【EN&CN】Chassis底盘分册 LD340

WORKSHOP MANUAL
维修手册
HFC1035L3KDT-LD340
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Chassis
底盘分册
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Version No 版本号：JAC-2015100301N2401
江淮汽车部门：客户服务部
Chassis 底盘分册
FOREWORD 前言 CONTENT 目录
This Manual is helpful for technical maintenance
staff for JAC and provides effective and correct
Overview & maintenance
概述与保养分册
maintenance and service for JAC vehicle. To ensure
the customer satisfaction of the JAC products, it is
extremely essential that the professional maintenance Engine
technicians for JAC have the friendly service and the 发动机分册
capability of proper operation; therefore, the
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maintenance technicians must fully understand the
Body structure& electrical
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，

对江淮汽车提供有效正确的保养及维修。为确保江淮
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底盘分册
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汽车产品的用户满意，江淮汽车专业维修技术人员的
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
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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
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
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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 translated 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。
Tel：0086-551-62296644
Fax：0086-551-62296633
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JAC 国际公司客户服务部
25 JAC International Customer Service Depart.
2015.10
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CONTENT 目录
Chapter Ⅰ Clutch 第一章离合器
Chapter Ⅱ Transmission 第二章变速器
Chapter Ⅲ Front axle 第三章前桥
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Chapter Ⅳ Rear axle 第四章后桥
Chapter Ⅴ Drive shaft 第五章传动轴
Chapter VI Suspension 第六章
第七章
25 悬架系统
转向系统
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Chapter VII Steering
Chapter Ⅷ Braking system 第八章制动系统

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ChapterⅠ Clutch
第一章离合器
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 off or transmit the input power through engine
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to 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; convenient to operate and labor saving.
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
离合器重要参数
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
最大分离行程
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The clutch pedal free stroke
10-20mm
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 gear box assembly 变速器总成
02 clutch platen unit 离合器压盘总成
03 driven plate unit of clutch 离合器从动盘总成
04 release sleeve 分离套筒
05 release fork 分离拨叉
06 guide bearing 导向轴承
□ The clutch circuit 离合管路
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01 clutch pedal and bracket assembly 离合器踏板及支架本体总成
02 vacuum booster inlet hose assembly 真空助力器进气软管总成

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03 clutch master cylinder inlet pipe assembly 离合器总泵进油管总成
04 vacuum booster with the clutch master cylinder assembly 真空助力器带离合器总泵总成
05 clutch master cylinder tubing assembly 离合器总泵出油管总成
06 two-way joint 二通接头
07 clutch before the steel pipe assembly 离合器前钢管总成
08 card 卡片
09 clutch front hose 离合器前软管总成
10 clutch tube assembly 离合器管总成
11 clip 管夹
12 the buffer valve assembly of clutch line 离合器管路缓冲阀总成
13 clutch line buffer valve bracket 离合器管路缓冲阀支架
14 clutch hose assembly 离合器软管总成
15 clutch cylinder pipe bracket unit (ii) 离合器管支架总成 1
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16 clutch cylinder 离合器分泵总成
17 clutch cylinder 离合器分泵总成
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clutch pipe assembly (ii)
clutch cylinder pipe bracket (iii) 25 离合器管总成 1
离合器管支架 2
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20 brake oil pipe perforation bolt 制动油管穿孔螺栓
21 braking oil pipe joint washer 制动油管接头垫圈

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22 brake oil pipe perforation joint 制动油管穿孔接头
23 single tube clip 单管夹片

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24 hexagon flange bolts 六角法兰面螺栓
25 hexagon flange nuts 六角法兰面螺母

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26 seal washer 密封垫圈
31 clip 管夹
32 clip A 型蜗杆传动式软管环箍
□ Clutch pedal 离合器踏板
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S/N 序号备件名称
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Spare parts name description
01 connecting bracket 连接支架

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02 flat washer 平垫圈
03 bolt 六角螺栓
04 nut 六角螺母
□ Driven plate of clutch pressure plate 离合器压盘从动盘
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01 clutch platen unit 离合器压盘总成
02 driven plate unit of clutch 离合器从动盘总成

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03 bolt subassembly 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

to be stopped by woods 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, unscrew the clutch oil drain plug,

put all the clutch fluid out
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 is: clutch oil jug, clutch linking pipe, 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、
离合器连接管路、离合总泵、离合踏板
□ Disassemble oil spout mounting bolts and lines link nuts
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and remove oil jug
拆解储油壶固定螺栓及管路连接螺母，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连接螺母，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：
□ Assemble the clutch pedal attaching bolts is critical

operations, and please refer to the overview and
maintenance manual about the specific torque
装配离合器踏板连接螺栓为关键工序，具体拧紧力矩
请参见《概述与保养分册》
□ When assembling the clutch pipe mounting bolts, please
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use leak-proof glue, and refers to the overview and
maintenance manual about the specific model number
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装配离合器管路固定螺栓时需涂防漏胶，具体型号请
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 is: clutch

pipes and hoses, clutch pedal, clutch pedal and bracket
assembly, clutch switch or limit bolts, spring, and clutch
cylinder, disassemble all the parts successively along the
clutch pipe
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.
装配：按照拆解相反步骤开展。
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4、Disassembly of clutch 离合器拆装
□ Disassemble the clutch and the remove order is:

transmission, clutch pressure plate, clutch driven plate,
release sleeve, release 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、车架、传动轴连接螺栓，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 plate
assembly free fall with a guide shaft. Mark on the
flywheel and pressure plate, and make sure that the
marks are aligned when re-install
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 clutch release sleeve assembly

together with the release 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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□ Check the clutch cover for wear, cracks and damage
visually. 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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□ Insert the guide shaft into splined hub. Guide shaft must
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be kept straight, measure the depth of platen rivet. The

driven plate assembly should be replaced if the
measured value exceeds limits
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 (shifting gears with gear grinding sound) 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 (part of clutch started make the body vibrate)
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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Chapter Ⅱ Transmission
第二章变速器
6th gear
六齿
LC5T255M3 TRANSMISSION GEARBOX
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LC5T255M3 变速器
SERVICE MANUAL 25
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使用维修说明书
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ANHUI XINGRUI AUTOMOTIVE GEAR-MANUFACTURE CO., LTD

安徽星瑞齿轮传动有限公司
Table of Contents
目录
一、Precautions 注意事项
二、General 概要
三、Common Failure Diagnosis 常见故障诊断
四、Disassembly and Assembly of Transmission Gearbox 变速器拆解与装配
1. Disassembly of Transmission Gearbox Assembly 变速器总成拆解
2. Exploded View of Reverse Gear Assembly 倒档轴总成爆炸图
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3. Exploded View of Output Shaft Assembly 二轴总成爆炸图
4. Exploded View of Upper Cover Assembly 上盖总成爆炸图
5. Exploded View of Input Shaft Assembly 一轴总成爆炸图
6. Exploded of Rear Cover Assembly 后盖总成爆炸图
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7. Exploded View of Counter Shaft Assembly 中间轴总成爆炸图
8. Exploded View of Housing Assembly 壳体总成爆炸图
9. Exploded View of Shift Fork Assembly 拨叉总成爆炸图
10. Exploded View of Clutch Housing Assembly 离合器壳总成爆炸图
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11. Reference View of Assembly Explosion 总成爆炸图
五、Inspection of Key Parts 总要零部件检查
六、Service Parameters 维修参数
1. Tightening Torque 拧紧力矩
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2. Main Technical Parameters 主要技术参数

七、Maintenance of Transmission Gearbox 变速器保养
1. Maintenance 维护与保养
2. Lubrication and Sealing 润滑与密封
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八、Contents of Quick-wear Pars for LC5T255M3 LC5T255M3 易损件目录

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I. Precautions
一、注意事项
■ DON'T reuse the discharged transmission gear oil.
■请勿重复使用排出的变速器齿轮油。
■ When inspecting or replacing gear oil for transmission gearbox, the oil replacement is irrelevant with cleaning
parts; the vehicle shall be kept horizontal.
■检查或者更换变速器齿轮油时，换油与清洗零件无关；应保持车辆水平。
■ Keep inside clean when installing and dismantling transmission.
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■拆卸与安装变速器的时候，应保持内部清洁。
Check and decide the correct installing position before dismantling and disassembly. If installing mark is needed, the
function of the part bearing such a mark after that shall not be affected adversely.
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■ Check and decide the correct installing position before dismantling and disassembly. If installing mark is
needed, the function of the part bearing such a mark after that shall not be affected adversely.
■拆卸或分解之前，检查确定好正确的安装位置。如果需要做安装标记，确保做上标记之后，不会影响做上
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标记部件的功能。
■ Tighten the middle and then the other bolts and nuts in a diagonal order step by step as required. If the
tightening sequence is defined, please follow it.
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■按照规定，分多步并按照对角线的顺序，先拧紧中间的，再拧紧外边位置上的螺栓与螺母。如果拧紧顺序
是有要求的，那么根据要求进行。
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■ Don't damage sliding and fitting surfaces.

■不要损坏滑动面与配合面。
■ Grease the circular surface before installing needle bearing

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■滚针轴承装配前应在其圆周表面涂抹润滑脂。
■ Grease the lip before installing oil seal.

■油封装配前应在其唇口部位涂抹润滑脂。
■ First align synchronizer slider to the slider slot on synchronizer converter ring, and then install the
synchronizer assembly.
■压装同步器组件时，应先将同步器滑块对准同步器齿环上的滑块槽后再压装。
II. General
二、概要
● Structure Pattern
●结构型式
Full synchronizer MT mechanical transmission gearbox has flexible gear shift, good operating
feeling, low noise, compact structure, high bearing capacity and good sealing performance. It has 5
forward gears and 1 reverse gear, all the gears are bevel gears, except the reverse gear is direct gear shift
of gear sleeve, the 3rd/4th and 5th gears are single-conical synchronizer, and the 1st/2nd gears are
3-conical synchronizer. The gear shift mechanism is cable operated in a distance.
全同步器手动换档机械变速器，换档灵活，手感好，噪音低，结构紧凑，承载能力大，密封性能好。五个前
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进档和一个倒档，所有齿轮均为斜齿，除倒档为齿套直接换档，3/4、5 档为单锥面同步器，1/2 档为三锥同步器。
换档机构为拉索式远距离操纵。
● Cross-section Drawing of Transmission
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●变速器剖面图
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Principle of movement: 运动原理：
1st gear 一档
Engine → Clutch → Input Shaft 1→ Driving Gear of Counter shaft 15 → Counter shaft 11 → 1st gear of output
shaft 6 → 1st/2nd Gear Synchronizer 5 → Output Shaft 10
发动机→离合器→输入轴 1→中主齿 15→中间轴 11→主一齿 6→1/2 档同步器 5→输出轴 10
2nd Gear 二档
Engine → Clutch → Input Shaft 1→ Driving Gear of Counter shaft 15 → Counter shaft 11 → 2nd gear of output
shaft 4 → 1st/2nd Gear Synchronizer 5 → Output Shaft 10
发动机→离合器→输入轴 1→中主齿 15→中间轴 11→主二齿 4→1/2 档同步器 5→输出轴 10
3rd Gear 三档
Engine → Clutch → Input Shaft 1→ Driving Gear of Counter shaft 15 → Counter shaft 11 → 3rd gear of output
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shaft 14 → 3rd/4th Gear Synchronizer 2 → Output Shaft 10
发动机→离合器→输入轴 1→中主齿 15→中间轴 11→中三齿 14→主三齿 3→3/4 档同步器 2→输出轴 10
4th Gear 四档
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Engine → Clutch → Input Shaft 1 → 3rd/4th Gear Synchronizer 2 → Output Shaft 10
发动机→离合器→输入轴 1→3/4 档同步器 2→输出轴 10
5th Gear 五档
Engine → Clutch → Input Shaft 1→ Driving Gear of Counter shaft 15 → Counter shaft 11 → 5th gear of output
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shaft 12 → 5th Gear of output shaft 9 → 5th/R Gear Synchronizer 8 → Output Shaft 10
发动机→离合器→输入轴 1→中主齿 15→中间轴 11→中五齿 12→主五齿 9→5/R 档同步器 8→输出轴 10
Reverse gear 倒档
Engine → Clutch → Input Shaft 1→ Driving Gear of Counter shaft 15 → Counter shaft 11 → Reverse Gear 13→
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Reverse Gear of Output shaft 7 → 5th/R Gear Synchronizer 8 → Output Shaft 10

发动机→离合器→输入轴 1→中主齿 15→中间轴 11→倒档齿 13→主倒齿 7→5/R 档同步器 8→输出轴 10
● Control
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● 操纵
Use the control lever in the cab to finally change gear by enabling both selector and shifting levers. Display
different gear selection and shifting positions correspondingly if pressing different directions shown on the handle
ball joint of control rod. After each downshift, the control lever will return to neutral automatically; you can select a
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gear only when it returns to neutral.

通过控制驾驶室内的控制杆，最终可操纵选档杆和换档杆进行换档操作。按照控制杆手柄球头显示的不同方
向，对应显示不同选档和换档位置。每次摘档后控制杆将自动回到空档位置；只有回到空挡时才能够进行选档，
1. When shifting gear, press the release pedal to the end so that transmission is disconnected from engine torsion
to control gearshift quickly. Low gear shall be used when starting the vehicle.
1.换档时，应将分离踏板完全踏下，使变速器脱开发动机扭力而迅速操纵变速杆，起步时应采用慢速档。
2. Slow down when going uphill or downhill, or taking a turning. DON'T taxi by separating the clutch.
2.上坡、下坡和转弯时应采用慢速档，不允许分离离合器滑行。
3. If it's difficult to use transmission lever, stop and check. Don't exert a thrust too much.
3.当操作变速器杆发生困难时，应停车检查原因，不得施以过大的推力。
The mileages applicable for forward gear positions of the transmission gearbox are as follows:
变速器前进档各档位适合的公里数如下：
Gear 档位 1st gear 一档 2nd Gear 二档 3rd Gear 三档 4th Gear 四档 5th Gear 五档
Mileage 公里数 0～15 20～30 35～45 50～60 65～75
Note: 注意：
1. The operation of gear shift for transmission gearbox shall be performed within the range of mileage.
1 变速器换档操作应在该公里数范围内进行。
2. The speed suitable for each gear may be different if a transmission is used in a different vehicle.
2 变速器匹配不同整车时各档位适合的公里数不同。
Gear shifting rule 换档原则

When the vehicle is going forward, gear shifting of transmission shall be as follows: gear shifting for speeding
shall be made level by level from Gear 1 to 5, and vice versa. Don't select reverse when the vehicle is going
forward. In principle, the reverse shall be turn on a 3s pause later after the clutch is pressed when the vehicle is
stationary; don't switch to the gear when the vehicle is running forward; don't turn on any forward gear when the
27
gear is in reverse position.
在整车前进状态下，变速器换档原则要求如下：增速换档应由 1～5 档逐级换档；减速换档应由 5～1 档逐级换档；
前进状态下，禁止挂倒档。。挂倒档原则上要求在整车静止下踩下离合后停顿 3 秒后进行；不得在前进状态下挂倒档；
同时，不得在倒车状态下挂前进档中的档位。
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Note: It's allowed not to observe the gear shifting rule of transmission in emergency when the vehicle is
working.
注意：整车运行时，在紧急情况下，可以不遵守变速器换档原则。
14
III. Common Failure Diagnosis
三、常见故障诊断
20
(Contact the authorized service shop or professional staff for any abnormal conditions of transmission gearbox and any
problem unable to solve personally. See the exploded view for details of disassembling legends and part numbers.)
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（变速器出现异常情况及不能自行解决的问题应当联系特约维修站或专业人员，详细的拆解图例及零件编号参看爆炸图）
Fault 故障情况 Possible Causes 可能原因 Judgment and Elimination 判断与排除
 Circular slot of fork shaft is (1) Check if the control system
over-worn and lock ball spring is pushes the gear shift rocker of
deformed elastically. transmission to the point; alternatively,
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 拨叉轴圆弧槽过度磨损，锁 dismantle transmission, push fork to the

球弹簧弹性变形。 point by hand and then check the
 The working surface of fork engagement.
is over-worn. (1)检查操纵系统是否将变速器的换
 拨叉工作面过度磨损。档摇臂推到位，或拆下变速器改用手推
 The mating surface of gear 动拨叉挂上档，检查啮合情况。
ring or sleeve is over-worn. (1) Check if the control system
Jump back to neutral when
 齿环或齿套接合面过度磨 pushes the gear shift rocker of
the vehicle is running. 在
损。 transmission to the point; alternatively,
汽车行驶中跳回空档
 Gear is loose axially. dismantle transmission, push fork to the
 齿轮轴向松动。 point by hand and then check the
engagement.
(2)如未完全啮合，则应检查拨叉是否
变形或工作面磨损过多。
(3) If gear sleeve is completely
engaged, check the wear to the back taper
of gear sleeve and soldered teeth.
(3)如齿套已完全进入啮合，则应检查
齿套与接合齿的倒锥部位磨损情况。
(4) If feeling over-clearance by
hand, check fork shaft slot. See if locating
spring is worn or out of service.
(4)如果拨动若感空隙过大，应检查叉
轴槽，定位弹簧是否磨损或失效。
When the clutch is OK, Replace synchronizer ring
it's difficult to shift gear Synchronizer ring is worn 更换同步器环
and there is some serious seriously.
impact noise, or difficult to 同步器环严重磨损。
shift to a certain gear.
在离合器没有故障的
情况下，换档困难并有严
重的冲击声或在某一档
挂档困难。
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Sounding of transmission  Caused by the damage of  Check the faulty parts. Eliminate the
变速器发响 individual gear tooth. fault.
① Regular impact  个别齿轮牙破碎引起。  检查发生原因的部位，予以排除。
sound;  Gear backlash increases or  Detach, check, clean and replace
①有规律的撞击声； gear are damaged. damaged gear or bearing.
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② Uniform noise  齿隙增大或齿轮损坏。  拆检清洗更换损坏的齿轮或轴承。
②均匀的噪音  Bearing wear.  Replace or add new oil.
 轴承磨损。  更换或添加新油。
 Insufficient lubricant
 润滑油量不足
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 Too much fuel is added and  Remove the oil filling screw plug, and
the level is too high. inspect the oil level.
 加油过多，油面过高。  拆下加油螺塞，检查油面。
 Oil seal is over-worn or  Replace oil seal.
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damaged.  更换油封。
 油封过度磨损或损坏。  Detach the components of each joint
 Uneven application of sealant face. Check collided points, level and glue
Greasing 渗油 or damage of sealing paper pad them evenly.
 密封胶涂抹不均匀或密封纸  拆下各结合面零件，检查磕碰点，
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垫损坏。修平，均匀涂胶。
 Breather plug failure.  Replace breather plug.
 通气塞失效。  更换通气塞。
 Bump on the adjoining
surface not trimmed in time.
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 结合面磕碰未及时修平。
(1) Lubricant is too dirty. (1) Replacing lubricating oil.
(1)润滑油太脏。 (1)更换润滑油。
(2) Insufficient lubrication (2) Check lubricant level. Add or
or unqualified lubricating oil, too replace lubricant.
Bearing is damaged
poor quality. (2)检查润滑油油面，加注或更换润滑
abnormally
(2)润滑不充分或润滑油不符油。
轴承非正常损坏
合要求，质量太差。 (3) Replacing bearing.
(3) Using unqualified (3)更换轴承。
bearing.
(3)使用不合格的轴承。
IV. Disassembly and Assembly of Transmission Gearbox
四、变速器拆解与装配
1. Disassembly of Transmission Gearbox Assembly
1.变速器总成拆解
(1) Drain oil.
（1）放油。
Note: 注意：
■ Remove the oil drain screw plug with wrench, and drain oil from the oil drain screw plug. It is
not allowed to drain oil from other positions.
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■用扳手拆去放油螺塞，从放油螺塞放油，不允许从其它部位放油。
(2) Remove the rear cover bolt with pneumatic gun or
wrench, and unscrew the nuts for flanges.
（2）用气枪或者扳手拆后盖螺栓，打掉凸缘螺母。
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14
20
(3) Remove the rear cover.

（3）拆后盖。
Note: 注意：
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■ If the housing adheres to the rear cover tightly, knock the

edge of the housing gently with rubber hammer or copper rod to
loosen it.
 若壳体与后盖贴合较紧，可用橡胶锤或铜棒轻轻敲击
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壳体边缘，使之松动。
(4) Remove the inner driving gear and spacer.

（4）取下里主齿以及隔套。
(5) Remove the transmission gearbox cover with pneumatic gun or wrench.
（5）用气枪或扳手拆变速器盖。
(6) Remove the clutch housing part.

（6）拆离合器壳部分。
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Note: 注意：
■ If the housing adheres to the clutch housing tightly, knock the edge of the housing gently with
rubber hammer or copper rod to loosen it.
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■ 若壳体与离合器壳贴合较紧，可用橡胶锤或铜棒轻轻敲击壳
体边缘，使之松动。
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(7) Punch off the elastic pin with punch, and remove all the shift forks, dial blocks and shift fork
shafts.
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（7）用冲头冲掉弹性销，拆除所有拨叉、拨快和
拨叉轴。
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(8) Remove the snap rings of all the bearings with clip forceps.
（8）、用卡环钳去除所有轴承卡环。
(9) Remove all the bearings with puller.
（9）、用拉马拆除所有轴承。
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(10) Remove the input shaft, and take the output shaft assembly out of the gearbox body.
（10）、拆掉一轴，在箱体内取出二轴总成。
14
(11) Loosen the snap ring of the 5th gear of counter
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shaft with clip forceps, adjust the position of the 5th

gear of counter shaft, and take out the counter shaft
assembly.
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（11）、用卡环钳松掉中五齿卡环，调整中五齿位
置，取出中间轴总成。
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(12) Remove the side cover, take out the pin of reverse
gear shaft, punch out the reverse gear shaft, and finish
disassembling the complete gearbox.
（12）、拆掉侧盖，取出倒档轴销，冲出倒档轴，整箱
拆解完毕。
(13) Disassemble the output shaft assembly. Remove each snap ring of synchronizer gear hub
with clip forceps. Refer to the exploded view for the specific sequence of parts.
（13）、二轴总成拆解。用卡环钳拆掉每一个同步器齿毂卡环。具体零部件顺序参考爆炸图。
(14) Disassemble the rear cover assembly. Refer to the exploded view for the specific sequence
of parts.
（14）、后盖总成拆解。具体零部件顺序参考爆炸图
(15) Refer to the exploded view for the specific disassembling sequence of other small
assemblies, and the assembly can be performed in the sequence opposite to the disassembling
sequence.
（15）、其余小总成拆解顺序均参考爆炸图，总成装配可按照拆解反顺序进行。
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2. Exploded View of Reverse Gear Assembly:
2.倒档轴总成爆炸图：
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No.
Quantity 数
序 Name 名称
量
号
14
Reverse
gear
1 1
20
assembly 倒
档齿合件
Reverse
2 1
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axle 倒档轴
Pin of
reverse gear
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3 1
shaft 倒档
轴销
3. Exploded View of Output shaft Assembly:
3.二轴总成爆炸图：
27
25
14
20
No. Quantit No. Quantity

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Name 名称 Name 名称
序号 y 数量序号数量
Roller bearing of Thrust washer of
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1 output shaft head 二 1 27 5th gear 1

轴头滚针轴承五档齿止推垫圈
Ball bearing
2 Snap ring 卡环 1 28 1
球轴承
3rd /4th gear
Check ring
3 synchronizer spring 2 29 1
止动环
3/4 同步器弹簧
3/4 speed
Front spacer of
synchronizer gear
4 1 30 inner driving gear 1
hub
里主齿前隔套
3/4 同步器齿毂
3/4 speed
synchronizer gear Inner driving gear
5 1 31 1
sleeve 里主齿
3/4 同步器齿套
Rear spacer of
Needle bearing
6 1 32 inner driving gear 1
滚针轴承
里主齿后隔套
3/4 speed
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synchronizer ring
7 1 33 Flange 凸缘 1
gear
3/4 同步器齿环
8
3rd gear assembly of
output shaft 1 25
34 O-ring “O”形圈 1
14
二轴三档齿合件
Disc washer
9 Snap ring 卡环 1 35 1
碟形垫圈
20
Thrust washer of 2nd

Screw of output
10 gear 1 36 1
shaft 二轴螺母
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二档齿止推垫圈
2nd gear assembly of
11 output shaft 1 37 Steel ball 钢球 1
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二轴二档齿合件
Needle bearing
12 2 38 ----- --
滚针轴承
1st /2nd gear
Thrust washer synchronizer
13 1 39 2
止推垫圈 spring
1/2 同步器弹簧
1st /2nd gear
14 Snap ring 卡环 1 40 synchronizer 3
slider
1/2 同步器滑块
1/2 speed R/5th gear

synchronizer gear synchronizer
15 1 41 3
hub slider
1/2 同步器齿毂 R/5 同步器滑块
1/2 speed R/5th gear
synchronizer gear synchronizer gear
16 1 42 1
sleeve hub
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1/2 同步器齿套 R/5 同步器齿毂
1/2 speed
25
synchronizer ring
17 1 43
gear
1/2 同步器齿环
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1st gear assembly of
18 output shaft 1 44
二轴一档齿合件
20
3rd /4th gear

19 synchronizer slider 3 45
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3/4 同步器滑块
20 Output shaft 二轴 1 46
Needle bearing
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21 1 47
滚针轴承
Reverse gear
assembly of output
22 1 48
shaft
二轴倒档齿合件
23 Snap ring 卡环 1 49
R/5 speed
synchronizer gear
24 1
sleeve
R/5 同步器齿套
3/4 speed
synchronizer ring
25 1
gear
3/4 同步器齿环
5th gear assembly
26 output shaft 1
二轴五档轮合件
27
4. Exploded View of Upper Cover Assembly
4、上盖总成爆炸：
25
14
20
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No. Quantity No. Quantity
序号数量序号数量
Transmission gearbox Reversing Lamp
1 1 10 1
cover 变速器盖 Switch 倒车灯开关
Outer gear shift rocker arm (Hex head bolt)
2 1 11 8
assembly 外选档摇臂合件六角头螺栓
Inner gear shift
3 Flat washer 平垫圈 1 12 rocker arm 1
27
内换挡摇臂
Spring washer
4 Oil seal 油封 1 13 8
弹簧垫圈
5
Inner gear selecting rocker
arm 内选档摇臂
1
25 14
(Hex head bolt)
六角头螺栓
2
14
Elastic cylindrical pin
6 1 15 Macro gasket 大垫圈 2
弹性圆柱销
R/5th gear resistance Spring washer
20
7 1 16 8
spring R/5 档阻力弹簧弹簧垫圈
(Hex head bolt)
8 Oil seal 油封 1 17 1
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六角头螺栓
9 Flat washer 平垫圈 1 18 Flat washer 平垫圈

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19 Gasket 垫圈 1 23 Flat washer 平垫圈 1
Outer gear shift

Knurled cylindrical pin
20 1 24 rocker arm assembly 1
滚花圆柱销
外换档摇臂合件
Oil filler screw assembly
21 1
加油螺塞总成
22 X-1702160-03-06 1
5. Exploded View of Input shaft Assembly
5、一轴总成爆炸：
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No.序号 Name 名称
25
Quantity No.
Name 名称
Quantity
14
数量序号数量
3/4 speed synchronizer
1 Snap ring 卡环 1 5 ring gear 1
20
3/4 同步器齿环
2 Check ring 止动环 1
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Ball bearing (input shaft)

3 1
球轴承（一轴）
Input shaft assembly
4 1
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一轴合件
6. Exploded of Rear Cover Assembly:
6、后盖总成爆炸：
27
25
14
Odometer guide sleeve
1 Rear cover 后盖 1 9 1
20
里程表导套
2 Breather plug 通气塞 1 10 O-ring O 型圈 1
(Hex head bolt)
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3 1 11 Elastic pin 弹性销 1

六角头螺栓
Spring washer (Hex head bolt)
4 1 12 5
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弹簧垫圈六角头螺栓
(Hex head bolt) Spring washer
5 2 13 7
六角头螺栓弹簧垫圈
Grooved ball roller
6 Oil seal 油封 1 14 bearing 1
深沟球滚子轴承
7 Oil seal 油封 1
Inner driven gear
8 1
里被齿
7. Exploded View of Counter shaft Assembly:
7、中间轴总成爆炸：
27
No. Quantity 25
No. Quantity
14
1 Snap ring 卡环 1 6 Snap ring 卡环 1

20
Cylindrical roller bearing 5th gear of counter shaft

2 1 7 1
圆柱滚子轴承中五齿
Main tooth of middle Cylindrical roller bearing
3 1 8 1
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shaft 中主齿圆柱滚子轴承

3rd gear of counter shaft
4 1 9 Check ring 止动环 1
中三齿
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5 Countershaft 中间轴 1 10 Snap ring 卡环 1
8. Exploded View of Housing Assembly:
8、壳体总成爆炸：
No. Quantity
Name 名称
序号数量
Flexible shaft bracket
1 1
assembly 软轴支架合件
27
2 Gasket 衬垫 1
3 Housing 壳体 1
Side cover gasket
25
4 1
侧盖衬垫
Transmission side cover
5 1
14
变速器侧盖
6 Side cover bolt 侧盖螺栓 6
Oil drain screw assembly

20
7 1
放油螺塞总成
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JA
9. Exploded View of Shift Fork Assembly:
9、拨叉总成爆炸：
27
25
14
20
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JA

5th /R dial block 1/2 speed fork shaft
1 1 9 1
5/R 拨快 1/2 档拨叉轴
5th /R shift fork shaft 1st /2nd gear dial
2 1 10 1
5/R 拨叉轴 block 1/2 档拨块
5th /R shift fork Elastic cylindrical
3 1 11 6
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5/R 拨叉 pin 弹性圆柱销
Lock ball spring Interlocking lifting
4 2 12 1
锁球弹簧 pin 互锁顶销
5
3/4 speed fork
3/4 档拨叉
1
25 13 Steel ball 钢球 7
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3/4 speed fork shaft Lock ball spring
6 1 14 1
3/4 档拨叉轴锁球弹簧
3rd /4th gear dial block Elastic cylindrical
20
7 1 15 5
3/4 档拨块 pin 弹性圆柱销
1/2 speed fork
8 1
1/2 档拨叉
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10. Exploded View of Clutch Housing Assembly
10、离合器壳总成爆炸：
27
25
14
Clutch housing Elastic washer
20
1 1 7
离合器壳弹性垫圈
Release bearing
2 1 8 Flat washer 平垫圈 1
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分离轴承
Separating shift fork
Front cover of input
3 1 9 assembly 1
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shaft 一轴前盖
分离拨叉合件
Shield of separating
4 Oil seal 油封 1 10 shift fork 1
分离拨叉护罩
Inner hexagonal
Ball bracket
5 cylindrical screw 6 11 1
球头支架
内六角圆柱螺钉
Bolt (clutch housing )
6 6
螺栓（离合器壳）
11. Reference View of Assembly Explosion:
11、总成爆炸参考图：
27
25
14
20
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V. Inspection of Key Parts
五、重要零部件检查
(1) Inspect the input shaft assembly
（1）、检查一轴总成
1) Inspect the input shaft for the phenomena of broken gear teeth, spot corrosion on gear surface,
serious wear on gear surface and gluing on gear surface. In any one of the above conditions, the input
shaft must be replaced.
27
1）检查一轴有无轮齿折断、齿面点蚀、齿面严重磨损和齿面胶合现象，若有上述任何一种情
况，则必须更换一轴。
2) Inspect the spline of input shaft for serious wear and damage. If yes, the input shaft must be
25
replaced.
2）检查一轴花键有无严重磨损和损坏，若有则必须更换一轴。
3) “Feel” the bearing with hand for flexible rotation and stagnation. If the bearing rotates inflexibly
14
or has stagnation, the bearing must be replaced.
3）用手“感觉”轴承转动是否灵活，有无卡滞现象，若轴承转动不灵活或有卡滞现象，则必
20
须更换轴承。
Note: 注：
■ When replacing bearing, pay attention to the check ring on the bearing, and replace it if
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deformed.
■更换轴承时，要注意轴承上的止动环，如果出现变形，则需更换。
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(2) Inspect the output shaft assembly

（2）、检查二轴总成
Inspect the gear on input shaft for the phenomena of broken gear teeth, spot corrosion on gear surface,
serious wear on gear surface and gluing on gear surface. In any one of the above conditions, the gear on
input shaft must be replaced.
检查二轴上齿轮有无轮齿折断、齿面点蚀、齿面严重磨损和齿面胶合现象，若有上述任何一种
情况，则必须更换二轴上齿轮。
Note: 注意：
■ “Feel” the bearing with hand for flexible rotation and stagnation. If the bearing rotates inflexibly
or has stagnation, the bearing must be replaced.
■用手“感觉”轴承转动是否灵活，有无卡滞现象，若轴承转动不灵活或有卡滞现象，则必须
更换轴承。
(3) Inspect the synchronous ring
（3）、检查同步环
1) Inspect the surface of the synchronous ring gear for damage or scratch.
1）检查同步环齿的表面有无损伤或损坏。
2) Inspect the conical part for damage or abrasion, and inspect the threads for damage by
compression.
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2）检查锥面部分有无损伤或磨损，螺纹有无压坏。
25
14
同步环齿轮
20
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3) Under the condition of pressing the synchronous ring towards gear, inspect the clearance “A”. If
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“A” is less than the limit value, replace it.

3）在同步环向齿轮按压的状态下，检查间隙“A”。若“A”小于极限值，应更换。
Limiting value: 0.5 mm 极限值：0.5mm
(4) Inspect the synchronizer gear sleeve and gear hub
（4）、检查同步器齿套和齿毂
1) Assemble the synchronizer gear sleeve together with the gear hub, and inspect if they slide
smoothly with stagnation or not.
1）将同步器齿套和齿毂组装在一起，检查它们是否圆滑滑动，有无卡住。
2) Inspect the front and rear ends on the inner surface of gear sleeve for damage.
2）检查齿套内表面的前后端有无损伤。
Note: 注意：
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■ When it is necessary to replace the synchronizer gear sleeve or gear hub, replace them together
as a set.
■ 如需更换同步器齿套或齿毂时，应成套更换。
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VI. Service Parameters

六、维修参数
1. Tightening Torque
1、拧紧力矩
Position Technical requirements (N.m)

部位技术要求（N.m）
Connection of clutch 68.6~93.2
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housing with gearbox body
离合器壳与箱体联接
Reversing Lamp Switch 29.4~39.2
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倒车灯开关
Bolts for rear cover and 25~35
transmission gearbox cover
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后盖、变速器盖螺栓
Support bolt 支架螺栓 25~35
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Bolt for side cover 14~24.5

边盖螺栓
Breather plug 通气塞 10.8~18.6
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Oil filling and drain screw 39.2~58.8

plug 加、放油螺塞
Screw of output shaft 160~210
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二轴螺母
Bolt for location pinhole of 9.8~14.7
gear shift shaft
换档轴定位销孔螺栓
Odometer shaft sleeve 9.8~14.7
里程表轴套
Separating ball support 30-42
分离球头支撑
Front cover of input shaft 9.8~14.7
一轴前盖
2. Main technical Parameters
2.主要技术参数
Type 型式 5 forward gears, 1 reverse gear 5 个前进档，1 个倒档
Operation method 操纵方式 Telecontrol 远距离操纵
Rated input torque

254.8N·m
额定输入扭矩
Mass of assembly 总成质量 About 78 kg 约 78Kg
Gear 档位 Speed ratio 速比
1 Gear 1 档
5.529
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2 Gear 2 档
2.782
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Speed ratio 3 Gear3 档
速比
1.641
4 Gear 4 档
1.000
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5 Gear 5 档
0.785
Reverse 倒档
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5.271
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VII. Maintenance of Transmission Gearbox

七、变速器保养
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1. Maintenance
1、维护与保养
1.1 The transmission gearbox shall be used and maintained according to the requirements for use
and maintenance of commercial vehicles, generally classified as technical maintenance of three
levels.
1.1 变速器使用保养按商务用汽车使用与保养要求进行，一般分三级技术保养。
1.2 Regularly inspect and replace (or add) lubricating oil for transmission gearbox.
1.2 定期检查更换（或补充）变速器润滑油。
List of Regular Inspection and Maintenance for Gearbox
变速箱定期检查和维修一览表
Distance and time (in months) are indicated for the items, perform inspection as required, whichever
comes first.
项目上都注明了距离和时间（以月计），检查应以先到者为准。
○ Inspection, tightening or adjusting; ★ Replacing lubricating oil
○ 检查位、拧紧或调整； ★ 更换润滑油
Interval of Overhaul (by the reading of Odometer and number of months, , whichever
comes first)
检修间隔（以里程表读数和月数的先到者为准）
Item Months － 3 6 12 18 24 30 36 42 48 54
项目月数
Odometer reading × 1,000 1 5 10 20 30 40 50 60 70 80 90
km
里程表读数×1000 公里
Internal inspection of gearbox
变速箱内部的检查
Inspect the level of gear oil in the gearbox.
○ ○ ○ ○ ○
检查变速箱内的齿轮油液位
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General service
conditions ★ ★ ★ ★ ★
Replace the gear oil in the
一般使用条件
gearbox.
Severe service
更换变速箱内的齿轮油。
conditions ★ ★ ★ ★ ★ ★ ★ ★
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严酷使用条件
Other inspection items
其它检查
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Note: The “severe service conditions” include the following items.
注：“严酷使用条件”包括下列各项：
 Running in dusty area or always exposed to salty air or salty water.
行驶于灰尘多的地区或汽车经常暴露于有盐份的空气或盐水中。
 Running on uneven road or mountain road with accumulated water.
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在凹凸不平、有积水的道路或山路上行驶。
 Running in cold area.
在寒冷地区行驶。
 In cold seasons, engine kept idling for long or always running in short distance.
在寒冷季节中，发动机长时间以怠速运转或经常以短距离行程行驶。
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 Have to use brake frequently and emergency brake for many times.
需要频繁使用制动器和多用紧急制动。
 Towing vehicle.
牵引汽车。
 Under the high temperature above 32°C, the time of driving slowly in jammed urban area exceeds
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50% of total driving time.

在 32℃以上的高温下在交通拥挤的市区缓慢驾驶汽车的时间超过总行驶时间的 50％。
 Under the high temperature above 30°C, the time of driving at the high speed above 120 km/h
exceeds 50% of total driving time.
在 30℃以上的高温下以 120 公里/小时以上的高速驾驶汽车的时间超过总行驶时间的 50％。
 Overloaded driving.
超载行驶。
2. Lubrication and Sealing

2、润滑与密封
Lubricating oil and

Items Quantity
sealant
项目数量
润滑油及密封胶
Gear oil for transmission
Gear oil 75W/90 GL-4
gearbox 2.7±0.1L
齿轮油 75W/90 GL-4
变速器齿轮油
Release bearing inner hole
Lubricating grease Appropriate amount
of transmission gearbox
润滑油脂适量
变速器分离轴承内孔
Transmission gearbox oil
Lubricating grease Appropriate amount
seal
润滑油脂适量
变速器油封
Adjoining surface between
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transmission gearbox
KESAIXIN®1596F Appropriate amount
housing and clutch housing
可赛新®1596F 适量
变速器壳体与离合器壳的
接合面
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Adjoining surface between
transmission gearbox KESAIXIN®1596F Appropriate amount
housing and rear cover 可赛新®1596F 适量
变速器壳与后盖的接合面
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VIII. Contents of Quick-wear Parts for LC5T255M3
八、LC5T255M3 易损件目录
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No. Name Quantity

序号名称数量
Side cover gasket
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1 1
侧盖衬垫
Transmission gearbox cover
2 gasket 1
变速器盖衬垫
Oil seal (rear cover )
3 1
油封（后盖）
Oil seal (clutch housing )
4 1
油封（离合器壳）
Chapter Ⅲ Front axle
第三章前桥
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：1° Full 满载：45′
前轮外倾角
Kingpin caster Angle
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Empty 空载：2°40′ Full 满载：2°
主销后倾角
Kingpin inclination
Empty 空载：7°30′ Full 满载：7°45′
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主销内倾角
Axial load
Common 出厂：10-25N Maintenance 保养：5-20N
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轴向负荷
Steering knuckle and front axle surface gap

≤0.1mm
转向节与前轴面间隙
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前束
Oblique tire 斜交胎 3mm-6mm Meridian tire 子午线胎 1mm-3mm
Front beam
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车轮最大内转角
37°±30′
Front wheel maximum amount of corner
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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 diagrams 爆炸图
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S/N 序号 Spare Parts Name 备件名称
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00 front axle assembly 前桥总成
01 wheel hub cover 轮毂罩

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02 cotter pin 开口销
03 front wheel huband brake drum assy,left 左前轮毂及制动鼓总成

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04 front wheel huband brake drum assy,right 右前轮毂及制动鼓总成
05 front axle 前轴
06 nut 转向节螺母
07 lock plate 锁片
08 nut 六角螺母
09 spring washer 弹簧垫圈
10 nut I 型六角螺母
11 oil seal 油封
12 oil seal seat 油封座
13 oil fender 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
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16 keen pin 主销
17 bolt 制动器底板螺栓
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19
bolt
plug 25 转向限位螺栓
螺塞
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20 nut 螺母
21 keen pin cover 主销盖

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22 lock bolt,king pin 主销锁栓
23 steering straight arm 转向直臂

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24 tie rod assy 横拉杆总成
25 thrust bearing 止推轴承

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26 steering knuckle-crank arm unit 转向弯臂总成
27 bolt 六角头螺栓
28 flat washer 平垫圈
30 cotter pin 开口销
longer remark.
1、 Remove front axle assembly 前桥总成拆卸
□ Before disassembling, vehicle front and rear wheels

need to be stopped by woods to prevent the slide
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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 of the 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液力制动管路并取下前桥
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总成
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2、前桥总成分解 Decomposition front axle assembly
□ □ Remove the hub caps and remove the front wheel nuts
拆下轮毂罩，拆卸前轮外螺母
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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
拆卸衬套与前制动器固定螺母，拆下前制动器总成
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□ Remove the main pin cover
拆下主销盖
□ □ Remove the cotter pin and remove steering lever and

steering 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
25
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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，取下转向横拉
杆
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□ Remove fixing nut of steering straight arm and bushing,

steering bend arm and bushing mounting nuts, 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 the disassembly sequence 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 the brake assembly should be checked before assembly, brake shoe surface can not have oil,
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brake tendon plate and brake wheel cylinder pump tank should have clearance, no clearance does not
allow assembly, each pipe joint shall be installed firmly;
前制动器总成装配前应进行检查，制动蹄片外表面不得有油污，制动蹄筋板与制动分泵泵槽
应有间隙，无间隙的不允许装配，各管接头应安装牢固；
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 Before assembly, front axle and steering knuckle, steering arm straight forgings convex mesa is
14
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
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from a crack in the parts of extrusion, front axle and steering knuckle end clearance and wheel hub
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
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
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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;
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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
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 center of the tire wheel track, and place the
25
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
20
□ Measuring the distance between the center line of the

tire in front of the vehicle (A), push the vehicle to the
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rear or forward to let each wheel rotate 180 degrees, in

accordance with the original mark measure the distance
between the tire center line of front-wheel rear side(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, loosen the end of the

connecting rod clamping bolt. 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 wooden
block under the rear wheels, and its thickness and
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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，直到转向角达到要求，
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拧紧锁紧螺母
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IV Fault diagnosis and solutions 故障诊断与处理
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：
Failures 故障 Fault cause 故障原因 Failure repair 故障维修
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Front axle fatigue
damage, cracks or Front axle load is too large, long-term
25
Parts should be replaced timely
broken fault overload
应及时更换新件
前桥疲劳损伤、裂纹或前桥负荷过大，长期过载
14
断裂故障
20
As front axle bear large

anti-competitiveness in the vertical
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direction from the ground and it is

easy to cause bent, will change the
The front axle happens pin pitch, outside of the wheel angle,
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bent failure in the the diesel vehicle steering heavy,

Beams should be corrected timely
vertical direction wheel hub bearing load increases, and
reduce its life 应及时校正横梁
前桥在垂直方向产生
弯曲变形故障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
Front axle bear the braking force in

the horizontal direction from under
The front axle happens
ground ,which is easy to cause bent,
bent failure in the There should be timely correction
will change Front Wheel toe-in and
horizontal direction front beams
increase tire wear
前桥在水平方向产生应及时校正前横梁
前桥在水平方向承受来自地面的制
弯曲变形故障
动力易产生弯曲变形，会改变前轮
27
前束，增大轮胎磨损
Front axle with a reverse deformation

The front axle has
25
will change the caster angle, and Replace the front beam or to correct
distorted fault
impact front-wheel driving stability repair
前桥产生扭曲变形故
前桥产生扭转变形会改变主销后倾更换前横梁或进行校正修理
14
障
角，影响前轮行驶稳定性
20
Shaft heat typically occurs after

maintenance, and often resulted from
bearing pre-pressure too tight to seat
C-
bearings with too tight when

assembly wheel hub. Wheel hub
bearing damage or pitting will not
JA
Check the bearings for tightness and

The front axle shaft only result in heat but also with some
wheel hub bearings for the oil
with Thermal fault noise. Wheel hub bearing lacking oil
can also cause shaft thermal failure 检查轴承配合松紧和轮毂轴承是否
前桥轴头发热故障
缺油
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
There is no gap between brake shoes

and brake drum, which will obviously
cause brake drum heat. At this time
The main reason of brake drum heat except check adjust clearance, should
is air brake chamber diaphragm do check the problem of air chamber
not return to the original place or diaphragm without returning, and
return too slow; brake shoe return when the brake air chamber
The front axle brake
spring broken or weak will cause diaphragm does not return, the air
27
drums heat failure
brake drum heat problem should check and check
前桥制动鼓发热故障 whether the brake camshaft stocked
制动鼓发热的主要原因是气制动室
25
膜片不回位或回位太缓慢所致；制制动蹄片与制动鼓没有间隙，显然
动蹄回位弹簧断裂或弹力不足也会也会造成制动鼓发热。此时除检查
造成制动鼓发热调整间隙外应检查气室膜片不回位
14
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
20
否发卡
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The pin bushing, the main pin, thrust

JA
bearings are worn, the absenteeism,

The master pin bushing,
will affect the wheel alignment, lower
main pin, thrust bearing Replace worn parts and re-front wheel
the lever stability
wear-out failure alignment
主销衬套、主销、止推轴承磨损、
主销衬套、主销、止推应更换磨损件并重新进行前轮定位
松旷，会影响前轮定位，降低操纵
轴承磨损故障
杆稳定性
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
Removal brake drum checks and
little, the two front wheels have a
makes the cut. Tire rims deformed
Step brake lightly with braking effect are not in sync, and
sometimes will also cause this
the front wheels failure some times in the left brake, and
problem
sometimes in right brake resulting
27
轻踩制动时前轮发摆
front wheel wiggle 此时应将制动鼓拆卸检查并进行光
故障
削修理。轮胎钢圈变形有时也会产
这主要是制动鼓圆度误差超值所
25
生这种故障
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
14
而造成前轮摆动
20
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Front brake drum swings oil, which is

clearly because of hub oil seal
JA
The front brake drum damage. Wheel Hub Oil Seal Leak Replace it with a new oil seal to
rotor oil not only caused shaking oil, but will troubleshooting
前制动鼓甩油故障 also enable brake failure 更换新油封才能将故障排除
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
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
27
pin-to-Bushing dry friction, not only
increase steering resistance heavily,
and can be as severe as the
25
pin-to-Bushing sintered. Therefore,
the service require apply grease to
Front axle steering system mechanical steering joint pin, generally first, lift
14
failure; steering hydraulic power up the I frame of front axle ,apply oil
Steering heavy fault
system failure with a grease gun to oil mouth which
转向沉重故障
20
前桥转向系统机械部分故障；转向 is installed on the camshaft holder

液压动力系统的故障 until the beam with pin holes, the flat
extruder oil
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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
JA
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，一般先将前桥工字梁顶起，
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、
下平面挤出油为止
The reason of that front tire wear and

tear are not are much complex, and
toe-in value is not right clearly will
Troubleshooting the issue is a
worn front tire, Steel ring
complex work, it is necessary to take
deformation, shaft and the
into account the front wheel alignment
absenteeism, the beam is deformed,
of the parameters of the change, but
27
the main pin clearance, and so on, all
The front tire wear and also to take into account other factors
of which can cause wear front tire
tear are not normal fault
排除此故障是一项复杂的工作，既
failure
25
前轮胎磨损不正常故要考虑到前轮定位各项参数的变
前轮磨损不正常的因素较为复杂，
障化，又要考虑其他方面因素的影响
前束值不对显然会磨损前轮胎，钢
14
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
20
There are two reasons for front wheel

brake deviation. The clearance
C-
difference between left and right

brake make the braking starting time When the vehicle's braking drift, by
is not synchronized; left and right adjusting brake shoes clearance
JA
brake shoes and brake drum to contact cannot be excluded when it is, and
The front-wheel brake
different size or the oil causing should be remove brake drum
drift
contact friction torque of the inspection and the mill
前轮制动跑偏故障
differences, which results in different 当汽车制动跑偏、通过调整制动蹄
brake torque to the brake run in 片间隙不能排除故时，应拆卸制动
deviation 鼓进行检查和光磨
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
Brake inefficiency is the problem of

braking drum and braking shoe except
the reason of braking control system.
27
In the actual repair, Check brake
effection often using the brake drum
and brake shoes contact area, and the
25
In the mill foot-and-mouth, its
general requirements for brake shoes
diameter should be slightly larger than
and brake drum contact area should
the diameter, in order to ensure that
be more than 70 per cent. From the
14
The brake failure shoes engage both ends, in order to
practical experience, two end-engaged
doesn't work get the most recent braking
of the brake shoes are much more
effectiveness
20
制动不灵故障 productive than the median engage.

在光磨蹄片时，其直径应略大于鼓
制动不灵除制动控制系统原因外，
的直径，以保证制动蹄片啮合两端，
就是制动鼓与制动蹄片的问题。在
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以便获得最近制动效果
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
JA
般要求制动蹄片与制动鼓接触面积
应在 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
Chapter Ⅳ Rear axle
第四章后桥
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.
27
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 assembly of driving axle by driving gear’s flange. It is sustained by two cone bearings, which is
25
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
14
of differential of some bolts.
Differential, which can make the right and left wheel’s rev different, consists of the housing of
differential, spider, four spider gears, and two side gears and some of other parts.
20
Drive axle’s half-shaft is connected with half-shaft gear by spine in one side, and with hub by some
bolts in flange in another side.
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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
JA
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
2400000D817XZ
Rear axle model
27
Gear oil model
（GL-5)85W / 90
齿轮油型号
25
Gear oil filling quantity
3.5L
齿轮油加注量 14
The main reduction ratio
5.375
主减速比
20
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Ⅱ Location map and exploded 位置图及爆炸图
1、 Location Map 位置图
27
25
14
20
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2、 Exploded diagrams 爆炸图
□ Rear axle assembly 后桥总成
27
25
14
20

C-
00 rear axle with brake assembly 后桥带制动器总成
JA
03 spring washer 重型弹簧垫圈
04 bolt 半轴螺栓
05 shaft 半轴
06 oil seal 半轴油封
07 lock washer 锁止垫圈
08 nut 后轮毂轴承锁紧螺母
09 bolt 制动器底板螺栓
10 nut 六角螺母
11 brake assy（leftt）后制动器总成（左）
11 brake assy（right）后制动器总成（右）
12 main reducer unit 主减速器总成
13 hex fine bolt 六角头细牙螺栓（预涂胶）
27
14 stud bolt 双头螺栓（桥壳）
15 nut 六角螺母
16
16
the rear wheel hub with brake drum assembly (left)
25
the rear wheel hub with brake drum assembly (right)
后轮毂带制动鼓总成（左）
后轮毂带制动鼓总成（右）
14
17 plug coke 六角头磁性螺塞
18 plug coke 加油塞密封垫圈

20
19 vent-plug 常开式通气塞
20 plug cock 加油塞

C-
21 plug coke 加油塞密封垫圈
22 rear axle assembly 后桥壳总成

JA
□ Drum assembly 轮毂总成
27
25
14
01 oil fender 挡油盘

20

C-
04 inner oil seal 后轮毂内油封
05 rear brake drum 后制动鼓

JA
06 inner bearing 后轮毂内轴承
07 rear hub 后轮毂
08 outer bearing 后轮毂外轴承
09 tire bolt assembly (left) 轮胎螺栓组件（左）
□ Main reducer assembly 主减速器总成
27
25
14
20
01 drive gear assembly 主动齿轮总成
02 oil seal O 形圈-主动齿轮轴承座

C-
03 shim 主齿轴承座调整垫片
04 nut 六角螺母
JA
06 spring sprag 导向轴承弹簧挡圈
07 guided bearing 主动齿轮导向轴承
08 stopping plate assy 导向轴承挡板总成
09 final drive housing assembly 主减速器壳总成
10 differential unit 差速器总成
11 bolt 螺栓-从动齿轮
12 bolt 轴承座螺栓
□ Differential assembly 差速器总成
27
25
14
20
01 bearing 差速器轴承
C-
02 Differential case 差速器壳总成
03 thrust plate 半轴齿轮止推垫片

JA
04 side gear combination 侧卫齿组件
05 spinder 行星齿轮轴
longer remark.
Ⅲ Remove, install and adjust 拆装与调整
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 clearance out of set standard, we must
change the partner parts and other accessories in accordance with relevant requirements.
27
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。
25
□ Some repairing parts which still in limited tolerance must be changed according to pre-maintenance
opinion.
14
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.
20
所有的橡胶件，如O形圈、油封、垫片等在拆下之后应抛弃，不准再使用。
□ When there have noise or shake in transmission system, check the total clearance of rear axle firstly
C-
then 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。
JA
□ 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 data is bigger than 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 improper adjustment assembly, we can solve them through adjusting the parts assembly
clearance 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。
27
2、Remove rear axle assembly后桥总成拆卸
□ Before disassembling, vehicle front and rear wheels
25
need to be stopped by woods to prevent the slide
14
20
□ Lift the vehicle to safety height with jack
用千斤顶将车辆举升至安全高度
C-
JA
□ Remove the tyre retaining bolt and remove the rear

wheel of the vehicle
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
27
□ Remove the rear saddle bolts. Remove the rear
bumper blocks
拆卸后骑马螺栓，拆下后缓冲块
25
14
□ Remove the rear brake and vehicle connect pneumatic
20
tubing and remove the rear axle assembly
拆卸后制动器与车辆连接液力制动管路并取下后桥
C-
总成
JA
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
27
25
 Disassembly the wheel hub bearing lock nut
卸下轮毂轴承锁紧螺母
14
20
C-
□ Disassembly the hub assembly
拆下轮毂总成
JA
□ Disassembly oil seal bush with inner bearing inner ring
同内轴承内圈一起，拆下油封衬套
27
□ Disassembly the brake drum
拆除制动鼓
25
14
□ Disassembly differential carrier assembly
20
分解主减速器总成
 Check and record the B/L of pinion & ring gear before
C-
disassembly
在分解之前，测量和记录主被动齿轮的齿侧间隙
JA
 Note: check the mesh condition of gears after adjust
注意：调整后，检查齿轮啮合情况
□ Disassembly lock plate
拆除锁片
□ Mark matching sign on the bearing cap & carrier
在轴承盖和壳体上，做上装配标记
27
□ loose bolt of bearing cap, 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
25
14
□ Disassembly B/R cover & bolt
20
拆下轴承盖和螺栓
C-
JA
□ Disassembly the differential case assembly
拆下差速器总成
□ 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
27
□ Disassembly differential case assembly
分解差速器总成
25
 Disassembly right case
拆下差速器右壳
14
□ Disassembly shaft gear & shim
20
拆下半轴齿轮和支承垫圈
C-
JA
□ Inspection and record the backlash of planet gear
测量和记录行星齿轮的齿侧间隙
 Note: locking the cross shaft when check backlash
注意：测量齿侧间隙时，要压住行星齿轮十字轴
□ 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
27
□ Take out shaft gear and shim
拿出半轴齿轮和半轴齿轮的止推垫圈
25
 Remove the ring gear
拆下从动齿轮
14
□ Disassembly differential case B/R
20
从差速器壳上拆下差速器轴承
C-
JA
□ Disassembly of pinion gear
主动齿轮的拆卸
 Disassembly the nut of pinion gear flange
拆除主齿凸缘螺母
□ 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
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□ 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
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拆除调整垫圈和轴承隔套
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□ Disassembly B/R from pinion gear
从主动齿轮上拆下轴承
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 than 3 point, standard values: 0-0.15mm;
limiting value: 0.3mm.
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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；
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
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The standard B/L and vary (according to table 5), should check it along ring gear edge 4 points, and
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
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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。
 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,
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assembly time adjustment is as follows
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：
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 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,
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。
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□ The rear brake clearance adjustment
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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Ⅳ Fault diagnosis and solutions 故障诊断与处理
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 replace 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 replace 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
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 sealant

tighten bolts or recoat 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
tighten the screw in accordance with
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the bolt bearing loose
the torque
轴承座紧固螺栓松
Lubrication leak 按规定力矩拧紧螺栓
润滑油泄漏
放油螺塞松或衬垫有损伤
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oil drain screw loose or pad damage tighten the screw or replace the gasket
拧紧螺塞或更换衬垫
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due to the overload bridge shell deformation
correct or replace the bridge shell
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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
通气塞被堵或损伤清洁或更换通气塞
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malfunction of camshaft check camshaft
凸轮轴旋转不灵检查凸轮轴工作情况
Problem of brake force
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 replace 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 force
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 V Drive shaft

第五章传动轴
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
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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
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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
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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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Drive shaft important parameters
传动轴重要参数
shaft torque limit 传动轴极限扭矩 2400N.m
Angular 摆角 ≥20°
Grease type 润滑脂型号 Mobil EP2 美孚 EP2
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Yield of static torque 屈服静扭矩 ≥2400N.m
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Torsion fatigue rated torque 扭转疲劳额定扭矩 1200N.m
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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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2、 Exploded view 爆炸图
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02 nut 1 型六角螺母
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03 rear axle drive shaft assembly 后桥传动轴总成
04 rear axle drive shaft bolt 后桥传动轴螺栓

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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.
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 which may cause deformation of parts.
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
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□ When disassembling the drive shaft assembly, the

disassembly order is differential end nut, middle
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hanging, transmission end nut, drive shaft assembly
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
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□ 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
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□ Disassemble drive shaft and transmission side coupling
nut
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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,但是需要注意以下事项：
□ 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
25
□ 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
装配：按照拆解相反步骤开展，但是需要注意以下事项：
□ 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 VI Suspension system
第六章悬架系统
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
04 Front right leaf spring assembly 前右钢板弹簧总成
05 Front U-bolt 前骑马螺栓
06 Front cushion block 前缓冲块总成
07 iron mat 前板簧垫铁
08 Front U-shape bolt nut 前骑马螺栓螺母
09 Front leaf springs hanging ear plate assembly 前板簧吊耳板总成
11 left upper bracket,front shock absorber 前减震器左上支架
11 right upper bracket,front shock absorber 前减震器右上支架
12 front shock absorber 前减震器总成
13 Front shock absorber rubber sleeve gasket (outer) 前减震器橡胶套垫圈（外）
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14 Front shock absorber rubber sleeve gasket (within) 前减震器橡胶套垫圈（内）
15 down pin ,front shock absorber 前减震器下销
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17
hexagon flange bolts
I type hex nuts 25 六角法兰面螺栓
Ⅰ型六角螺母
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19 Hexagon head bolts 六角头螺栓

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Rear suspension 后悬
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01 rear steel spring front pin 后板簧前销

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02 front u-shape bolt nut 前骑马螺栓螺母
03 rear leaf spring assembly(left) 后钢板弹簧总成（左）

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03 rear leaf spring assembly(right) 后钢板弹簧总成（右）
04 rear u bolt 后骑马螺栓
05 rear spring iron cover plate 后簧上盖板
06 rear spring iron mat 后板簧垫铁
07 rear horse bolts gasket 后骑马螺栓垫片
08 rear cushion block unit 后缓冲块总成
09 absorbers outer gasket 减震器外垫片
10 rear absorber unit 后减震器总成
11 shock absorber inside the gasket 减震器内垫片
12 rear the spring lug plate 后簧吊耳板
13 steel spring sleeve 钢板衬套
14 rear steel spring suspend plate 后板簧吊耳板总成
15 steel spring pin 板簧销
16 nut 螺母
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17 rear horse bolts nut 后骑马螺栓螺母
18 straight slide grease nib 直通式滑脂嘴
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spring washer
nut 25 弹簧垫圈
螺母
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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
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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
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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装配：按照拆解相反步骤开展，并注意以下事项
□ Make a assembling mark on the leaf spring intersecting

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surface before removal leaf spring
拆卸钢板弹簧之前，要在钢板弹簧横面上做安装标记
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□ 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，应更换新的中心螺栓
□ 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

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
□ Pay attention to filling lubricating oil (until the oil oozes
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a little) when assemble lug pin
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
acceptable
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检查减振器的泄露，允许有少量渗漏
□ Check the temperature of shock absorber rises or not,

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after driving for some distance, if the temperature does

not rise, it indicates that the shock absorber is not
working and should be replaced
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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
2、后悬拆装 Removal rear suspension
□ When disassembling the rear suspension, the

disassembly order is front shock absorber、U-bolt、lug
pin、steady pin、leaf spring
拆解后悬，拆解顺序为后减振器、U 形螺栓、吊耳销、
板簧销、钢板弹簧
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□ Fix rear –wheel, and jack automobile, then jack front
axle with lift equipment
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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
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 Loosen(not dismantle) 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 let it supports on the chassis

holder
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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
拆解后减震器
 Remove rear shock absorber upper bracket and front

axle hold-down nut
拆解后减震器上支架与前轴固定螺母
 Remove front shock absorber lower bracket and front

axle hold-down nut
拆解前减震器下支架固定螺母
□ Remove rear axle assembly
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拆解后桥总成
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□ Remove rear leaf spring
拆解后板簧
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 Remove rear leaf spring hold-down nut
拆解后板簧固定螺母
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 Remove rear leaf spring lug pin, and take down rear leaf
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spring assembly
拆卸后板簧吊耳销，取下后板簧总成
□ Make a assembling mark on the leaf spring surface,

before removal leaf spring
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
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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
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leaf spring
更换钢板弹簧时，使用相同弧高的钢板弹簧
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□ 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
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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

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little),when assembling lug pin
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

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
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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
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□ Stretch shock absorber, if feel no heavy resistance, it
indicates the absorber does not work and should be
replaced
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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 VII Steering system
第七章转向系统
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。
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Steering important parameters
转向系统重要参数
For maximum front axle load

（1.5—2.5）T
适用最大前轴负荷
Theory of maximum output torque

1863N.m
最大理论输出力矩
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Turning laps
≥4.5
转向圈数
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Output Angle
46°±1.5°
输出角
Input spline (diameter x number of teeth)

Φ17.5×36
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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

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(8～11)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
08 Hexagon flange bolts 六角法兰面螺栓
09 Hexagon flange bolts 六角法兰面螺栓
10 cross recessed pan head screw and washer assemblies 十字槽盘头螺钉和平垫圈组合件
11 steering cover button 转向护罩卡扣
12 hex head bolt, spring washer, flat washer assembly 六角头螺栓弹簧垫圈和平垫圈组合件
13 Hex nut and taper washer 六角螺母和锥形弹性垫圈
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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
05 oil pump outlet perforation bolt 油泵出油穿孔螺栓
06 seal 组合式密封垫圈
07 power steering pump unit 动力转向泵总成
08 compressor bracket tightening bolt Ⅱ 压缩机支架紧固螺栓 2
10 hose clip 橡胶管夹
11 worm drive type hose clamp B 型蜗杆传动式软管环箍
12 clamp 卡箍
13 hose clip 软管夹
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15 power steering return pipe 动力转向回油软管
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pump inlet hose
oil tank bracket 25 油泵进油软管
油罐支架总成
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18 power steering oil tank 动力转向油罐总成
19 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
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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
拆解方向盘
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□ Remove the steering wheel cover with both hands, and
remove the retaining nut that fixing the steering wheel
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with sleeve
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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

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cover of the steering column
拧下固定螺母，拆解转向管柱上护罩
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□ 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
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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
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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
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□ Disassemble the coupling nut that connect the power
steering oil tank and the frame, then remove the tank.
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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
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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
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steering gear. Then start the engine in less than 15 seconds, and turn the steering wheel in both directions
consecutively to each extreme position to drain the oil .Then refuel according to the refueling procedures.
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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
exhaust air and vaporized fluid. With the bubble discharging, the oil in the tank will fall. At this time oil
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should be added continuously until the oil surface keep placid, which completes the exhaust process.
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
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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。
Precautions 注意事项：
 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
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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
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
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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

should be coated with leak-proof glue when assembling.
Specific brands and smear standard, please consult
"Overview and maintenance manual "
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 Ⅷ Braking system

第八章制动系统
I Interview 概述
Braking system consists mainly of brake, braking lines, parking drawing, brake pedal, brake master
cylinder and other components, which are series of specialized devices supposed to make the outside
world (mainly roads) exert a certain force on some parts of the vehicle (mainly wheels) to achieve some
degree of forcible brake. The function of braking system is: to slow down or even stop the moving vehicle
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forcibly in accordance with the requirements of the driver; to achieve stable parking under various road
conditions (including the slope); to keep the vehicle downhill at a stable speed. Only the external force
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with an opposite direction to the traveling direction of the vehicle applied to the vehicle can achieve
braking effect on the vehicle. But the strength of the external force is at random and uncontrollable. So
series of specialized devices should be installed on the vehicle to achieve the braking function.
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制动系统主要包含制动器、制动管路、驻车拉丝、制动踏板、制动主缸等零部件，是汽车上用
以使外界（主要是路面）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
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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
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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
Joints on both ends of steel tube

Joints on both ends of hose
Vacuum hose
Flexible hose
Vacuum steel tube
Brake line
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S/N 序号 Spare Parts Name 部件名称

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A oil pot 储油壶
B vacuum booster with tandem master cylinder assembly 真空助力器带串连制动总泵总成

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C five-way connector 五通接头
D front brake wheel cylinder 前制动器分泵
E oil tube tee 油管三通
F rear brake wheel cylinder 后制动器分泵
G vacuum pumps 真空泵
H vacuum tee 真空管三通
I auxiliary exhaust brake 排气辅助制动器
J auxiliary exhaust brake solenoid valve 排气辅助制动电磁阀

K vacuum tube; 真空筒
L vacuum tube junction plate 真空管连接板
□ Brake 制动器
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00 brake assembly 制动器总成
01 braking soleplate 制动底板
02 brake shoe assembly 制动蹄总成
03 brake shoe return spring 制动蹄回位弹簧
04 setting bolt spring pedestal 压簧座
05 braking pump assembly 制动分泵总成
06 setting bolt spring pole 压簧拉杆
07 setting bolt spring 压簧
08 oil pipe assembly 端油管总成
09 oil pipe assembly 端油管总成
10 three-way connection 三通接头
11 braking pipe clip 制动管卡
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□ Brake lines 制动管路
25
14
20
C-
JA
01 double steel wire ring hoop 双钢丝环箍
02 vacuum soft hose(v) 真空软管 5
03 three-way 三通
04 vacuum soft hose(ii) 真空软管 2
05 clip 管夹
06 vacuum hose 真空管
07 vacuum hose tube (i) 真空软管 1
08 vacuum soft hose with connecting bracket unit 真空管带连接支架总成
09 vacuum soft hose(Ⅶ) 真空软管 7
27
10 vacuum soft hose(Ⅵ) 真空软管 6
11 vacuum soft hose(ii) 真空软管 2
12
13
connecting board unit
vacuum soft hose 25 真空管连接板总成
真空软管
14
14 vacuum soft hose(Ⅳ) 真空软管 4
15 vacuum cylinder unit 真空筒总成

20
16 vacuum booster with in series brake main pump unit 真空助力器带串联制动总泵总成
17 clutch master pedal and bracket noumenon unit 制动踏板及支架总成

C-
18 inlet oil pipe assembly-front chamber of master pump 制动总泵后腔进油软管总成
19 inlet oil pipe assembly-front chamber of master pump 制动总泵前腔进油软管总成

JA
20 oil storage boat 储油壶总成
21 brake master pump front brake pipe unit 制动总泵前制动管总成
22 brake master pump rear brake pipe unit 制动总泵后制动管总成
23 seal board unit 密封板总成
24 connecting bracket ,brake pipe 前制动管连接支架
25 two-way 二通
26 brake pipe assembly-front chamber of master pump（Ⅱ）总泵后制动管管总成 2
27 brake pipe assembly-front chamber of master pump（Ⅰ）总泵前制动管管总成 1
28 card 卡片
29 brake pipe unit 制动前软管总成
30 diffluence tie-in unit 分流接头总成
31 five-way bracket unit 管夹
32 left front brake pipe unit 左前制动管总成
27
33 pipe nip 管夹 2
34 left-front brake pipe bracket unit 左前制动管支架总成
35
36
front brake pipe unit
right front brake pipe unit 25 前制动管总成
右前制动管总成
14
37 rear brake pipe unit（Ⅰ）后制动管总成 1
38 clip 管夹
20
39 hose clip 橡胶管夹
40 clip 管夹
C-
41 right-front brake pipe bracket unit 右前制动管支架总成

JA
47 front brake pipe unit(Ⅰ) 前制动管总成 1
51 clip 管卡
52 clip for three pipe 三线管卡
53 clip for three pipe 三线管卡
27
25
14
20
C-
JA
01 two-way 二通
02 rear braking pipe unit 后制动管总成
03 front brake pipe unit 前制动管总成 2
04 clip 管夹
05 rear brake pipe unit (iii) 后制动管总成 3
06 load sensing proportion valve 感载比例阀
07 rear axle left brake pipe unit 后桥左制动管总成
08 rear axle right brake pipe unit 后桥右制动管总成
09 rear brake pipe unit 后制动软管总成
10 three-way 三通
27
13 bracket 感载阀支架
14
15
card
hexagon flange bolts 25 卡片
六角法兰面螺栓
14
□ Parking Drawing 驻车拉丝
20
C-
JA
01 parking brake control handle 驻车制动操纵手柄总成
02 parking cable front joint nut 拉丝前接头螺母
03 Drawing Wire 拉丝
05 wire clip 线夹
27
□ Brake master cylinder 制动主缸
25
14
20
C-
JA
01 vacuum booster unit 真空助力器总成
02 brake master cylinder assembly 制动主缸总成
Remarks: The above picture is a typical component picture. Even if there is a subtle difference between some
models, it is no longer identified 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
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";
27
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”；
□ 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；
25
□ Do not use excessive force when removing, because it may cause deformation of parts.
14
拆卸时请勿用力过大，因为可能导致零件变形。
20
2、 Removal and installation of braking pipe 制动管路拆装

C-
□ Dismantling the vehicle braking lines: Remove one by

one along the brake pipe
拆解整车制动管路：沿制动管路走向逐一拆解
JA
□ Preparation: Unscrew the bleeder screw, and exhaust

braking fluid out of braking pipe
准备工作：拧下放气螺塞，排出制动管内制动液
Assembly: Installation should be in the reversed order of removal, and cautions are as follows:
□ Make sure that there is no air in the braking pipe when

re-install. If there is air in the system, the steps to
exhaust air are as follows:
复装时确保制动管内无空气，万一系统内有空气进
入，排除空气的步骤如下：
27
□ Unscrew the oil lid, add brake fluid, start the engine and
repeatedly step on the brake pedal. Then step on the
25
brake pedal to the end and open the bleeder plug to
exhaust the brake fluid. Then tighten the drain screw,
release the pedal and repeat the above two steps until no
14
air bubbles in the brake fluid. Tighten the bleeder plug
and repeat the above steps on each wheel.
20
拧下油壶盖，加注制动液，启动发动机反复踩踏制动
踏板，然后将制动踏板踩到底松开放油塞，把制动液
放出来，然后拧上放油螺钉并松开踏板反复上面两步
C-
骤，直到制动液中再没有气泡拧紧放气塞对每一个车
轮都做一次上面的操作。
JA
3、 Removal and installation of brake 制动器拆装
□ Dismantle brakes, dismantling order: setting bolt spring,

brake shoe, return spring, brake cylinder
拆解制动器，拆解顺序为：压簧、制动蹄片、回位弹
簧、制动分泵
□ (The steps to remove the brake from front axle and rear
axle can be referred to in "front axle" "rear axle" section)
27
（将制动器从前桥、后桥拆解下来步骤详见《前桥》
《后桥》章节）
25
□ Remove the two symmetrical setting bolt springs from
the brake
14
拆解制动器上的对称的两个压簧
20
□ Remove the brake shoe

C-
拆下制动蹄片
JA
□ Remove fixing nuts from the brake cylinder and remove

the brake cylinder
拆解制动分泵固定螺母，取下制动分泵
Assembly: Installation should be in the reversed order of removal, and cautions are as follows:
□ When install brake shoe, orient the point to brake

cylinder and adjuster
安装制动蹄片时，要使尖端朝向车轮制动器分泵和调
整器
27
□ Adjust the screw When install the brake cylinder, the
25
shallow slot side should be outward
调整螺钉安装制动分泵调节器时，使浅槽一侧朝外
14
20
C-
4、 Removal and installation of parking brake control lever assembly 驻车制动操纵手柄总成拆装
□ Remove parking brake control lever assembly: the

JA
removal order is to remove front joint nut of the cable

and then remove fixing nuts of parking brake control
lever
拆解驻车制动操纵手柄总成：拆解顺序为拉丝前接头
螺母，驻车制动手柄固定螺母
□ Remove the front connector nut of the cable,

disconnecting the parking cable and the parking brake
control lever
拆解拉丝前接头螺，断开驻车拉丝与驻车制动手柄连
接
□ Remove the fixing bolts of the parking brake control
27
lever, and remove the parking brake control lever
拆解驻车手柄固定螺栓，取下驻车手柄总成
25
14
Assembly: Installation should be in the reversed order of removal.
20
装配：按照拆解相反步骤开展
C-
5、 Removal and installation of parking brake 驻车制动器拆装
□ The steps of removing parking brake are as follows:

JA
拆解驻车制动器拆解步骤为：
□ Remove the bolts connecting the transmission shaft and

parking brake
拆解传动轴与驻车制动器连接螺栓
□ Remove the parking brake front cover
27
拆解驻车制动器前盖
25
14
□ Dismantle rod spring, remove the parking brake shoe,
20
and remove the bolts connecting the manipulate drawing

assembly and parking brake, disconnecting the parking
drawing and the parking brake
C-
拆解拉杆弹簧，取下驻车制动蹄片，拆解操纵拉丝总
成与驻车制动器连接螺母，断开驻车拉丝与驻车制动
JA
器连接
6、Removal and installation of parking drawing 驻车拉丝拆装
□ Dismantle the parking drawing, removing order: remove

the brake control lever, and then parking drawing
拆解驻车拉丝，拆解顺序为：驻车制动操纵手柄、驻
车拉丝
27
□ Remove the front joint nut of the parking cable and
fixing nut
25
14 拆解拉丝前接头螺母与固定螺母
□ Dismantle the connecting nut between the control

20
drawing assembly and the parking brake, disconnect the

parking drawing and the parking brake, and remove the
C-
parking drawing assembly
拆解操纵拉丝总成与驻车制动器连接螺母，断开驻车
拉丝与驻车制动器连接,取下驻车拉丝总成
JA
7、Removal and installation of brake pedal 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
27
25
14
20
C-
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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。
27
□ The cause of the problem
故障原因
25
 Brake master cylinder, wheel cylinder, pipe or pipe joint leakage
制动主缸、轮缸、管路或管接头漏油
14
 Storage tank to save oil or without oil
储液罐存油不足或无油
20
 The brake fluid spoiled or pipe blockage
制动液变质或管路堵塞
C-
 There is air brake system
制动系统内有空气
JA
 Master cylinder, wheel cylinder cup, excessive piston and cylinder wear
主缸、轮缸皮碗、活塞或缸筒磨损过度
 Master cylinder oil hole, compensation hole or blockage in a storage tank vent
主缸进油孔、补偿孔或储液罐通气孔堵塞
□ Diagnosis and treatment
诊断与排除
 on the brake pedal if pedal position is too low, two consecutive or pedal a few times, if its height
subsequently heighten and system efficiency can be improved, you should check the brake pedal free
stroke and brake clearance.
踩下制动踏板若踏板位置太低，则连续两次或几次踩踏板，如果其高度随之增高且制功效能好
转，则应检查制动踏板自由行程及制动器间隙。
 After stepping on the brake loosen the brake pedal several times in a row, if its high slowly or rapidly
falling, somewhere that brake pipe burst and joint sealing, cup wheel cylinder seal bad or master
cylinder cup, sealed aprons, etc., can be the first on the brake pedal, observe whether the brake fluid
leakage. If the external normal, should check repair master cylinder failure.
连续几次踩制动后松开制动踏板，如果其高度缓慢或迅速下降，说明制动管路某处破裂、接头
27
密封不良、轮缸皮碗密封不良或主缸皮碗、皮圈密封不良等，可首先踩下制动踏板，观察有无
制动液渗漏部位。若外部正常，则应检查修理主缸故障。
 After successive foot brake, if pedal height is too low, and after the first foot brake, feel master
25
cylinder piston does not return, on the brake pedal has a master cylinder push rod and the piston
impact noise, that master cylinder cup rupture or return spring is too soft.
14
连续几脚制动后，如果踏板高度仍过低，并且在第一脚制动后，感到主缸活塞未回位，踩下制
动踏板有主缸推杆与活塞碰击响声，说明主缸皮碗破裂或回位弹簧太软。
20
 For several times after the brake pedal height increased slightly, and a sense of the springback,
suggests that in the brake pipe air.
连续几次制动后踏板高度稍有增高，并有回弹感，说明制动管路中有空气。
C-
 After a few consecutive braking brake pedal were stepping on to the end, and feel the pedal has no
reaction, shows that indoor brake master cylinder reservoir fluid serious deficit.
JA
连续几次制动后制动踏板均被踩到底，并感到踏板毫无反力，说明主缸储液室内制动液严重亏
缺。
 For several times after the brake pedal height low and soft, show master cylinder oil hole or blockage
in a storage tank screw air vents.
连续几次制动后踏板高度低而软，说明主缸进油孔或储液罐螺塞通气孔堵塞。
 A foot or two foot brake, pedal highly appropriate, but it's too hard and poor braking performance.
Shall check the working performance of the vacuum booster, then check the tubing for aging,
concave flat, brake fluid is too sticky, finally check the brake drum and the friction surface condition.
一脚或两脚制动，踏板高度适当，但太硬且制动效能不良。应检查真空助力器的工作性能，其
次检查油管是否有老化、凹瘪、制动液是否太黏，最后检查制动鼓与摩擦片表面状况。
2、 The brake failure
制动失效
□ The fault phenomenon：on the brake pedal, the vehicle don't slow down, even for several foot brake
has no obvious reduction effect.
27
故障现象：踩下制动踏板，车辆不减速，即使连续几脚制动也无明显减速作用。
25
故障原因
 Master cylinder liquid storage tank has no brake fluid

14
主缸储液罐内无制动液
 The master cylinder cup serious rupture or brake system leaks

20
主缸皮碗严重破裂或制动系统严重泄漏
 Brake hose or tube rupture

C-
制动软管或金属管断裂
 The brake pedal to the master cylinder of the release of mechanical connection
JA
制动踏板至主缸的机械连接脱开
诊断与排除
 check whether the main cylinder of the brake fluid reservoir tank is sufficient, if not should find out
the leakage place, foot brake fluid again after repair.
检查主缸储液罐内制动液是否充足，若不足应查明泄漏之处，修复后重新加足制动液。
 Check the master cylinder push rod fork shrouds in presence of brake fluid leak, if you have that
master cylinder cup stampede up or serious damage, should repair or replacement.
检查主缸推杆防尘套处有无制动液泄漏，如有说明主缸皮碗踩翻或严重损坏，应修复或更换。
 Check the edge of the wheel brake drum leaks brake fluid, such as a cup wheel cylinder pressure to
turn over or badly damaged. Should repair or replacement.
检查车轮制动鼓边缘有无泄漏制动液，如有说明轮缸皮碗压翻或严重破损．应修复或更换。
 The above check is normal. Check the mechanical connection parts for release, if any should be
repaired.
上述检查均正常．应检查各机械连接部位有无脱开，如有应修复。
27
3、 Braking wandering
制动跑偏
25
□ The fault phenomenon： when the car braking, the vehicle driving direction deflection.
故障现象：汽车制动时，车辆行驶方向发生偏斜。
14
故障原因
20
 The wheel brake shoe lining material different or condition
左右车轮制动蹄摩擦片材料不同或新旧程度不同
C-
 The wheel brake shoe and brake drum of lining (disc) of different contact area, position or brake
clearance
JA
左右车轮制动蹄摩擦片与制动鼓(盘)的接触面积、位置不同或制动器间隙不等
 Around the wheel cylinder technology condition is different, cause working time or opening force is
not equal
左右车轮轮缸的技术状况不同，造成起作用时间或张开力大小不等
 Around the wheel brake shoe return spring force is different
左右车轮制动蹄回位弹簧弹力不同
诊断与排除
 Used in car brake, auto skewed to the left, that the right wheel brake performance is poor; Whereas
that revolver braking performance is poor. After the parking brake, check the tires on the road of
printing, pulling the printed short or no drag wheel is defective.
汽车行驶中使用制动，汽车向左偏斜，说明右轮制动性能差；反之说明左轮制动性能差。制动
停车后，查看轮胎在路面上的拖印，拖印短或没有拖印的车轮即为有故障的车轮。
 Check the defective wheel braking pipeline leaks oil, tire pressure is enough, if normal, check the
clearance between the brake shoe and brake drum is in accordance with the provisions, or to be
27
adjusted. If still invalid, can check whether the wheel cylinder is seeping into the air, without seeping
into the air, you should remove the brake drum, according to the reasons one by one to check parts,
especially the size and precision of the brake drum and so on.
检查有故障车轮的制动管路是否漏油、轮胎气压是否充足，若正常则检查制动蹄与制动鼓的间
隙是否符合规定，否则予以调整。如仍无效，可检查轮缸内是否渗入空气，若无渗入空气，则
25
14
应拆下制动鼓，按原因逐一检查各部件，特别是制动鼓的尺寸和精度等。
 If the wheel brake drag basic requirements, but still wandering the braking, fault is not in the brake
system, should check the frame and front axle technology condition. If appear twitched running
20
deviation phenomenon, should check the front wheel toe or straight, tie rod ball head pin for wear
loose.
C-
如果各轮制动拖印基本符合要求，但制动仍跑偏，说明故障不在制动系统，应检查车架和前轴
的技术状况。如果出现忽左忽右的跑偏现象，应检查前轮前束或直、横拉杆球头销是否磨损松
旷。
JA
27
25
14
20
C-
JA
ANHUI JIANGHUAI AUTOMOBILE CO., LTD
Compiling 编制 Champion.Wong 汪庆平

Audit 审核 Youwang.Zhang 张有旺
Approve 批准

【EN&CN】Chassis底盘分册 LD340

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【EN&CN】Chassis底盘分册 LD340

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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，

in design, addition or improvement for the product.

25 JAC International Customer Service Depart.

Chapter Ⅰ Clutch 第一章 离合器

Chapter Ⅱ Transmission 第二章 变速器

Chapter Ⅲ Front axle 第三章 前桥

Chapter Ⅴ Drive shaft 第五章 传动轴

Chapter VI Suspension 第六章

Chapter Ⅷ Braking system 第八章 制动系统

cooling capacity; convenient to operate and labor saving.

Pressure plate static torque

Moment of inertia of the clutch assembly

The clutch pedal work Angle

1、 Location map 位置图

□ Clutch assembly 离合器总成

S/N 序号 Spare parts name description 备件名称

01 gear box assembly 变速器总成

02 clutch platen unit 离合器压盘总成

03 driven plate unit of clutch 离合器从动盘总成

04 release sleeve 分离套筒

05 release fork 分离拨叉

06 guide bearing 导向轴承

S/N 序号 Spare parts name description 备件名称

01 clutch pedal and bracket assembly 离合器踏板及支架本体总成

02 vacuum booster inlet hose assembly 真空助力器进气软管总成

03 clutch master cylinder inlet pipe assembly 离合器总泵进油管总成

04 vacuum booster with the clutch master cylinder assembly 真空助力器带离合器总泵总成

05 clutch master cylinder tubing assembly 离合器总泵出油管总成

06 two-way joint 二通接头

07 clutch before the steel pipe assembly 离合器前钢管总成

09 clutch front hose 离合器前软管总成

10 clutch tube assembly 离合器管总成

12 the buffer valve assembly of clutch line 离合器管路缓冲阀总成

13 clutch line buffer valve bracket 离合器管路缓冲阀支架

14 clutch hose assembly 离合器软管总成

15 clutch cylinder pipe bracket unit (ii) 离合器管支架总成 1

17 clutch cylinder 离合器分泵总成

clutch cylinder pipe bracket (iii) 25 离合器管总成 1

21 braking oil pipe joint washer 制动油管接头垫圈

22 brake oil pipe perforation joint 制动油管穿孔接头

23 single tube clip 单管夹片

24 hexagon flange bolts 六角法兰面螺栓

25 hexagon flange nuts 六角法兰面螺母

26 seal washer 密封垫圈

27 hexagon flange bolts 六角法兰面螺栓

28 hexagon flange nuts 六角法兰面螺母

29 hexagon flange bolts 六角法兰面螺栓

30 hexagon flange bolts 六角法兰面螺栓

Spare parts name description

01 connecting bracket 连接支架

02 flat washer 平垫圈

S/N 序号 Spare parts name description 备件名称

01 clutch platen unit 离合器压盘总成

02 driven plate unit of clutch 离合器从动盘总成

03 bolt subassembly 六角螺栓和弹簧垫圈组合件

□ Before disassembling, vehicle front and rear wheels need

□ Before disassembling, unscrew the clutch oil drain plug,

□ Disassemble clutch control assembly and disassembly

□ Disassemble oil spout mounting bolts and lines link nuts

□ Disassemble the clutch pedal and bracket nuts, remove

the clutch pedal

□ Assemble the clutch pedal attaching bolts is critical

Chapter Ⅰ Clutch 第一章离合器

Chapter Ⅱ Transmission 第二章变速器

Chapter Ⅲ Front axle 第三章前桥

Chapter Ⅴ Drive shaft 第五章传动轴

Chapter Ⅷ Braking system 第八章制动系统

shaft 中主齿圆柱滚子轴承