG2 Urea heater relay Urea ta nk liqui d le vel sensor ON file relay 1
r0.5
2 R04后顶灯 2
03W
R03前顶灯
A
2
switch CAN 线短路器尿素加热电磁阀 X26 sensor Gril e heater relay Fuel heating ON relay X28 X29 Dryer ON relay X3 X6 X8 LO
08G
IC08 B/W 0.85
ST 34 16 35 36 4 尿素加热继电器 sensor 尿素罐液位传感器 wiper relay wiper relay
G
M42洗涤电机 3 3
PD
ON档继电器 1 1 3 1
-
/ l 0.5
4 11 SCR出口温度传感器 SCR进口温度传感器 2 M23 Insert the 3 1
PD
PD06 B/R 3.0 4 12 燃油加热 ON继电器干燥器 ON继电器 HIW 6
B1 冷却液位开关格栅加热继电器 86 30 86 30
IP06aBB
5 1 2 低速雨刮继高速雨刮继 WAS AB7LgY1.25
AC IC06 R/Y 3.0
J5-1 Urea feeding device 尿素加料装置 NO sensor NO传感器 1 1 B key switch AB34Lg1.25
D03eB0.85
6
IC07 G/B 2.0 2 86 87 87a 86 30 电器 86 30 电器 86 30 H AB33LgB1.25
IG1
C M40 Wiper motor
0.5
B M23钥匙插入 DOOR DOOR
.5
r1.25
r0.5
BF01 86 87 86 87a 87 86 87a 87
EU14LgB12
BF02
IP03W
0.5
3 2 1
48aB
B14 2 2
r0.85
58W
M40雨刮电机
48B
AB55BlW1.25
12f
23 28 22 3 1 2 5
G
WW04 Br/R 0.5 5 开关
l/B0.85
/R05
L01W
/ 0.5
50A
.
80A
EU
4
08G
EU
EU
D23B0.5
B09 OFF OFF
19BR
19 22 7 6 6
/ 0.5
18W
13
05aB
ON ON
PD
B04 M58 AB54LgW1.25
G
M16 Combination instrument
BC17YR
Fuse box copper Urea pi pe heater
RL02R/G0.5
MC01
TA
B09 B14 B14 B10 1 8 8 3 5 4

TA
B09
W
G
/ l 0.5
GD32B0.5
保险盒铜板
IP15G/O0.5
R12
CANL
W
CANH 尿素管加热器 Grid heater 1 B08 B08 B01 B10 B11 B11
lY0.5
Y0.85
IP14BB
l 05
AVW
W05
l 0.5
3.0
D03B3.0
.
0.5
rB0.5
R0.5
l 05
01W
02B
CA10 Y 0.5 2 3
.
IP03W
EU02B
EU09B
Sensor RF Sensor RB
38G
格栅加热器
50R
G0.5
DL15V/W05
Sensor 传感器LF 传感器 Sensor 传感器LB 传感器
M16组合仪表
DL06G/R0.5
DL08G/R0.5
EU02B
/ l 0.5
DL07G/Y0.5
DL09G/Y0.5
1
44B
54B
/ l0.5
/ 0.5
01R/Bl0.5
DL14V0.5
EU
l 0.5
Y0.85
/ 0.5
DH
HS02R/W05
EU
IL01G/O0.5
G
.
C60
EU
l 0.5
EU32Y
PD18aBB
WW03 Br/B 0.5
C10cY0.5
IP15aGO
EU
19G0.5
FL02P0.5
20cB
18BB
EU
F24
B
BF03 BF04 CA20a Bl 0.5 MR01
02W
DH02R
FL08B
5
r/B0.5
0.8
9 10
CA
PD
AVSR5.0
HS
R
PM
PD
10A
G
125A 125A Water temperature alarm 3 CAN line short-circuiter
RL02R/G0.5
15 14 20 21
03aB
.5
02Y/B05
8
.
12
J4
D0
CAN 线短路器 WW05 Bl/B 0.85
lY
P
W
S elf GND
8B
水温报警 16
W
Cool ant temperatur Coolant level alarm
B
W
Barometer F uel gauge Speedometer
A
4 45 1 21 14 48 58 9 50 36 49 38 2 44 54 32
W
Tachometer 自身搭铁 85 30
冷却液位报警 2
5
Dryer干燥器
1.25
15 e gauge Fuel alarm
1.2
Air filter cloggi ng 气压表燃油表转速表车速表 Fuel heater
C1 C9 C2 C10 B5 B1 B2 B3 B4 A30 A11 A5 A19 A6 A7 A28 A12
gR
0.5
r0.5
r05
r0.5
lR
0.5
05
05
05
.
B09 水温表
.
燃油加热器
5L
6B
空滤器堵塞 X30
9B
8B
7B
1B
0B
5B
44B
M17 Diagnostic interface ECU VCC
ECU OEM端
燃油报警
2B
BCM(M37-A,M38-B,M39-C)
2
C46
2
3
B
B
B
2
B
C20
A
Exhaust brake relay
IB
A
A
A
/ 12f
Charge la mp
M17诊断接口 ECU电源端
IC03R12f
Left turning
B
Right turni ng 3 4 2 1
IC01W
排气制动继电器
B
IC05B/W0.5
充电指示灯
左转向 C8 C18 A3 A17 B16 B19 B10 B9 A15 B7 B8 B11 A18 C4 C12 A14 A20 A13 A4 A29 A22 B21 C14 A2 A16
AV 40f R CPU 右转向
5 6 14 1 33 41 16 19 30 15 24 5 27 35 28 26 25 22 55
1 MD02 MD02 MD04 MD04
/ l 0.5
/ 0.5
HS20Y/B05
/ 0.5
DL07G/Y05
/ 0.5
DL09G/Y05
87
RL03R/Bl0.5
/ 0.5
/ l 0.5
86 87a
l 05
CA10cY0.5
l 0.5
AC09G/R0.5
DL04G/B0.5
DL05R/G0.5
.
C C C C
r0.85
0.5
AC26B/R05
06V/Y05
EB01aLg0.5
D03gB0.5
R0.5
.
D03fB0.5
0.5
.
r0.5
r 0.5
IL11GO
DL06GR
DL08GR
BC06P0.5
L04P0.5
BC05Y0.5
L03BB
07PB
12W
HS11B
20RB
20cB
EU05Lg/Y0.5
01W
/ l0.5
A
EU15R/W0.5
RL04B
55G
/ 0.5
/ 0.5
/ 0.5
IL08B
IL09G
16Y/B05
.
16 17 1 2 5 4 6 9 7 8 10 13 11 18
HS
41GR
EU24YR
BC
CA
TA
AC
PM
30W
EU
11
19W
2 2 11
F
l 05
G
0.5
5
F
27R0.5
35G0.5
28B0.5
26Y0.5
.
EU25W
22B
1 2
D60bB0.5
D40aB0.85
2 6 6
EU
EU
EU
B09 B13 B13 B09
EU
GD60aB0.5
MC02 1
IP05G/Br0.5
/ 0.5
/ 0.5
EU
7 6 3 8 12
EU
EU
EU
EU
/O0.5
0.5
MD02 MD02
IP09G/Y05
IP07B/O0.5
IP10G/B05
MC02
D20aB0.5
8 MD02 MD04
.
2 6 7 11 9 3
IP06B0.5
IP04BW
ABS
/ 0.5
IP13Lg/W
33W
+ Built-in
/ 0.5
IP08W
MF01 MF01 MF01 MF01 MC02

l 05
l 05
G
G
10Y0.5
D10gB0.5
IL07aLg/R0.5
IL07aLg/R0.5
IL07bLg/R0.5
G
CA10bY0.5
MC01
G
l 0.5
MC01 MC01 MC01 MC01 MC01 MC01

IC02W
PD01O3.0
01R0.5
IC05B/W05
IP17YB
EU
20B
20bB
.
r 0.5
r 0.5
02B
temperature
/ 0.5
BC06P0.5
DL04G/B0.5
DL05R/G0.5
IL08B
IL09G
CA
CA
CA
G
EU
BC07P/B0.5
EB01aLg0.85
ST
IC02W
/ l 0.5
01Lg0.85
RL03R/Bl0.5
/ 0.5
/ 0.5
Batte ry switches
R05
05Y0.5
IP09aG/Y05
IP10aG/B05
.
B
EU15RW
R
.
3 15 8 6 18 15 17 13 14 16
EU30W
2 9 2 9 2 9
EU19W
HS09bR/Bl0.5
30 85 30 2内置温度开关 1 4 2 3 1 2
RL04B
85
05Lg/Y0.5
EU24Y/R05
.
IL07bLg/R0.5
MC02 MC03 MC03 MC03 MC01 MC01 MC01 MC01 MC01 MC01
EB
BC
蓄电池 1 1
D40eB1.25
/ 05
41G/R05
16Y/B05
.
.
D 1
B
1 1
EU33W
EU
Starting M11 Rearview mirror heatin g switch
0.5
M20 Left combination switch
M
Neutral 1
EU
EU
M20 Left combination switch
/ 0.5
IP13Lg/W
G
Starting rel ay X22 F05 Bel t swi tch M 15 Rear fog la mp switch
l 05
B+ D
X17 protecti on relay W/S03 M14 Front fog la mp switch M11后视镜加热开关
EU35G0.5
0.5
IP17YB
85 30 W/S03
EU27R05
EU28B05
EU26Y05
.
P ositi on Hand brake
.
M20左组合开关
25W
+
A2 A1 D13 Left courtesy D14 Right courtesy
EU22B
启动继电器启动保护继电器 2 9 1 M18 On-off swi tch B12 1
22 F 05安全带开关 F 03 Roll over test switch M15后雾灯开关 M14前雾灯开关 M20左组合开关 2 2
Speed output to ECU
r20
/ r0.5
Switch 4 8 4 8 4 8
EU
r2.0
.
- M 18离合开关 Exhaust brake MC01 lamp switch
3B
IP06B0.5
T A1 A1 A1 A1 A1 A 1 A1 lamp
IP05GB
F03翻转检测开关
aB
空档开关 M21 Exhaust braking switch P
4
车速输出给 ECU
D20bB0.5
D20cB0.5
D20dB0.5
D20eB0.5
D10bB0.5
D10aB0.5
3
B
GD05dB0.5
GD06bB0.5
10 Braking signal relay 排气制动阀 2 P
4
A
B
24V 87 86 2 87 86 X35 2 D13左踏步灯 D14右踏步灯
87a M20 Left combi natio n switch
手刹开关
dY0.5
A
3 OF
l 05
M21排气制动开关 Lower beam近光 3 2 5 4 3 0 4 O Q R H
.
MC01
D60B1.25
D60B1.25
Magnet 制动信号继电器 2
dB
2 2
D20mB0.5
M12 Crui se master swi tch
aB0.5
M20左组合开关 5
G
D60cB0.85
+
D10 Right door lock motor
0
D09 Left door lock motor
20
exciting
TAIL 5 3
l 3.0
0.5
Hig h beam远光
A
3 5 2 6 4 1 F
02G0.5
Oil measurement sensor
A
C
EU44W
C
D20m
IC04B
M55 M12巡航主控开关
G
coil
4 8 2 B10
D05aB0.5
1 A11
GD40bB0.85
H D09左门锁电机 D10右门锁电机
G
励磁
油量传感器 86 87 87a Overtaking超车 HEA D15 D16
ST
G
G
Battery
/ 0.5
/ 0.5
/ 0.5
/ 0.5
/ 0.5
D10cB0.5
线圈 3 10 4 11
GD20B0.85
Air filter 1
D30fB05
4
EU41dGR
41cGR
EU41bGR
EU41aGR
EU41eGR
.
3
G
蓄电池 2 M46 M46 D M46 M46 1 1
D50eB0.5
clo ggi ng switch MF01
EU
D16
G
1 1
G
空滤堵塞开关 CANH CANL 1 5 4 3 2 6 Throttl e position sensor 1 Throttle positi on sensor 2
D20mB0.5
W/S01 W/S04 W/S04 W/S01 CANH CANL
D10jB05
G
GD05B2.0
GD06B2.0
3 1 2
.
V olta ger eg ulator
Starter 2 9 油门位置传感器 1 油门位置传感器 2
D05B2.0
电压调节器
1
M46 M46
C F02 Right door lamp switch
G
3 3
G
起动机 W/S02 14 4 7 M32 Accelerator pedal 14 3 4 5 6 3 2 11 7 7 2
G
W/S01
D40B3.0
D08B3.0
1 2 1 2
D70B3.0
D70B30
GD40B30
F02右门灯开关 1 14
.
-
CANH CANL 8 GD10g B 0.5 GD20 B 0.85
M54 MD01 MD03 7
M54 M56 M32油门踏板 M56
D50B3.0
F01 Left door lamp switc MD01

D07B3.0
G
D40B3.0
G
D08B3.0
M07 Pressure sensors1 M54
D03gB0.5
M08 Pressure sensor2 1 1
D03fB0.5
1 1 1 h M55 M46 M46
D05B2.0
D06B2.0
D30B3.0
D10B3.0
D10B3.0
D30B3.0
D10B3.0
D05B2.0
Vehic le speed sensor
G
M07气压传感器 1 F01左门灯开关
G
M08气压传感器 2 CANH CANL
G
车速传感器
G
G
J9 Sel f GND Sel f GND J7-1 Sel f GND J6-2 J1 J7-2 J5-2 J5-1 J1 J2 J5-1 J7-1 J6-1 J7-1 J5-1 J4 J4 Body sel f GND J1 J1 J2 Self GND J1 J2
自身搭铁自身搭铁自身搭铁车身自身搭铁
自身搭铁
Lighting灯光
Electric horn 电喇叭 Cigar lighter点烟器 Radio收音机 Carcorder行车记录仪 Power window电动车窗 Rearview mirror defrosting后视镜除霜 Air-condition空调
B2 B2 B2 B2 B2 B2 B2 B2
B2
B1 B1 B1 B1 B1 B1 B1 B1
B1
ACC ACC ACC ACC ACC ACC ACC ACC
ACC
IG1 IG1 IG1 IG1 IG1 IG1 IG1 IG1
IG1
IG2 IG2 IG2 IG2 IG2 IG2 IG2 IG2
IG2
SBF8 SBF8 5 SBF1 SBF1

40A F29 F5 F27 40A B05 F12 F2 F25 240A F40 F10 F3 F6 SBF10 F30 F37
F7 060A F22 F16 F22
7.5A 10A 10A 10A 15A 15A 10A 10A 10A 15A 10A 20A 15A 60A 20A 10A
10A
1 1 1
/ 3.0
PD02 Y 3.0 PD02 Y 3.0
11 PD02 Y 3.0 PD02 Y 3.0 7
04B/R50
MC05 MC05
PD04B/R5.0
07BR
.
B09 MC04
B14 8
PD
PD
/ 5.0
B10 1 2 2 3 14 3 6
PD04BR
/ 0.5
5 B13 2
G
MC04 B05 MC05 B15

L01W
B05 B07 B09 B10 AC28 B/R 0.85

TA01R0.85
/ 0.5
5 2
G
/ 0.85
F
L01aW
/ 0.5
6 B05 C
AC28aBR
B14
G
AU02G0.5
L01bW
B10 3
F
6 S hort connector PD04 B/R 5.0 PD07 B/R 3.0 B05 6

F
B06 短接器 M48 2 B09

85 30 85 30 85 30 85 30 85 30 85 30 1 85 30 AU01a R 0.5 85 30 B01 85 30
10 5 6 9 M 34 Flasher 2 TA11 B/R 0.85 8
r 1.25
R LS03a G 0.5
/ 1.25
IL07dLg/R0.5
28B/R0.85
B06 B06 B01 B09 5 13 5 1
05B
Small lights relay M34 闪光器
/ 0.85
3 1 Electric Windows rela y
05GY
High beam relay Lower beam relay Front fog lamp relay Rear fog lamp relay TA10 W/R 0.85 Electri c horn rel ay Blower relay
AC
Brake la mp rel ay R L B10 B07 B07 MC03
01BY
X15 X13 小灯继电器 X16 X9 X33 X1 L X7 X12 X2
PW
电喇叭继电器
电动窗继电器
AC
远光灯继电器近光灯继电器前雾灯继电器后雾灯继电器制动灯继电器鼓风机继电器 M26 Blower speed switch
BU
AU01R0.85
6 5
AU02G0.5
.5
5 2 3 4 12 9 10 11 5
IL02G/R08
r0.85
.5
3
02R/W05
03R/B0.5
03G0.5
28aB/R08
M26鼓风机调速开关
.
LS01B
MD01
86 87a 87 86 87a 87 86 87a 87 86 87a 87 86 87a 87 86 87a 87 86 87a 87 86 87a 87 86 87a 87
/ 0.5
/ 1.25
C C C C
LS
IL05Y0.5
r0.5
.5
TA
TA
1 S hort connector
05G/Y12
IL04GR
AC
06BY
IL03G
1 5 M47 2 HI
04R0.5
03R0.5
MC02 短接器
L09R0.5
M25 A/C switch
PW
30 85
PW
9 9 6 9 D05 Left electric window switch M2 85 30
U V G 5
PM
PM
3 4 9 B08 2 8 2 14 8 9 B11 B09 B11 3 5 M25 A/C开关
F
B08 M35 Blower M1 6

/ 0.85
B08 B09 MC02 MD01 MC02 MD03 MC02 B13 B14 Cigar lighter rel ay
B11 7 D05左电动窗开关 MD03
30 M
01BY
F28 85 M35鼓风机 LO X20
IL07dG/Y05
X32
.5
8 6 5 3
06B/Y12
点烟器继电器
01R/Bl0.5
4 8 2 6 3 7
BU
A/C relay
.5
09R/Bl0.85
HS02R/W05
/R0.85
02R/B08
Antenna天线
.5
OFF
.
HS08G/W05
7.5A
/R05
/R05
/R05
19B/R05
13B/R05
15B/R05
TA17B/R08
B11 B11 MC03 MR01

.
l 0.5
Rearview mirror
IL07cLg/R0.5
.
IL01G/O0.5
1
l 0.5
/ 0.5
07R/W05
/ l 0.85
1
.
01B
A/C继电器
08R/W05
04R/W05
18W
12W
14W
16W
W/S Welding short circuiter焊接短路器

09R/B05
05R/B05
PW
.
.
.
IL07eG/Y05
06RB
HS
FL08B
.
X31
LS03aG0.5
01aR0.5
/ 0.5
09aRB
HO
HO
defrosting relay
/ 0.5
HS
TA
TA
TA
TA
TA
TA
TA
08RW
L02P0.5
/ 0.5
B Cab electrical box of plug-in驾驶室电器盒插件
09RB
Reverse switch 87 87a 86
09O0.5
AU08P0.5
09O0.5
TA
TA
86 87a 87
TA
TA
8 4 5 6 1 2
26BR
TA
TA
HS
1 3 8 后视镜除霜继电器
AU
10 15
TA
TA
倒档开关 A7 A8 4 C Chassis wiring harness plug底盘线束插接件
/ 0.85
F14 F11
AU
AU
F11
F
F15
AC
7 8 9 6 2
IL07eLg/R0.5
MC02 MC02
LS02Lg0.85
MC02
AC02GY
V U R M28 Hazard al ertion switch 87a 87
l 0.85
BCM 10A 10A BCM 10A 10A BCM BCM BCM L B12 B13 A1 A12 A11 A10 B18 A2 UP DOWN UP DOWN 86 5 4 M Cab wiring harness plug驾驶室线束插接件
2 F
04B
M28 危险报警开关
/ 0.5
HS09R/Bl 0.85
C M24 Radio M24收音机 Carcorder 行车记录仪(M27-A、M09-B) A Power transfer D Door wiring harness plug门线束插接件
AC
HS08G/W05
J K I 10 L M
.
HS08aGW
10O1.25
3 2 4 6 5
09P1.25
/ 1.25
D20kB0.5
2
/B05
D30dB1.25
B14
BCMA13
/ 0.5
10aR1.25
D20lB0.5
电源传递 F Floor wiring harness plug地板线束插接件
10R1.25
12Y1.25
14R0.85
3 8 7 2 12 M20 Left combi natio n switch 2 4 7
.5
D05eB1.25
02W
AC06VY
AC13GY
G MC03
08G1.25
1
l 12
9 9
PW
.5
PW
.5
L10aG/W08
B06 B01 B06 B11 B07 O

L10G/W08
A3
IL07Lg/R0.5
07B
B11 A6 A4 A8 A9 B7 B8
G
R Roof light wir ing harness plug顶灯线束插接件
PM
M20 左组合开关
AC
AC
AC
AC
M29 M30
A Sign al tran sfer
G
L09R0.5
B08 MC03
G
IL05aY0.5
PW
IL05Y0.5
PW
16 3 14 4 11 15
G
10dY0.5
信号传递
l 05
MC Cab and chassis wiring harness for plug-ins驾驶室与底盘线束对插件
BCMA30
.
3 8
IP18B/W0.5
/ 0.5
/ 0.5
.5
CA20dB
F
05aV0.5
l 08
A9 A3
F
IL07cLg/R0.5
N
03aG/Y0.5
07aG/Y0.5
IP04YR
IP04YR
HS04G/W0.85
05V0.5
7
/ 0.85
/ 0.5
Cigar lighter
.5
MD01 MD01
04B
CM Chassis wiring harness and cab for plug-ins底盘线束与驾驶室对插件
02G/Y08
CA
5 2 1 5 2 1
接
Illu minatio n
HS07GY
03GY
B07
AC
05R0.85
06R0.85
PM
PM
M04 Rig ht front 点烟器
10O1.25
.5
09P1.25
r0.85
M03 Left front MD Cab and the line of plug-ins驾驶室与门线对插件
04G/B08
照明
r 0.85
AU06Y0.85
.5
HS
HS
13G/Y12
HS
AC
2 4 P
AC12Y1.25
turn lamp 5 5 4 3 J1 Cab left GND驾驶室左搭铁
05G
HS
HS
03B
turn la mp D01 Left turn lamp Left rear turn la mp
PW
TA20R/Bl 0.5
PW
2 1 4 2 M04右前转向灯 1 D02 Ri ght turn lamp 4 Rig ht rear turn lamp DM Line and cab harness for plug-ins门线与驾驶室线束对插件
AU
3 8 MD02 MD04
AU
AU
M29 M31
02aR/B0.85
AC
/ 0.85
1 M13 Headli ght M03左前转向灯 D01左侧转向灯左后转向灯

D02右侧转向灯右后转向灯 2 1 2 J2 Cab right GND驾驶室右搭铁
IL10 G 0.5 MD03 MD03 MF Cab and floor wiring harness for plug-ins驾驶室与地板线束对插件
05aV0.5
M
02RB
05V0.5
IL10a G 0.5 electri c swi tch
12 M33 Electronic temperature
IL10G0.5
IL10aG0.5
4 2 3 FM Floor lines and cab for plug-ins地板线与驾驶室线对插件

HO
HO
M13 大灯电调开关 J3 Left front longeron GND左前纵梁搭铁
PM
PM
1 4 1 4 7 D07 Left ele ctric win dow motor controll er M41 Air pressure switch
3 5 BCM MD01 MD01 MD03 MD04 Warni ng switch MR Cab and the roof light to plug-in驾驶室与顶灯线对插件
10O1.25
J4 Right front longeron GND右前纵梁搭铁
09P1.25
MC03 D07左电动窗电机 1 1 M33电子温度调节器 M41空调压力开关
D20kB0.5
D20lB0.5
5 5 2 1 M03 Left hi gh beam1 M04 Ri ght hi gh beam 6 6 2 2 6 1 1 3 3 2 2 2 2 2 2 R 报警开关 RM Roof light and the cab of plug-in顶灯与驾驶室线对插件
C
PW
PW
B uzzer assembly 2 1 2 1 M01 Left front M02 Ri ght front M03 Left front M 04 Ri ght front 2 3 2 3 D11 Left rearvie w D12 Ri ght rearvie w J5 Central longeron GNDⅠ 中部纵梁搭铁Ⅰ
IP04Y/R05
Left back lig ht Rig ht back lig ht R01 Left roof R02 Ri ght roof Speed output instrument
D10dB0.5
.
Left rear fog la mps 2 5
D20jB05
D20iB05
4 3
GD05bB05
4
.
.
M03 左远光灯 M04 右远光灯
G
Left front side Left rear sid e Rig ht front side
.
G
Left middle si de Right middle si de 10
D10fB0.5
GD10eB0.5
蜂鸣器总成 M05 Left fog la mps fo g la mps small lig hts small lights Left rear brake Right rear brake Rig ht rear side mirror heating mirror heatin g
左倒车灯右倒车灯 M06 Ri ght 左后雾灯 clearance la mp clearance la mp 13 12 J6 Central longeron GNDⅡ 中部纵梁搭铁Ⅱ
/ 0.5
.5
D05cB2.0
D06aB0.5
r0.85
车速输出给仪表
AU04G/B08
marker light marker light 1 marker light marker light
r 0.85
.5
M01左前雾灯 lights/small lights 1 marker light 1 marker light D11左后视镜加热
/ 0.85
M02右前雾灯 1 1 1 D12右后视镜加热
09GR
4 4 1 2 2 2 M04 Ri ght 2 M03 Left 1 1 4 2 M03左前小灯 2 M 04右前小灯 lights/small lig hts
G
G
AU06Y08
G
M
headli ght M
headli ght R01左顶示廓灯 R02右顶示廓灯 4 4
05G
G
03B
1 M55
AC01BG
左前侧标志灯左中侧标志灯左后侧标志灯右前侧标志灯右中侧标志灯右后侧标志灯 Hig h to ne lo udspeaker Low tone lo udspeaker 2 2 J7 Central longeron GNDⅢ 中部纵梁搭铁Ⅲ
low beam low beam 左后制动灯 /小灯右后制动灯 /小灯 M36 Air conditioning control resistanc
AC
adj ustment 1 1
AU
G
AU
adjustment 3 2
D80aB1.25
.5
D80bB1.25
.5
D80bB1.25
GD80bB1.25
高音喇叭低音喇叭
D80aB12
GD80aB12
M04 右近光灯 M03 左近光灯 1
3 m otor eM36空调调速电阻
/ 0.5
3 motor Front brake D15 D16 1 10 J8 Central longeron GNDⅣ 中部纵梁搭铁Ⅳ
IP04YR
Rear brake 11 10
D05cB0.5
D06cB0.5
M05 左大灯 M06 右大灯 1 2 1 2 5
D70aB0.85
D70bB0.85
MC03
G
调节电机
swi tch swi tch 1 1 M55 M55 D06 Right electric window Q J9 Battery cathode GND蓄电池负极搭铁
D01aB0.85
D03aB0.85
D01cB0.85
D01aB0.85
D01aB0.85
调节电机
D03aB0.85
D01aB0.85
GD03cB0.85
D03aB0.85
D03aB0.85
D01bB0.5
+ - + - Vehic le speed sensor 5

D03bB0.5
D70dB0.85
G
前制动开关后制动开关 D15 4 4
/ 0.85
UP DOWN switch
G
12
D05B2.0
D06B2.0
D20B0.85
D20B0.85
W/S05 2 2 1 1
1 签署栏目签名日期
AC01BG
W/S05 W/S05 车速传感器 1
D30eB0.5
D20B0.85
G
M46 M46 D06右电动窗开关 D15 D16

G
G
D70cB0.5
W/S05
D50fB0.5
D30dB1.25
D10iB0.85
.5
G
1 5
G
D50bB0.85
D30cB0.5
D30iB12
安徽江淮汽车股份有限公司
M22 Horn switc h
G
r1.25
2 2 2 2 3 3 2 2 2 2 2 2
D50aB2.0
CANH CANL 1
D50aB2.0
12R1.25
D50aB2.0
7 7 1 1 设计
D50aB2.0
G
G
G
D05B2.0
D05B2.0
D06B2.0
11B
W/S02 M22喇叭开关 D03 Left door speakers D04 Ri ght door speakers
MD01 MD03
G
M58 14
G
G
M57 M58 M58 M57 M57 M58 M57 M58 M57 M57
PW
PW
G
D
G
G
2 3 6 5 D04右门扬声器 4 10 5
G
GD50c B 0.85 D03左门扬声器

G
W/S02 W/S04 校对
G
1 1 1 1 1 1 1 1 1 1 W/S01 GD50d B 0.85 1 1 14 5 14 7 7 7 M54
D70B3.0
W/S02 M54 W/S02 W/S02 M56 M56 MD01 1 2 MD01 MD03 M56 Compressor
图样来源 W/S02 M54 M54 M
D70B3.0
D50B30
1
D50B3.0
.
压缩机
D26aB0.5
1 审核
G
D22B0.5
D26B0.5
D14B0.5
1 1 1 1
D50B3.0
D50B3.0
0B2.0
D10B3.0
D50B3.0
D20B3.0
D30B3.0
D30B3.0
D10B3.0
D01B3.0
D03B3.0
D50B3.0
1 1 D08 Right electric window motorD
D05B2.0
D05B2.0
D06B2.0
D10B3.0
GD10B3.0
D10B3.0
G
G
D03B3.0
D01B3.0
D01B3.0
D03B3.0
D01B3.0
D03B3.0
D01B3.0
D03B3.0
D01B3.0
D05B2.0
D06B2.0
0.3
G
3
D
G
B
G
整车电气原理图
G
D03G
G
G
G
08右电动窗电机
G
工艺
G
G
G
G
G
G
G
底图总号 J6-2 J3 J4 J3 J4 J3 J4 J1 J1 J3 J4 Sel f GND Sel f GND J3 J4 J7-1 J6-2 J6-2 J7-1 J1 J1 J1 J1 J3 J1 J6-2 J4 J2 J7-1 J1 J1 J1 J1 J1 J2 J1 J1 J2 J2 J1
阶段版次数量重量比例
J6-2 Steering hub column GND Self GND
自身搭铁自身搭铁
方向管柱搭铁自身搭铁
标准化
1 1:1
签字日期会签 4000002LG016
批准共 1张第 1张
27
25
14
20
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Manual Trabajo JAC 5

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WORKSHOP MANUAL

本手册用于帮助 JAC 授权的专业维修技术人员， Chassis

Model identification information

Vehicle identification number description

Recommended material filling standard

Recommended tightening torque standard

Recommended special tools list

I. Adoptable vehicle models of this manual 本手册适应车型

Model Series No. Engine model Transmission model

N Series Light Truck

III. Health and safety notes 健康与安全注意事项

□ Always keep battery surface(especially top) clean and dry.

□ When connecting, first connect positive terminal post of battery.

□ After installation, it is allowed to apply mineral oil on each terminal post.

□ Avoid being spilled on the skin, eyes and clothing.

□ Highly flammable and explosive, and should adhere to anti-smoking regulations.

□ The skin can be frostbited if you contact.

lighting, and wear appropriate protective gloves and goggles.

□ Air condition refrigerant - what should be avoided 空调冷媒 –应避免之动作

Do not explore the refrigerant bottle in the sunlight or heat sources.

Do not discharge or exhaust the refrigerant to the atmosphere in any cases.

□ Installation of refrigerant filling instrument 安装制冷剂加注仪

□ Operation of Refrigerant Discharge 制冷剂排出操作

Connect the refrigerant filling instrument to the

Put the cleanly cleaning cloth in the open place of

Gradually open the HP manual valve and discharge the refrigerant.

Evacuation Operation of Refrigeration System 制冷系统真空操作

Confirm whether or not engine is under “Close” status.

Confirm whether or not refrigerant is discharge from the system.

10 min 之后低压检测仪标尺大于 0.96kg/㎠真空，否则就是系统漏气，应按照以下步骤修理。

Make use of the filling system for the refrigerant container.

Discharge the refrigerant and evacuate the system.

Continue evacuation, if no leak evidence is found.

Re-operate vacuum pump.

Continue evacuation until measuring scale displays 0.96kg/cm2.

□ Use of Refrigerant Control Valve 使用制冷剂控制阀

Tighten the nut after exhaust for several seconds.

□ Filling of Refrigerant (in Gaseous State)加注制冷剂（气体状态）

Install the refrigerant container to the regulating valve.

Start the engine and turn on the air conditioning system.

Close the LP valve after specified quantity is filled.

Install the regulating valve for refrigerant container.

Fully open the HP valve and then upend the container.

Close the valve of filling instrument after specified refrigerant is filled.

□ Highly flammable, combustible.

if swallowed, and should be taken to hospital immediately.

7、 Brake Fluid 制动液

□ Ensure that electrical equipment is protected by the right fuse.

□ When the electric shock occurs.在发生电击时：

Do the first aid immediately if you have been trained before.

Seek the medical assistance.

□ Highly flammable - shall comply with the non-smoking regulation.

13、 Lubricating oil and grease 润滑油与润滑脂

14、 Waste 废弃物

15、 Other matters 其他事项

□ Put wheel chocks or other tire blocks under the wheels

the vehicle. After jacking up the vehicle, support the

请务必使用 JAC 纯正备件。只能使用本手册中推荐的油液和润滑剂。需要时，使用认可的粘结

and special tools correctly.

IV. Standard operating procedures 标准作业程序

1、 When repairing vehicle in the workshop, it is important to determine 在维修车辆时，务必确定：

3、 Connect the backup battery by the cross-connection 用跨接线连接备用电瓶

4、 Components cleaning 组件清洁

To remove the dirt with a soft brush or a steel brush.