English Repair Manual WP12

Service Manual
WP12
SHACMAN
Chapter 1 Engine (WP12)
WP12 Euro Ⅲ is high-speed diesel engine developed by Weichai Power Co., Ltd
on the basis of WD 615 and WD618 diesel engine with new design idea to meet the
emission regulation of Euro Ⅲ and have the potential of Euro Ⅳ. With advantages
such as close structure, reliable performance, excellent technical index on power and
economy, quick start, simple operation and convinient maintenance, this series of
engine is perfect power for heavy duty automobiles.
This chapter introduces technical specifications, performance index, structure
features, notice of using and maintenance and repair, dismantle and assembly issues of
WP 12 series Euro Ⅲ diesel engine.
Section 1 General introduction

1.Power and rotation speed
he power range of WP12 engine is from 199～353kw, with rated rotation
2100r/min.
2. Main structure features
●one cylinder with one cap which works reliable and easy to dismantle.
●right-installed common rail system (see from engine free end), convinient to
make chassis arrangement.
●frame type main bearing structure and high rigidness, which is good for
relaibility and endurance of engine.
●middle-equiped supercharger and little change of engine external dimension.
●The whole series are all 6 cylinder in line and can be used in most models
which is convinient for complete vehicle match.
3.Meaning of WP 12 series model number
4. WP12 series diesel engine outline drawing (see picture 1-2)
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Section 2 Technical and performance specifications
1.Main technical specifications of WP12
1 Number of cylinder 6
Liquid cooled, 4 strokes, with Exhaust valve
2 type
brake, direct injection, supercharger, intercooler
3 bore/stroke(mm) 126/155
4 displacement(L) 11.596
5 Compressure ratio 17：1
6 Ignition sequence 1-5-3-6-2-4
7 Air valve clearance in cold(mm) Inlet valve 0.4 exhaust valve 0.6
distribution phase Inlet valve open 20° before up stop point
Inlet valve close 34° back down stop point
8
(when air valve clearance is 0.4 at inlet Exhaust valve open 49° before down stop point
and 0.6 at exhaust) Exhaust valve close 21°back down stop point
9 Thermostat actuating temperature (℃) 83
10 Actuation type electrical
11 Lubrication type Pressure lubrication
12 Lubricant capacity(L) 36
13 Cooling type Water-cool compulsive circulation
14 Oil pressure(kPa) 350～550
15 Oil (kPa) ≥100
allowed
16 longitudinal front/rear Long time10/10 Short time30/30
inclination (°)
allowed traverse By exhaut pipe/by
17 Long time 45/5 Short time 45/30
inclination (°) injection pump
Crankshaft rotaion direction(see from free
18 Clockwise
end)
2.Main performance specifications of WP12
Unit WP12 Euro Ⅲengine

Engine model — WP12.375 WP12.400 WP12.440 WP12.480
Liquid cooled, 4 strokes, with Exhaust valve brake, direct
Engine type —
injection, supercharger, intercooler
displacement L 11.596
bore×stroke mm 126×155
Number of cylinder — 6
Air valve number per — 4
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cylinder
Oil injection device — Electrical control high-pressure common rail
Rated power kw(PS) 276(375) 294(400) 323(440) 353(480)
Rated rotation r/min 2100
Max torque Nm 1125 1200 1360 1500
Max torque rotation r/min 1200-1500
Emission level — EuroⅢ
fuel consumption at
g/kWh ≤215 ≤215 ≤210 ≤212
rated power
Mini fuel consumption
g/kWh 192
with full load
coldstart-without
auxiliary start ℃ -10
equipment
Light
white smoke emission opaque After 20 seconds idle speed≤15％
rate
coldstart-with auxiliary
℃ -30
start equipment
Noise at 1 meter dB(A) <98
B10 life span km 800,000
3. Main specifications of accessories
S. No Name Item WP12 series

1 Fuel filter Type Double course filter element
Type centrifugal
2 Water pump
Demarcate rotation 3770r/min
Type Gear pump
3 Oil pump Air valve open 1200kPa
pressurede
Type Silicon oil
4 Crankshaft absorber
External diameter Φ280
5 Supercharger Type GTA42
Type Screw-install paper element, double
6 Oil filter sleeve parallel connection
Model
Type Wax-type, element combined with
device
7 Thermostat
Actuating (83±2)℃
termperature
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Type Plate wing
side valve open 600kPa
pressure
8 Oil cooler
pressure of 2500kPa
pressure endurance
test
Direct current self-excitation
Type
magnetic
9 Starter Model O 001 OEA 9KA
Power 5.4kw
Voltage 24V
Type Commute and pressure adjust in one
Model 0 124 555 030
10 Generator
Power 980～4000W(35～150A)
Voltage 28V
Fan Type Ring-shape fan
11
External diameter Φ640 Φ704
Type Piston water-cool
Bore 86
Total piston Double cylinder (with ESS)
displacement 640L/min
Work pressure 80OkPa
l4 Air compressor Max pressuer 1200kPa
Speed ratio with
1.67
engine
Lubrication type Pressure lubrication
Work type continuous
Mass 16.6kg
Min rotation 750
Max rotation 3900
Max 18MPa
Hydraulic pump Flux ( Handed ) 16L/min
15
(option) Max work
110℃
temperature
Oil inlet screw M26×1.5
Oil outlet screw M18×1.5
voltage 24V
AC compressor Displacement 536L/min
16
(option) Max rotation 7000r/min
Mass 5kg
4. Screw torque and method of main engine bolts and nuts.
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allowed use
Technical
Bolt Size Bolt length mm times(including
requirements
first installation )
Main bearing bolt M18-10.9 14Nm+210° 169 2
Auxiliary bolt of crankshaft
M8-8.8 8Nm+30° 25,110 2
case
main cylinder cap bolt M14-10.9 6Nm+2×l20° 185 3
20+10Nm seal 195， mini over
Auxiliary cylinder cap bolt M12×1.5-88 with LOCTIT engine for 3
262 175mm
Auxiliary cylinder cap nut 25Nm+2×l20° 3
crankshaft pulley bolt M12×1.5-0.9 45Nm+135° 75 2
Absorber bolt M10-8.8 15Nm+30° 30 2
Flywheel bolt M16×1.5-1.09 105Nm+270° 120 2
Manual
screw：
115Nm+90°
Connecting bar bolt M14×1.5-88 67.5
Automatic
screw：80Nm
+153°
1×3Oplate2×40
air compressor fastening bolt M10-8.8 40Nm
flywheel house
Air compressor gear fixing
bolt (cylinder 1 and 2) M20×1.5 200 十 50Nm 2
idler gear bolt pin M121.5-10.9 105Nm 90

common rail pump gear
M24 250+50Nm 2
fixing nuts
injector clamping bolts M8-8.8 8Nm+90° 50 3
camshaft gear bolt M8-8.8 8Nm+120° 30 2
piston cooling nozzle bolt M10 3ONm 25
Exhaust branch pipr bolt M10 15Nm+60° 65 2
Water pump bolt (connecting
water pump cover to middle DIN931;M10-8.8 Max 46Nm 4×80
Standard M6 bolt 8.8 8Nm 10.9 13Nm

Remark: ①Angle value means the angle to rotate after screwing to stipulated
moment.
②all bolts and nuts at every postion on engine has their relevant requirements on
hardness level. It is not allowed to incorrect install or replace any bolts or nuts with
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same size but different hardness level. It is not allowed to exceed its max allowed use
times, otherwise it may cause serious result.
Section 3 Introduction on engine main structure

1.Cylinder block, crankshaft case
The engine is devided into two parts from main bearing hole center: upper parts
is cylinder block and bottom part is crankshaft case. Crankshaft case and 7 main
bearings compose a integral frame with good rigidness. There is no washer between
frame and cylinder block. LOCTIT 510 seal glue shall be spread at the bottom plane
of cylinder block when installing.
Between cylinder block and crankshaft case, besides 14 main shaft bearing bolts,
there are 24 M8 bolts which connect the two parts into a good rigid structure.
Concentrating equal cylinder center distance and thin wall dry cylinder sleeve are well
adopted. Main oil passage goes from front to the rear at left side of block when
front-look. At the right side, an auxiliary oil passage connects with 6 cooling nozzles
as injection cooling piston.
Principal axis tile is alloy tile with thin wall and anti-friction plating at its
surface.
2.Cylinder cap
Cylinder cap adopts four-air-valve structure and low bow wave ratio. It is a
six-plane one-cylinder-one-cap structure machining part. Air inlet and exhaust
passages are arrange at its two sides. One each cap, there are 4 M14 cap bolts and 4
M12×15 double-head bolts sharing with its neighbouring cylinder. Auxiliary bolts
are pressed by pressing block with V-shape pressing plane and two ends adopts
suspending pressing block. Both main bolts and auxiliary bolts are screwed by corner
screw method.
On cylinder cap, injector is installed vertically between air inlet valve and
exhaust valve.
Cylinder liner is steel plate structure which allows repeated use. However,
carefully check is needed for timely relplace of damage. Cylinder cap and cylinder
line have respective fix position with engine block. Please note when installing!
3. Piston
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Inne r cooling oil passage piston (picture 3-1)with compulsive cooling is used to
improve life of piston and piston ring. The first ring. The goove is cast iron inlay ring
which requires good adhesionto guarantee good adhesion strength and heat pass effect.
There are two gas ring and one oil scrape ring. The first gas ring is double-plane
trapezium bucket ring with cuts inside the cast iron inlay ring. The second ring is
conic ring. The third ring is supporting spring cast iron oil ring, chromeplated at its
double blades surface.
Pistons are grouped on weights. Weight difference in same group piston is

regulated to be within 10g.
Piston cooling
Piston with inner cool oil passage needs to be cooled through oil supply from
nozzle. However, when the engine is at low speed or idle speed, heat load of piston is
not very high. Too much oil supply will increase piston heat transfer, lower effective
power which is actually not good for combustion. Meanwhile, in order to guarantee
sufficient pressure to lubricate when engine running, we use pressure limit valve (see
picture 3-2) on nozzle. When oil pressure is lower than 0.15Mpa, engine is always at
low speed, and oil presure is too low to overcome spring pressure and open pressure
limit valve. Pressure limit valve closes oil passage. Nozzle stops injection to
piston.With increase of roation speed, engine oil pressure become higher. When the
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pressure is higher than 0.15Mpa, it starts to overcome spring pressure. The pressure
limit valve starts to open. And the nozzle starts injection. With the increase of oil
pressure, the open extent of pressure limit valve becomes bigger untill fully open. In
this way, the engine under different work conditions guarantee good cooling to inner
cool oil passage in difference extent. It not only guarantees piston heat radiation, but
also decrease oil consumption.
4. Connecting rod
Connected by two M14×1.5 connecting rod bolts. Screw of the bolts is subject
to rotation screw regulation requirements.
Note: Connecting rod bolts are only allowed to use once and then replace.
Overuse is not allowed, otherwise it may result in damage accident due to bolts
broken.
When installing engine, mass difference in same connecting rod group is

regulated within 29g.
5. Crankshaft and flywheel
Crankshaft is forged with alloy steel mould with12 balance azotized blocks and
needs dynamic balance. Silicon shock absorber is installed in front of crankshaft. And
front and rear oil seal of crankshaft are box type.
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Crankshaft gear is installed onto crankshaft with heat.
Using SAE1 flywheel shell and flywheel (flywheel combination disc diameter
Φ475), gear ring fixed with flywheel by bolts.
6.Gear system and air distribution structure
WP12 series diesel engine uses integral structure of gear chamber and flywheel
shell. Rear-installed gear drive decreases gear noises and improve integral reliability.
1.1 gear systerm drawing
1.2 air valve and EVB clearance adjustment
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Piston locates on upper stop position.
Loosen nut 1: adjust adjusting bolt 1 till its touch area with air valve bridge
becoming 0.
Loosen nut 2: adjust adjusting bolt 2, insert 0.6mm clearance gauge between
adjusting bolt 2 and air valve bridge; adjust adjusting bolt 2 till piston to its end and
clip the gauge.
Adjust air valve clearance to 0.6mm, screw adjusting bolt untill no clearance
with gauge, keep this condition and lock the nut; adjust adjusting bolt 1, insert 0.4mm
clearance gauge between adjusting bolt 2 and air valve bridge; adjust adjusting bolt 1
till piston to its end and clip the gauge, keep this condition and lock the nut; check air
valve clearance again and adjust if necessary.
7.Lubrication system
The function of lubrication system is friction decrease, rinse, cooling and against
rust. The choose of oil should be in accordance with company standard regulations.
Multi-degree oil is better for cold-start performace and should be choosen at priority.
The oil using the whole year such as 15W40 can only be used in regulated
temperature range. For occasional low temperature, oil can be pre-heated or changed
into the degree which is suitable with environment temperature.
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●when doing vechile design, the convinience of changing lubrication and
checking oil level should be taken into consideration.
●On engien delivery, lubrication is usually not filled and should be filled before
starting the vechile.
●WP12 Euro III diesel engine is regulated to use CF-4 or CH-4 degree
lubrication.
●Please choose adherence degree of lubrication according to environment

temperature (see table 7), and only allow to use multi-degree lubrication.
●Weichai special lubrication is recommended.
●When engine is still and vehicle is on horizontal ground, oil gauge must show
the oil level between maximum and minimum value.
●The inclination angle of oil basin is not allowed to over regulated value.
●Up to now, no positive fuction of oil additive was found to the running of
WP12 series engine. Therefore, any kind of oil additive is not allowed to use.
Please note: CE 、CD 、CC 、CB 、CAdegree lubrication are all forbidden to
use on WP12 series diesel engine. Also note: oil filter element shall be replace every
time when replacing oil.
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1.1 Pressure lubrication
Through filter collector, oil pump sucks oil from oil basin and presses to oil filter
and oil cooler, and then distributes to the lubrication point through oil passages. Most
oil reaches main bearing and through oil holes on crankshaft finally reaches
connecting rod bearing. Cylinder cap surface and piston pin are lubricated by oil
injection from nozzle. Air valve control system, supercharger, common-rail oil pump,
air compressor and middle gear bearing all realize pressure lubrication though oil pipe
and oil groove. Piston top is cooled by injecting oil from nozzle to inner cool oil
chamber; oil is cooled by cooling water through oil cooling device. Oil pressure in oil
circulation system is adjusted by pressure limit valve inside oil pump.
When starting engine, due to low oil temperature and high adherency, the oil
pressure meight be high in short time.But with water temperature in engine increase,
oi temperature increases and oil pressure will gradually decline. When engine
full-load water temperature is at 80 ℃-95 ℃, normal oil pressure shall be 350kPa～
550kPa.
1.2 oil basin
In order to guarantee engine life, improve its reliability and extend oil replace
interval, oil capacity of oil basin is enlarged. With welded moulding, its combination
insection with crankshaft case has deep overlapped margin with high hardness. It has
concaved oil basin seal liner fixed by 12 oil basin holding block and M8 bolts which
ensures good seal effect.
Dry engine oil filling volume (oil gauge upper line): WP12-36L.
8. Oil supply system
Fuel injection and oil supply system
High pressure electric control common rail is newly designed

environment-protect fuel system. WP12 series Euro III engine use common rail
system produced by Bosch company which ensures engine reaches maximum
160Mpa fuel injection pressure, realize flexible control of fuel and time correctness
and therefore obtain low displacement and low fuel consumption.
Note: all the fuel should meet the regulation in appendix C of National standard
GB17691-2005.
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1.1 Fuel return
When installing fuel returning pipe, avoid touch with high-temperature parts on
vehicle (such as exhaust pipe, turbo charger, exhaust smoke return pipe etc.)
Throttling area is not allowed to exist in fuel return pipe. Do not touch fuel return pipe
with sharp edges, fold with angles nor twist. Improper installing of fuel return pipe
may cause fuel leagkage to engine.
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Fuel return of WP series diesel engine is through inner fuel return of cylinder
cap(illustration 3-7). In this way which injector installing hole is inside cylinder cap,
complete seal of fuel return must be ensured.
1.2 Internally connected high-pressure connection
When high-pressure fuel carrys out proper high-pressire seal to a standard fuel
inlet connector through fuel inlet connector inside cylinder cap and go to injector, the
minimum pressing force needed is 12kN and maximun 22kN. Too high force may
cause overload on fuel inlet connector and then result in leakage.
1.3 Fuel coarse filter components
Function
Coarse filter system is installed at down part if fuel tank fuel passage. It will
separate the water and tiny grains from fuel (making use of its multi-medium
structure)
The water separated will be collected to the water utensile at the bottom of filter.
And then discharged from discharging plug.
Optional heater
If installing electric heater at the top of coarse filter, when fuel flows over coarse
filter, it will be heated by 350W heater.
The capability of coarse filter is limited by minimum filtration temperature.
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Table 8
S. No Name Specifications Descriptions

coarse filter
cover Fuel inlet opening: M16×1.5 Install flange: quadrate holes
1
with/without Fuel outlet opening: M16×1.5 size 50 -87mm
manual pump
Flux of spinning coarse filter: 420L/h
Spinning
2 Water separate rationH2O > 93%(at
coarse filter
normal flow speed)
water
Seal: radial oil seal
3 collector with
Capacity: about 05L (Preline420)
releasing tool
Voltage/power: 24V/350W
Heater Activate point: +5℃ (Automatic)
4
(optional) Power ： cathode(terminal 15) ，
Grounding
Exhaust the system by manual pump
Notice!
When replacing spinning coarse filter or reistalling fuel pipeline, coarse filter
needed to be exhausted.
Steps: (as illustration 3-9)
1. Stop engine 2. Loose air discharge bolts
3. Inflate with manual pump untill only fuel emits from air discharge bolts
4. Refasten air discharge bolts
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Drain from water collector
Notice!
When water collector is full or spinning filter has been replaced, it is necessary
to drain the collected water out.
Warning!
Freezing danger!
Drain water out before getting frozen.
Steps (see illustration 3-10)
1. Open fuel discharge plug (1) at the bottom of water collector (2), drain out
water.
2. Refasten fuel discharge plug
Replacing water collector
Notice!
Special spanner for dismantling and screwing new water collector is attached
with the package.
Steps (shown in illustration 3-11)
1. Stop the engine
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2. Drain water from water collector
3. If possible, manually dismantle the bolts of water collector. If it is too tight,

use the tool in new water collector.
4. Deal with it properly, do not throw.
5. Lubricate the seal ring of new water collector with several drops of oil.
6. Install bolts manually and screw it with tool.
7. If water utensile will be used on a new spinning filter, check if there is

damage.
8. Use torque spanner to install. Torque is 20Nm.
Notice!
Water collector and spinning filter can be screwed together by using installing
tool.
Warning!
When installing, do not damage spinning filter
Replacing filter
Notice!
Before removing old filter, open the new filter to check if completeness and
possible of damage during transportation.
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Only can install filter without damage.
Noice!
Old filter may be tightly connected with filter cap. Loose it with proper tool.
Warning!
Fuel leakage will pollute environment.
When dealing with filter, put a collecting utensile at the bottom of engine and
properly deal with collected fuel.
The following steps shall by complied to remove filter:
1. Stop the engine
2. Remove the old spinning filter
3. If the utensile is still usable, put it away.
The installation of Spinning filter according to following steps:
1. Lubricate the seal
2. Manually screw filter until seal combined with interface.
3. Continue screw the filter manually until filter is tightly installed (about 3-4
circles)
4. Exhaust until no air bubble appears
5. Carry out leakage test
Maintenance
Maintenance time
Maintenance item Time interval Remarks

According to water volume or
Water discharge
before water frozen
Replacing screw-installed
20000-40000km
pre-filter
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△ Warning! Do not dismantle manual oil pump!
Table 9 installation instruction of fuel secondary filter
Only apply to fuel filter
Do not install damaged filter
Clearance under filter cap:262.5mm+length of screw connector

Stop engine
Wipe oil membrane on washer
Put the filter under filter cap
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Illustration 3-19 interface drawing of oil pressure sensor
And oil pressure temperature sensor produced by BOSCH connects with ECU
directly.
1.5 water temperature gauge sensor
The working temperature of water temperature gauge sensor is -25～120℃ with

two kinds of structure: normal one and the other with alarm. Sensor with alarm alarms
at temperature 96±3℃. The sensor allows outer force torque 19.6N.m (2kgfm) and
rated voltage 6-24V. Illustration 3-20 below shows its nterface dimension.
Illustration 3-20 water temperature gauge sensor interface
And water temperature sensor produced by BOSCH connects with ECU directly.
12. air compressor
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WP12 series diesel engine uses double-cylinder air compressor (with ESS
system).
Air inlet of air compressor is natural air inlet.
Table 10
Engine WP12
Engine type(in line or V-X arrangement) 6 cylinder in line
air compressor gear transmission ratio 1.166
Rotation speed(r/min) Engine Air compressor
Idle speed(r/min) 600 700
Rated rotation speed(r/min) 2100 2449
Engine brake speed (r/min) 2600 3032
Engine maximum allowed rotation
2950 3440
speed(r/min)*
*Time should not longer than 10 seconds
The air is taken from natual air inlet of vehicle. The air taken is clean air filtrated
through air filter which can filtrate 90% of 10μm grain out.
Max limited inlet resistance from engine: 3KPa
Air compressor rotation direction: clockwise see from front side
When air compressor working with load at 2500r/min, 1200kPa, it consumes

power: 13W/(L/min).
Table 11
User’s location China
Woriking pressure 800kPa
Air compressor load time 30%
Air compressor 225cm3 460cm3
Displacement at idle speed(NL/min) 80 180
Displacement at 2500r/min (NL/min) 320 640
13. Back end driving gear system
Gear chamber is rear installed. The whole gear system use low-noise design,
driving starter, hydraulic pump, injection pump and air compressor components. PTO
output interface is reversed and maximum satisfy 1000 Nm power output.
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Illustration 3-21 Back end driving gear system
Chapter 4 Operation and maintenance
of WP12 series diesel engine
1. Notices for operation
Check if coolant level, fuel and oil level meet requirements before starting
engine.
When starting engine, if the engine not started within 15 seconds, try again after
2 minutes.
After starting engine, run the engine at idle speed for 2-3 minutes. Oil pressure
should be higher than 100kPa. Before cooling water temperature is higher than 60℃,
do not suddenly run with big load. It will influence engine endurance and reliability.
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Engine oil level check: check should be 5 minutes after stopping the engine. For
engine working with load, must reduce load and lower speed rotation.keep at least 5
minutes at idle speed.
For safety purpose, rotation parts and high-temperature parts should be installed
with guards.
Under any condition, there must be enough running space between engine and
accessories and outer fixed parts such as chassis. In this way, when engine works with
inherent movements (such as start and stop), it will avoid conflict with chassis and
meanwhile provide convinience to engine inspection at great extent.
2.Maintenance regulation
Table 12 Three types of using conditions
(WG typeⅠ) (WG type Ⅱ) (WG type Ⅲ)

Bad condition(extremely cold or
hot climate, high dust content,
short distance transportation.
Used at construction working
Annual mileage less than 6×104 Annual mileageover 6×10
site or public, city construction
km, short and middle distance 4km, for long distance
vehicle, snow remover and fire
transportation(mainly for cargo transportation
truck) or vehicles which annual
delivery)
mileage less than 2×104km or
annual working hour lee than
600h
Table 13 maintenance periods
Using
condition
(WGⅠ) (WGⅡ) (WGⅢ)
Item
At 1000-1500km mileage At At 1500～2000km At 1500～2O00km
First check
30～50h running hour mileage mileage
Every other 5000KM Every
Routine check Every other 1×104km Every other 1.5×104km
other 150h
1st class Every other 1×104km Every
Every other 2×104km Every other 3×104km
maintenance other 300h
2nd class Every other 2×104km Every
3rd class Every other 4×104km Every Every other 8×104km Every other 12×104km
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th
4 class Every other 8×104km Every
Table 14 Oil change periods in maintenance regulation
Using (WGⅠ) (WGⅡ) (WGⅢ)

condition
Annual mileage less than Annual mileage less than Annual mileage over 2×
Item 2×104km 6×104km 104km
At 1500～2O00km
First check At 1000-1500km mileage At 1500～2O00km mileage
mileage
P Every other 5000 Every other 1×104km Every other 1.5×104km
WD1 Every other 1×104km Every other 2×104km Every other 3×104km
Table 15 Engine maintenance criterion
1st class 2nd class 3rd class 4th class

First Routine
Engine maintenance items maintenan maintenan maintenanc maintenan
check check
ce ce e ce
Changing engine oil ● ● ● ● ● ●
Changing oil filter or
● Every time when changing engine oil
element
Checking and adjusting air
● ● ● ● ●
valve clearance
Changing fuel filter
● ● ● ●
element
Check coolant volume and
● ● ● ● ● ●
refilling
Fastening cooling pipe
●
clips
Fastening connections of
● ● ● ● ●
air pipeline, hose and cam
Check air filter
● ● ● ●
maintenance indicator
Check dust collectingcup
of air filter (excluding ● ● ● ● ●
automatic dust discharge)
Cleaning air filter main
When indictor is on
element
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Changing air filter main
See relevant regulation in Instructions Manual
element
Changing air filter safety
After cleaning main filter element for 5 times
element
Checking and fastening
● ● ● ● ● ●
V-belt
Checking
turbochargerbearing ●
clearance
Checking, adusting clutch
● ● ● ● ● ●
stroke
Remarks: ●maintenance needed mark
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Chapter 5 Work theory of electric-control system
1. Injection system work theory
Electric control common rail system includes: electric control unit, high pressure
pump, common rail pipe,injector, fuel tank, fuel filter, sensor etc.
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See above picture for structure of high-pressure oil pump
Gear pump
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Injector
The blue part in the picture is pressure releasing valve.The pink part is common
rail pressure sensor.
2.Euro III electric contrl connects with complete vehicle
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Comparison between double modulus and single modulus of accelerator pedal
Two brake switch signalL: main switch+ redundancy switch
The design purpose of redundancy: comparing two

signals to ensure pedal reliability.
If pedal reliability cannot be ensured, it is not

suggested to use cruise function.
Brake pedal signal analysis
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In order to ensure reliable cruise function, please use reliable speedometer
sensor.
Chapter 6 Problem diagnosis and elimination
Weichai Euro III diesel engine is designed and produced under strict quality
guarantee system. Every unit has passed regulated tests. And engine is a kind of
precise machinery. To keep long time function and good performance has close
connection with normal maintenance. Usually, the following reasons result in early
breakdown:
Improper operation, management and use;
Not mainten according to regulation even take repairing instead of maintenance;
Bad quality spare parts. Especially use fake parts to save cost, which will greatly
shorten engine life;
Improper or inqualified fuel and lubrication.
Principles and Methods to diagnose engine problem
The causes of engine problem are complicated. Sometimes, problems shows

similar but caused by different reason. In order to improve the correctness of problem
diagnosis and avoid mistakes, it is suggested to customers diagnosing problems
according to following principles:
Related to theory according to features; make clear phenomenon without

omittance; From simple to complicated and from outer to inner; check and analyse by
sections and system.
The common methods to diagnose engien problem are as below:
1) Method of observation: Through observe problem features such as engine

smoke to make judgement.
2) Method of stethoscopy: find out nature and extent of problem part through
listening to its abnormal sounds.
3) Method of stopping certain cylinders: Stop a certain cyliner to find out if

problem happened in this cylinder. The usual operation of this method is stop oil
supply to the cylinder douted to have problem, comparing the engine condition
change before and after stopping oil supply and reduce scope for further find out
problem parts.
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4) Method of comparison: For some assemblies and components, replace it to see
if there is problem on it.
The above methods are for mechanical problems which can be also used on Euro
III engien. Such problem can be eliminated according to the methods of Euro II
engine elimination.
5) Problem diagnosis light: when a problem happens, flashing code can be read
through flashing code light on dashboard. And reason can be found with reference to
flash code explanation table.
Operation instructions for reading flash codes:
It can be done both when ignition key is switched on or engine is running:
◆Ignition key is switched on
◆Press down-release problem diagnosis request switch
◆Flash code light reports codes
◆Every operation only activate one code.(such as 3-2-4)
Untill it circulated to the first.
Flash mode(e.g. speed sensor problem, code: 324)
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Note: Flash time and intervals of flash code can be difinted by engine
manufacturer.
6) Special tool: problem diagnose device
These devices can furtherly judge problem. The devices includes:
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Note!
It is very careful work to judge the cause of engine problem. Before the cause is
clear, do not dismantle or remove engine casually. Otherwise, more seriour problem
may be caused due to improper distantling or remove.
Not only special repair and maintenance devices shoule be used for key parts like
high-pressure oil pump and supercharger, but also experienced mechanics
needed.Therefore, customers without experience and condition should not dismantle
or adjust by themselves.
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Problem 1: engine can not start
Diesel engine is press combustion type internal-combustion engine. The smooth

start of engine not only needs sufficient fuel complete pulverization and injecting to
cylinders, but also requires certain temperature and pressure in cylinder after air
compressed. In this way, diesel can combusted spontaneously. Therefore, if engine
can not start, the reasons are mainly in starting system, electric control fuel system, air
inlet and outlet system or engine match clearance. Customers can analyse and judge in
steps according to concomitant features of problem:
1.Starter does not work
For vehicles whose starter is controlled by ECU, when starting, ECU firstly
check neutral speed signal, and then put out electricity-driving start relay. When relay
is connected, battery will drive starter to work.
There are several factors for check: neutral switch, starter relay, battery,
connections of vehicle stop switch under vehicle.
◆check if the speed is on neutral position
◆check the position of vehic le stop switch under vehicle (it should be at
disconnection position)
◆check neutral speed switch (usually installed on gearbox) and its connections.
Try to use emergency start (press down ignition switch and keep for over 5 seconds)
◆check if voltage of battery is too low to drive starter
◆check if starter relay and its connection is normal
◆check if starter is burnt
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◆check if ignition switch and start switch is damaged.
Common rail systems has high requirements to fuel passage. Both low-pressure
fuel passage (fuel tank coarse filter, secondary filter, fuel return)and high-pressure
passage (high-pressure oil pump, common rail, high-pressure oil pipe, injector) should
be complete sealed. Any problem happens at any of above tache, rail pressure cannot
be normally established.
Note: The first start of vehicle must exhaust and refill oil for low-pressure fuel
passage and high-pressure fuel passage.
◆Check if the fuel level is two low in fuel tank.
◆Check if manual pressing pump works normally
◆Check if there is air in low-pressure passage and exhaust the air.(Sometimes

leakage in low-pressure passage is not obvious and needs careful check)
Method of exhaust: Mainly exhaust air in coarse filter. Loose deflation bolts on
coarse, press the manual pressing pump on coarse until oil come out continuously
from deflation bolts.
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◆After deflating all air in low-pressure passage, if the engine still cannot be
started, then it can be judged that there is air in high-pressure passage. Air needs to be
deflated from high-pressure passage, then.
Method of deflation: loose high-pressure oil pipe of one cylinder, drive the
engine by starter to run until continuous oil come out from high-pressure oil pump.(It
is not suggested to dismantle high-pressure oil pipe connector frequently!)
◆Check if there is leakage in high-pressure passage.
◆check if oil passage is unblocked. Check if fuel filter is blocked or not. It is

suggested to change fuel filter element in time.
Method to check: loose outlet bolt of secondary filter. Drive the engine by starter,
see if there is fuel injected out or flowing out. If only a little fuel flows out, then it can
be judged that filter elements is blocked.
◆Check initial voltage value of rail pressure sensor is around 500mV, or if set
rail pressure is 300-500bar (by KTS problem diagnosis device). If not normal, first
check if connected parts are fixed. If there is no inspection device, pull out rail
pressure sensor connector and try to restart.
◆Check if flux meter is working normally. Pull out connectors and try to restart.
3. Injector wiring harness, sensor wiring harness, vehicle wiring harness

connectors do not connected well or wiring harness is open circuit or short
circuit.
◆Check installation of connectors. Use multimeter (better connecting circuit

checking device) to check if circuit is unblocked or cut according to finger difinite of
circuit drawing.
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Engine wiring harness
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Cylinder wiring harness
4.Loss of crankshaft signal and camshaft signal
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Two rotation sensors are installed on engine at outsides of flywheel shell and
high-pressuure oil pump. The respective functions are: crankshaft position sensor and
cylinder judging sensor. Timing of electric-control engine injection depends on these
two sensors. If engine cannot start, thest two signals will all lose.
◆Possible reason causing both two signals loss
①Sensor damaged, short circuit or open circuit.
②Sensor is not fixed tightly which results in too big or too small clearance
between sensor and induction teeth. (usually 1±0.5mm)
Method to eliminate: check if sensor is damaged, wire is well connected, or

sensor is loose and so on.
Remarks: Installation after dismantling high-pressure oil pump and flywheel

should be strictly subject to relevant craftmanship documents to ensure synchron
signals.
Problem 2: Difficulty in starting engine
The reasons and elimination methods of difficulty in starting engine
①The engine does not run for a long time: extend oil return pipe under diesel
level.
②A little air exits in low-pressure passage: Deflate it.
③Crankshaft rotation signal and camshaft signal are too weak. Synchron reaction
time is too long: readjust it.
④Environment temperature too low and preheating device not working: replace
preheating device.
⑤Quality of diesel and oil is too bad and cannot reach standards: replace into
standard diesel and oil products
⑥Starter or flywheel gear ring conflicts: replace starter or flywheel gear ring
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⑦Worn piston ring and cylinder liner or not airproof in air valve: replace piston
ring, cylinder liner or air valve seat and air valve
⑧Exhaust brake butterfly valve is blocked at close position resulting in not

smooth air exhaust: replace butterfly valve
⑨Fuel inlet and return pipe of fuel tank does not meet requirements on inner
diameter and pressure design
Problem 3: Insufficient power on engine
Gammy return: It is a kind of mode that engine running with problem. ECU finds
problem on engine but does not stop it. It only restricts engine powet so that engine
rotation can only reach 1500r. Then the driver can drive the truck to nearest service
station to repair.
1.1 problem on injector
Problems on injector can mainly devided into mechanical failure and connection
failure.
◆Mechanical failure is: Needle valve is completely blocked. As too much

impurity in diesel or inlet water rust, needle valve is blocked in injector and cannot
move. (Notice: ECU may not report error!)
◆Connection failure: Due to vibration or wearing, wiring harness disconnects or

directly touch with cylinder cap which resulting in short circuit with earth. ECU will
report error.
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◆Unstable idle speed. Engine sound is abnormal
◆judge by method of stopping a certain cyliner, or method of high-presure oil

pipe touch.
◆Do acceleration test by problem diagnosis device and find out problem
1.2 Too high temperature of water, oil and air inlet
When water, oil and air inlet are at too high temperature, ECU will activate
overheating protection function and limit engine power.
◆Before problem is eliminated, firstly eliminate sensors and gauges distortion

reaction.
◆Reasons causing too high water temperature and method of elimination
①Too low water level in water tank: check if there is leak. Refill water
②Too slow fun rotation speed or no rotation: check driving parts of fun
③Water tank block: check water tank, clean and repair.
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④Water pump belt loose: adjust strain according to regulation
⑤Water pump washer damaged, water pump leaf wheel worn: check and repair
or replace
⑥Thermostat problem: replace it
⑦water pipe seal damage and air go inside: check water pipe, connectors,
washers and change damaged parts
◆Reasons causing too high oil temperature and method of elimination
①Too low oil level in oil basin or oil lack: check oil level and leaks, repair and
refill.
②High water temperature: Find out above mentioned reason and eliminate
③Oil cooler flow unsmoothly: check and clean
◆Reasons causing too high inlet air temperature and method of elimination
Check radiator capacity of intercooler
1.3 Synchron signal error
This is usually caused by signal of one sensor invalid. Check flash code
reference to find out reasons. Method of elimination is same with 1.4.
1.4 Flowmeter units problem
Flowmeter unit is executive system to control rail pressure and is installed on

high-pressure oil pump. If there is problem, high-pressure oil pump will supply
utmostly oil to common rail pipe. Then pressure release valve on common rail pipe
will usually open and engine will have sounds like “Kaka”. Problems on rail pressure
sensor will also show similar phenomenon.
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Method of elimination: Check circuits to see if it is flowmeter units or rail sensor

problem. Inform office to repair.
1.5 fuel pipe leakage resulting in abnormal fluctuant rail pressure
During driving, the speed is unstable and sudden frequent short acceleration
happens.
◆Method of Elimination: Cut off electricity and restart. If the problem still
exists, check seal of fuel pipe and eliminate it.
1.6 Sensor problem
◆ Air inlet pressure sensor is a sensor for ECU to estimate air inlet
volume(installed on air inlet pipe). Water temperature sensor is for judging engine
heat load(installed on water discharge pipe). Rail pressure sensor is for measuring fuel
pressure of commom rail pipe (installed on commom rail pipe).
◆Method of elimination: Check sensors to see if the connections are tight.
Note: If problems in 3.1, 3.3, 3.4, 3.5, and 3.6 happen, engine will enter “Gammy
return” mode.
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Problem 4: Engine keeps running at 1000r.
Under this condition, accelerator pedal does not work: ECU estimates load
through signal from pedal potentiometer. When there is problem on pedal,
considering of safety, ECU will control engine return to 1000r idle speed.
◆electronic accelerator cable loose or mismatch
Pull out and reinsert or check if connection is right. Reconnect it.
◆water penetration in electronic accelerator connections
Use tools to blow and dry the connections. Restart it.
Notice: Replacing accelerator with same model.
Problem 5: vehile sliding at idle speed
The reasons and methods of elimination:
Injector does not work normally: Check every cylinder injector and wiring
For trucks with speed sensor, speed signal still put out when stop: check
speedometer and speed sensor signal and connections
Bad quality of fuel, water or wax inside: clean fuel system and replace fuel filter.
Air exits in fuel low-pressure passage: check seal of oil pipe and connectors,
deflate air.
Unstable pulverization at injection nozzle: check and repair
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Note: ① It is ECU normal function to increase idle speed due to low water
temperature.
② when there is other load (e.g. A/C is on), idle speed will natually increase
100r.
Explanation:
◆Weichai Euro III engine uses Bosch 2nd-generation high pressure common rail
system. High pressure oil passage has high requirements to oil passage (both
high-pressure and low-pressure).Many problems casued by oil passage problems.
◆Vehicle wiring harness is also a main problem source.
When problem happens, these two aspects of reason should be taken into
consideration firstly.
Chapter 7 Stitch drawing and flash code table
1.Electric control unit stitch drawing
Electric control unit stitch drawing includes four parts: vehicle linker, control
unit linker, engine linker and cylinder linker. Mechanic can analyse, find out problem
causes and eliminate problems according to stitch connections combining with
vehicle circuits working theory.
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2.闪码表分析 Analysis on flash code table
1. Flash code is shown by three-digit number. First digit devides errors according to
different system. For example, if an error is caused by ECU, hydraulic parts, sensor
executor; the second digit shows the parts which has error. The third digit shows error
route.
2、Common problem
1 )Engine cannot start or is difficult to start
Reasons of problems Possible code Method to eliminate

Check neutral speed switch, key switch and
Engine not work 121 122 123
starter relay
Rail pressure cannot
Check fuel pipe and deflate.
establish
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wiring harness of injector,
Check installation of connections. Check
sensor and whole vehicle
and connect of circuit according to stitch
not connect well, or short
drawing by multimeter
circuit or open circuit
Signal of crankshaft or Check sensors of crankshaft and
camshaft loss camshaft loss
Electricity loss on battery Charge or replace with new battery
2) Insufficient power
Reasons of problems Possible Method to eliminate

code
Judge by method of stopping certain
Injector not work 141-146
cylinder or method of oil pipe sensing
water temperature and air inlet
242 Check engine cooling system
temperature too high
112 113 Check sensors of crankshaft and
Synchronizing signal error
114 camshaft loss
Starter relay not work 132 Repair circuits or components
Flowmeter unit not work 135 Check circuits or replace flowmeter unit
Fuel pipe leak resulting in
abnormal rail pressure 251-257 Check fuel pipe seals
fluctuation
133 231 Check water temperature & air inlet
Sensor error
241 temperature rail pressure sensors
3) Engine keeps running at 1000r/min
Reasons of problems Possible code Method to eliminate

Wires of electronic accelerator Reconnect loosed wires. Check
221
pedal loose or misconnected accelerator wires to see if match
Water penetration in electronic Blow connections to dry with
accelerator connections tools and restart
4) Sliding drive
Check wiring harness on all

Injector works abnormally 141 146
cylinder injectors
Vehicle factory checks
For trucks with cruise function,
324 instruments and speedometer
speed output when stop
sensor
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2.3 Main failure flash code table
Parts code
ECU converter error 111
112
Camshaft rotation speed sensor or crankshaft
113
rotation speed sensor error
114
Starter relay error 121
Inner electricity error 131
Main relay error 132
Rail pressure sensor 133
Common rail pressure releasee valve problem 134
Flowmeter unit error 135
Cylinder 1 injector error 141
Water mixed in oil 211
Pedal sensor error 221
Clutch switch error 222
Brake switch error 223
Accelerator and brake reliability test error 225
Air inlet pressure sensor error 231
Atmospheric pressure sensor 232
Air inlet temperature sensor error 233
Cooling water temperature sensor 241
Water temperature too high warning 242
Oil pressure sensor 243
Oil pressure too low warning 243
Oil temperature sensor 244
Oil temperature too high warning 244
Overspeed test 262
Exhaust brake valve error 311
Air conditioner comperssor relay failure 313
Air inlet heating relay 321-323
Speedometer sensor failure 324
Cruise switch 341
Exhaust brake switch 342
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Chapter 8 Electrocircuits theory drawing of complete vehicle
1. Engine ECU circuits part (see drawing 1)
2. Electricity, start, key switch circuits part (see drawing 2)
3. Flame preheating, horn, air drier, cabin lock signal light (see drawing 3)
4. Brake loop I/II, fuel, oil pressure, coolant temperature, signal lights (see
drawing 4)
5. Brake light, reverse light, engine stope/engine stopping brake, parking brake
(see drawing 5)
6. Rear-vire mirror heating, heating, dashboard lightness setting (see drawing 6)
7. Headlamp, steering flash, wiper (see drawing 7)
8. Wiper, tachograph, rotation speed (see drawing 8)
9. Left headlamp, left rear light, right headlamp, right rear light (see drawing 9)
10. High and low beam, lighting circuitry (see drawing 10)
11. Reserved light connection, rear fog light(see drawing 11)
12. Pedal illumination, cabin inner illumination, heating illumination, cigar

igniting, ashtray box. (see drawing 12)
13. High-roof cabin illuminating light, Earth wire distributor, 24V radio (see
drawing 13)
14. Inter-wheel, hub differential lock, 24s trailer socket, 24N trailer sockets(see
drawing 14)
15. Electric instruments components arrangement drawing of complete vehicle

(see drawing 15)
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Chapter 2 Front axle and driving axle

When using non-independent suspension, the axles can install the wheels onto a
whole solid or hollow shaft, and then they connect to frame through the suspension
system. The solid or hollow shaft is called axle.
When vehicle is running, its axle housing connects crossbeams through flexible
components, and the axle housing is bearing the braking force, towing force and the
gravity and direction-testing force from the vehicle. All components on the axle are
connected by the housing and it also can guarantee the relative distances between
components.
Axle is the last assembly in the running system of vehicle. Its basic functions are
reducing speeds, increasing torque, changing the axes of rotation. From the
characteristics of engine we can know that the output torque of engine is less, but
when started, the vehicle must overcome the running resistance, which is about the
1.5% to 2.0% of the total mass of the vehicle. So, the vehicle must have the part to
increase the torque. The output rotation speed of the engine is higher, if the engine is
connected directly with axle, the too high rotation speed cannot meet the using
requirements. The core part of the axle is the main reducer. Besides the function of
decreasing speed, it can also change the rotation direction of the rotating shaft to
make the vehicle advance or back off.
The steyr heavy duty axles of Shanqi are non-driving axle, driving axle, driving
rear axle and driving mid-rear axles.
The front axle of non full drive vehicle has the normal 工 shape structure,
called steering front axle. Its load capacity is 6.5 ton. Besides supporting the vehicle,
the steering axle can make the vehicle turn by making the front wheels swerve when
the vehicle is turning.
Driving steering axle, from its name we can see, is an axle which can have
driving ability. The front axle of full drive vehicle has the structure of central spiral
taper gear one stage reduction combined with planet gear reduction and has many
ratios for option. The half shaft of the front driving axle is connected with steering
knuckle by the universal connector with uniform angle and velocity. The thickness of
the axle housing is 16mm and its load is 13ton.
Shanqi Steyr vehicles have two models of rear driving axle accord to different
driving type. One is mid-rear axle and the other is driving axle. In the vehicles with
4*2 driving type, its structure is central spiral taper gear one stage reduction combined
with planet gear reduction.
In the vehicles with 6*4 driving type, 6*6 driving type, 6*2 driving type and 8*4
driving type, their driving type is mid-rear type (two axles). Mid driving axle pass the
power to central spiral taper through a pair of columnar gear with diagonal gears; this
is the first stage reduction. The half shaft passes the power to columnar solar gears by
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the planet inter-wheels reducer; this is the second stage reduction. The structure of the
mid-rear driving axle is also the central spiral taper gear one stage reduction
combined with columnar planet gear inter-wheel reducer.
In recent years, Hande axles have formed four models of axles; they are
respectively standard, enforced, quenched, and enforcedly quenched. Their load
capacity is mainly 13 ton and 16 ton. Their main characteristics are big capacity, wide
range of ratios, good reduction ability. Their performances are far better than the
similar products in the domestic market. Its range of ratios are from 4.42 to 9.49;
becaue of its inter-wheel reduction system, the size of the central reduction part is
decrease greatly so the vehicles have very good passing capacity; due to its thirty-year
experiences in R&D and manufacturing, advanced international equipment, optimized
master slavery gear design, all imported seal parts, the Hande axles have longer lives
and low maintenance charge. After optimization and strict test the inter-wheel brakes
can guarantee your safety. The brakes have many structures, such as 420*185,
410*220, and so on. And the axles can be installed with ABS devices.
Section one front axles
1. Steyr front axles
The Steyr front axles are designed and manufactured under the Steyr technology
from Austria. They are fist shape and 工 shape structure. Its capacity is 6.5 ton. Its
installation size is shown as the chart.
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The main specifications of Steyr front axles

items Specifications
Rated load capacity(kg) 6500
Kerb mass(rim and tire are not included )(kg) About 450
The max. turning angle of front wheel(inner/outter) 45°/30°
Toe-in(mm) 2－4
inner inclination of main pin 3°
Rear inclination of main pin 1°
Outer inclination of front wheel 1°
the braking type of wheels Air chamber cam braking
The brake size(mm) 420×160
Braking chamber 24 diaphragm
Item Specifications
Braking chamber 24 diaphragm type
Rim size For 12.00R20,20－85;for 11.00R20,20－8.0
Rim setover E(mm) For 12.00R20,172.5;for 11.00R20,163
The corrective arm of force(mm) For 12.00R20, 91.5;for 11.00R20,102
Track width S(mm) For 12.00R20,1939;for 11.00R20,1958
1.1 the structure of wheel border and brake of Steyr front axle
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1. nut of wheel 2 hexagonal notch nut 3.cover 4. Washer 5.taper roller bearing 32310 6.wheel boss
7.braking drum 8.taper roller bearing 32314 9.braking hoof 10.idler wheel 11.accessional washer 12. O
shape seal 13. Braking cam shaft 14.seal for shaft 15. Lining 16.o shape seal 17.washer 18.accessional
washer 19.braking adjusting arm assembly 20.ajustment washer and flexible side ring for shaft 21. Lining
22.ajustment washer 23.bearing 24.lining 25.cover 26.flexible side ring for holes 27.steering transverse rod
arm 29.steering pin 30.工 shape beam 31.steering knuckle 32.bracket
1.2 The structure of Steyr front axle
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1. hexagonal bolt 2.spring washer 3.cover 4.open pin 5.2 shape hexagonal notch nut 6.thrust ring
7.taper roller bearing 32310 8.wheel nut 9.wheel boss assembly 10.wheel nut 11.taper roller bearing 32314
12.sear for shaft 13.seperating ring 14.o shape seal 15.steeing knuckle 16.columner pin 17.o shape seal
18.lining 19.lining 20.bracket (left) 21.double head stud 22.self lock nut 23. Grease hole 27.steering knuckle
arm 30.steering transverse rod arm 34.steering knuckle pin 35.braking hoof supporting pin 36.lining
37.cover 39.adjustment washer 40.thrust roller bearing 41.front axle 42.bracket 43.steering transverse rod
arm 44. Steering transverse rod
1.3 The assembly outline of Steyr front axle
1)steering knuckle main pin of front axle and 工 shape beam of front axle are closely
pressed into assembly. When pressed, the main pin should be vertical to steering knuckle hole of
工 shape beam. The steering knuckle pin 29 is supported by the upper lining 21 and lower lining
24. The clearance between the lining and steering knuckle is 0.018-0.059mm.
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2) Assembly outline of steering knuckle: when assembling thrusting roller

bearing 23 of steering knuckle, put one side of bearing with small hole close to the
end face of 工 shape beam, adjust washer 22 and then install it between the bracket
and the end face of 工 shape beam, and then install the steering knuckle on the main
pin from down side to up side. Adjustment 22 is used to adjust the thrust bearing
clearance of steering knuckle, making it between 0.05 and 0.1 mm, meantime insuring
that the pull force of bearing pre-tight force vertical to steering knuckle shaft is from
15 N to 35 N, and that the bearing can run smoothly.
3) The upper lining of steering knuckle is installed on the bracket of braking air
chamber to facilitate assembling and disassembling the steering knuckle, but this can
add more requirements to assemble bracket and steering knuckle. The bracket is
closely connected to the steering knuckle through four double-head bolt and
positioning pin. the Tiansan 1262 screw thread fixing glue should be laid on the
surface of the bolts. The nuts are self lock nuts. These nuts should be screwed down
on across and their torque of screwing down are from 170 N.m to 200 N.m.
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4) Assembling the supporting pin of brake shoes: install the transverse steering
track rod on the steering knuckle and put the hexagonal notch nut onto it, and then test
it by the torque spanner to insure its torque is between 290 N.m and 340 N.m, and
then put the open pin on it. Meantime install the steering knuckle arm on the left
steering knuckle. The tightening torque of its self lock nut is between 305 N.m and
335 N.m.
5) Assembling the braking camshaft: when installing this part you should
differentiate between the left and the right and check the clearance of camshaft and
lining. The technical requirement for this clearance is from 0.16 to 0.26 mm. if it is
not according with the requirement, it should be replaced or used rimer to correct it,
but attentions should be paid to the coaxiality of two linings. Before assembling, put
some lubricant to the inner side of linings of the bracket, and also put the auxiliary
washer and o shape seal on the shaft. After installing the shaft, put the isolation cover
and auxiliary washer on the other side to make the braking camshaft go smoothly.
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6) Assembling the braking adjustment arm: install the braking adjustment arm on
the spline of camshaft, install the adjustment washer and flexible ring for shaft, and
then check the clearance of adjustment arm and make sure it is between 0.3mm to
0.7mm. If the clearance is bigger, the thickness of the adjustment washer should be
modified. Please pay attention to the left and right of the braking adjustment are and
installation direction.
7) Assembling brake shoe assembly: put the anti stagnancy lubricants equally on
the supporting pins of brake shoes, and then install the well-assembled brake shoes.
the tightening force of the hexagonal notch nut of position limitation plate is from the
225 N.m to 275 N.m. And then install the pull-off spring. The pull-off spring should
be in the arc trough of pull-off spring pin and the roller should be assembled in right
position.
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8) Assembling the wheel border: use the special tool to install the isolation ring
with the o shape seal onto the steering knuckle shaft and it should be in right position.
And then install the bearing 32314 fully with 2# lubricant onto the steering knuckle
shaft; install the well-assembled wheel hub with bearing assembly. Lastly install the
bearing 32310 with 2# lubricant.
9) Assemble the thrust ring gasket, tighten the notch nut with tightening force
350±50 N.m, back the nut by 1/10-1/6 loop, shake the wheel hub to eliminate the
clearance to ensure the pre-tightening force of wheel hub between the 18 and 35 N.m
(the test method is on the chart), make it just opposite the cotter, install the cotter and
lock the nut.
10) Assemble the brake drum and test the clearance between the brake drum and
brake shoe from the observer hole. The clearance should be less than 0.3mm. If the
clearance is bigger, special tools should be used to polish the brake shoe. When
polishing, brake shoes should be opened a little bigger, simulate the braking position
to make sure that the friction disc has a very good contact with the braking drum and
that the clearance between lower shoes and upper shoes should be less than 0.3 mm to
make it has best braking ability.
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11) Assembling the transverse steering rod and adjust toe-in: install the
transverse steering rod on the transverse rod arm and fasten it with hexagonal notch
nut, the torque should be between 270 N.m and 300 N.m, make it opposite to the
cotter hole, and then lock the nut. Adjust the adjustment screw thread of the transverse
steering rod to change the value of toe-in to make sure it is between 2mm and 4mm.
after adjustment, lock the clip nut of transverse rod. The tightening force should be
between 70 N.m and 90 N.m.
1.4 The common failures of Steyr front axle and trouble-shooting

1) Overheat of axle head
The overheat of axle head is very common and it is related closely to the usage
and maintenance of the vehicles. It is mainly expressed by void of wheel hub bearing
lubricant and lack of lubricant due to long-time usage; or after repair and maintenance
the wrong adjustment to the pre-tightening force of wheel hub bearing causes extra
resistance when the bearing is running; the wear and tear of wheel hub bearing can
also cause the overheat of axle head. But this case is very easy to judge because it is
accompanied by abnormal sound. After occurring the overheat of axle head, parts
should be disassembled and checked step by step and the key point should be the
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check for bearing and its lubricant, and then adjust the pre-tightening force of wheel
hub(18-35N.m).
Braking shaking is a more sophisticated matter and thorough check should be
carried out. The first reason is the toe-in value is not according with technical
requirements(2-4mm); the braking drum becomes not round and has a very bad
contact with friction disc when braking, the torque of braking is decreasing; the partial
friction of friction disc can also cause the non synchronization of braking and then
shaking; the wear and tear of lining of main pin, the increasing clearance of steering
knuckle, the loose of ball head of transverse, straight steering rod, the distortion of
wheel hub and wheel rim, the bad installation of front suspension system can also
cause shaking when braking. When the vehicles are in long term heavy load situation
and bad working conditions can cause the change on the inner obliquity, rear obliquity
of the front axle, and consequently cause the shaking and swaying of direction when
braking. So, when eliminating the problem, complete analysis should be carried out.
3) Braking deviation:
There are three factors which cause braking deviation: the first one is that the
clearance between the lower and upper shoes is too big, which makes non
synchronization of torques when braking; the second factor is the out of round of
braking drum and it cause the contact area of friction disc less than 2/3 of its whole
area, and this can also cause the non synchronization of torque when braking; the
manufacturing precision of parts and components can indirect tly influences the
contact area of friction disc and braking drum. So when solving this problem, careful
examination should be carried out, meantime fine turning and polishing should be
carried out on the vehicles.
4) Overheat of braking drum
Overheat of braking drum is relative. The vehicle speed should be according

with the rotation speed of braking drum. When braking, the friction disc rubs on the
braking drum and this can cause heat. The main factor for overheat is that the braking
clearance is too small. After braking the brake shoes back slowly or stay. We should
check the braking circuit and braking air chamber to see if there any jam of air circuit
or leakage of air, and then we should check the back of braking camshaft to see if its
back is smooth.
1) heavy shift
There are two factors for the problem. The first one is the mechanical problems
of steering system of front axle, such as oil lack of main pin of steering system due to
bad maintenance. This can cause dry abrasion between main pin and lining and add
steering turning resistance and cause the oil lack and wear and tear of thrust bearing
of steering knuckle and the bad lubricant of transverse rod. The second reason is the
failure of hydraulic booster steering system.
The steyr front axle is comparatively simple. If there is no overload, if

maintenance can be carried out regularly, if the clearance among parts can be well
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adjusted, the occasion of failure will be avoided or decreased. The no. of lubricant for
wheel hub bearing of steyr front axle and pin is: No. 3 lithium lubricant in summer,
No2 lithium lubricant in winter.
2. MAN front axle
MAN front axles are the products under the technology of MAN. They are
mainly two models: disc type and drum type. They are international advanced level.
Their main characteristics are high load capacity, high reliability. Their rated load is
7.5 ton, which is biggest load in domestic market. They are suitable for many kinds of
trucks and buses whose capacity is larger than 15 ton. The wheel hub bearing of MAN
front axle is taper roller bearing imported originally. Also the bearings between the
brake camshaft and sub pump bracket shaft, the bearings between the main pins and
steering knuckle shaft are needle roller bearings imported originally, so the turning,
backing, camshaft of MAN front axle can work very smoothly and bear big radial
load and impact load. Imported seals have good airproof ability and a long life. The
brake friction disc is variable section and has a big contact area and this can promote
the barking performance of the whole axle and prolong the usage life of friction disc.
As a result of this, the safety of the vehicle can be greatly improved and the repair and
maintenance work of the drivers can be decreased greatly. It has ABS system and
braking clearance auto adjustment arm and air suspension system. It is mainly used in
big buses, trucks and project vehicles.
1.1 The structure and parameters of MAN front axle
MAN drum front axle of 7.5 ton
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The structure chart of MAN front axle(chart 1)
The structure of braking system of MAN front axle(chart 2)
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The basic parameters of MAN front axle
Items parameters
Rated load(kg) 7500
Plate spring span(mm) 850(trucks)880(buses)
The max. turning angle of
50°/30°
front wheels (inner/outer)
Toe-in(mm) 1.8－3.2
the inner oblique angle of
5°
main pin
the rear oblique angle of
0°
main pin
outer oblique angle of front
1°
wheels
the braking model of wheel Pneumatic sub chamber and cam braking type
The size of brakes (mm) 410×160
brake pneumatic chamber 20 diaphragm braking pneumatic chamber
the braking torque(Nm) 31500
Wheel hub setover(mm) With 12.00R20,172;with11.00R20,172
the model of wheel hub With 12.00R20,20－8.5;with 11.00R20,20－80
tread S(mm) With 12.00R20,2036;with 11.00R20,2037
1.2 The assembling outlines of MAN front axle
1 parts assembling
a) The assembling of steering knuckle: daub some grease on the holes of main
pins of steering knuckle, press the lining 17 and needle roller bearing into it using
pressing tools, and then press the seal 16 used for shaft into it, lastly install the
steering position limitation bolt 22.( chart 1)
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b) Assembling wheel hub: first put the big end of wheel hub up, and then put the
disc 6 at the bottom of bearing hole, meanwhile press the outer ring of bearing 5;
Turning the wheel hub small end of wheel hub up and fix the disc and press the outer
ring of bearing 11 into it, meantime daub the grease inside the wheel hub and bearing;
press the shaft seal 12 into the wheel hub using special tool. Attention: the shaft seal
must be well positioned to avoid distortion of seal, and then press the pulse gear ring
into good position; put 10 tire bolts into the hub, making sure that the cut of bolt
should be tangent with the limiting slot of wheel hub.(chart 1)
c) Assembling subsection cylinder bracket: take one piece of subsection cylinder

bracket, and then press the needle roller bearing 8 and shaft seal 9 into the big end of
it. The needle roller bearing and the seal must be daubed with grease. And then turn
the bracket of subsection cylinder and press the needle roller bearing 8 and shaft seal
9 into the small end.
2) Assembly assembling:
a) Assembling the steering knuckle: put the two ends of front shaft on a flat roof,
and then connect the steering knuckle assembly, adjustment washer 28, and thrust
column roller bearing 29 to the front shaft by using technics shaft according the chart
below. And then use the ruler to measure the gap between the thrust bearing and front
shaft, making sure that the biggest gas should not exceed the 0.1 mm, and that the
steering knuckle should run smoothly. If the gap is not according with the requirement,
the thickness of the washer must be adjusted. When assembling, make sure that grease
should be put on the needle roller bearing, thrust bearing and upper lining.
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b) Put the main pin of steering knuckle into the liquid nitrogen and freeze it for
30 minutes (the freezing temperature should be lower than minus 30 degree). And
then take it out, put the two ends of front shaft with steering knuckle under the oil
pressure machine, put it just opposite to the bearing hole and then press the main pin
of steering knuckle into good position. And then install the O shape seal, seal disc
assembly, shaft flexible ring into the lower hole and upper hole of the steering
knuckle. The grease mouth of seal disc should be opposite to the center of front shaft,
and fill the inside fully with grease.
c) Assembling adjustment arm: install the ABS on the steering knuckle; install
the brake bottom plate 15, spread thread grease on the bolts 13,14, and then spin them
inside. The tightening force should be 270±20Nm; install the wind pump on the
bottom plate with tightening force 270±27Nm; install the wind pump onto the bracket
with tightening force 165±20Nm. Attention: all the bolts should be spread with thread
grease.
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d) Install the left and right brake camshaft inside the wind pump, install
respectively the clearance auto adjustment arm 35 and 36, indicator plate 37, washer
and flexible shaft ring to the end of camshaft with spline, and then make sure the
clearance should be between 0.3 and 0.7 mm. Requirements: the direction of arrow on
the clearance auto adjustment arm( braking direction), the mark on the arm, the mark
on the camshaft and the gap on the indicator plate should be on the same line; the
control arm of clearance auto adjustment arm must be in the starting position.
e) Assembling the steering knuckle arm: install the left steering knuckle arm 23
on the upper part of the left steering knuckle with the bolt tightened force 800±80Nm;
install the steering trapezia arm 27 with bolt tightened force 800±80Nm. All the bolts
should be spread with thread grease.
f) Assembling the brake shoe assembly: spread the high temperature lubricant
inside the lining 32 of assembled brake shoes, put the seal 31 inside on the both ends,
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make the bottom plate aligned, install the brake pin 30 and make the pin clip aligning
with pin slot, and put the protection plate 27 inside the slot with bolt tightening force
40 Nm; and then put the back spring of brake shoes into the pin slot.
g) Assembling the wheel hub: install assembled wheel hub with full grease onto
the steering knuckle shaft and make sure they are in right position. And then install
respectively the thrust washer 4, lock nut 3, with tightening force 275±27Nm. And
then turn the wheel a few round and eliminate the clearance. And then confirm the
torque value, back the lock nut 60 degree, use the spanner lock the lock bolt 2; spread
the sealant on the head of the wheel hub and screw down with tightening force
140±15 Nm, and then install the brake drum.
h) Assembling transverse steering track rod: install transverse steering track rod
on the steering trapezia arm, taper face is connected closely, and screw down the
notch nut with torque 275±27 Nm, and install the open pin and then lock it. Adjust the
toe-in value using the toe-in value measurement tool and make sure the value is
between 1.8 and 3.2 mm; and then align the open gap of clasp with the open gap of
the transverse track rod, lock the clasp with a distance 10-15mm from the side of rod
with torque 80±10Nm.
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i) Assembling the ABS sensor: put some grease on the lining of sensor, and
install the sensor into the lining and then put them all into the hole of steering knuckle.
If the head of sensor contact with ABS gear ring, it is ok. The clearance should be less
than 0.7mm.
3) The usage and adjustment of clearance auto adjustment arm:

Install the auto adjustment arm and inner stopper washer onto the camshaft, and
make sure that the hole on the arm is aligned with the hole on the end of fork. Fix the
dial plate (1) to make the gap on the plate superpose the mark (3) of camshaft. Choose
the needed washer, adjust the clearance of camshaft (1mm), and then install shaft
flexible ring. Turn adjustment bolt (4) clockwise until pin (5) can easily enters into the
holes of end of fork and adjustment arm, and then move the control arm (6) to the
control disc and fix it. Screw down the bolt with torque 20-25Nm and make sure the
control arm are not under force. The clearance between the bearing base and
adjustment arm should be between 0.3 and 0.3 mm.
Attention: false adjustment of control arm can result in the failure of control arm
(increasing the wear and tear or damaged).
The basic adjustments are as follows: turn the adjustment bolt clockwise until the
brake shoes contact brake drum, and turn the bolt back around 270 degree. Here you
can hear a sound. Brake many times and check the working conditions of adjustment
arm. When removing the braking, turn the adjustment bolt clockwise. To check it,
remove the pin of fork and move the control arm to braking cylinder. The arm should
stay still, otherwise they should be installed again. Turn the adjustment nut clockwise,
adjust the brake and decrease the clearance; or turn it anticlockwise, loose brake and
increase the clearance; meantime please make sure that the clearance between lower
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shoe and upper shoe should be less than 0.3mm and then install the pin of fork head
and lock it with open pin and install the back spring.
1.3 the common failure of MAN front axle and trouble shooting
1)the overheat of brake drum
MAN front axle uses the clearance auto adjustment arm. The brake clearance is
automatically adjusted by the arm and the clearance keeps a constant range. If the
clearance is too small when starting braking, the radiating of heat produced in the
running will be affected. And then check the return spring to see if it can return
normally; check the air circuit, the airproof performance of brake pneumatic chamber
and its returning; when removing the braking, check if the camshaft can return
smoothly. Furthermore, if both the axle head and wheel hub are overheated, check the
pre-tightening force of the wheel hub bearing and grease and the wear and tear of
bearing.
2) Direction swaying when driving
The direction is swaying and cannot be controlled when the vehicle is running.
Regarding this problem, first check if there are any loose parts of steering system,
check if the steering hydraulic oil pump works normally; check if the hydraulic circuit
leaks. Next step check if the pre-tightening clearance of wheel hub bearing is normal,
check if the toe-in is in normal range, check if the there are any wear and tear of
steering knuckle lining and check if there are any wear and tear, loose of steering
transverse track rod head.
3) Braking deviation
There are many factors that affect the braking deviation when vehicles are
running, such as road conditions, environment change, the failure of braking system,
or the change of vehicles’ geometrical structure. Asphalt road can become very rough
due to sunshine and the pressure of vehicles; cement road is easy to crack and go
down because of long term use; when braking, because the friction forces between the
wheels and ground are different, it is easy to produce lateral force and brake slippage
and deviation. When the vehicles are running on the inclination roads, wet and
slippery roads, sloping roads, or curving roads, the center of gravity of the vehicles
are easy to deviate and then affect the lateral force and the centrifugal force of the
vehicles and last produce braking deviation. Regarding the braking system, because
the clearances of left and right brake shoes are different, it can cause different torque
when starting braking. As the result of this, braking deviation is produced. In another
side, because of the different areas left and right brake shoes contact with brake drum
or different contact friction force produced by oil stain, the vehicles can also produce
different brake torque and therefore cause braking deviation.
4) Braking shaking
The braking shaking of MAN front axles are largely identical but with minor
differences. The out-of-round of brake drum can cause discontinuous frictions
between the friction discs and brake drums; therefore the decreasing of braking torque
is coming out; the increasing clearance of steering knuckles, the wear and tear of
linings, the loose of transverse track rod, abnormal toe-in, vibrating wheel hub, the
error of axiality of brake drums, geometrical angle changes caused by the impact of
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front axle produced by heavy load on bad road conditions, all these can affect the
braking performance, and make the front axle shaking. So the factors affecting the
braking shake are much more than that cause braking deviation and direction swaying,
so careful and comprehensive considerations should be carried out when checking.
5) Braking failure
Braking failure can create longer braking distance and cause unsafe factors. It is
caused by the following reasons: the first one is the contact area between the brake
shoes and brake drums less than 70%. When braking, it cannot supply enough braking
torque. To solve this problem, polish the brake shoe assembly. The better one is to
increase its axiality positioning by the wheel hub bearing; the second reason for
braking failure is the system failure. Braking air pressure and other hardware should
be checked ( like whether clearance auto adjustment arm is slippery).
1.4 illustrations of assembling and disassembling tools for wheel hub of MAN front axle
To assemble or disassemble the wheel hub of MAN front axle is more difficult
than Steyr front axle. To guarantee other parts to be in good condition when doing
maintenance, to lower the maintenance cost and labor intension, our company has
developed one kind of assembling and disassembling tool for wheel hub. The
following is the demonstration of its usage.
When assembling and disassembling: first remove the braking dram, use tool 2
and put it on the hexagon, and then use handle bar 7 to remove the nut of wheel hub.
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Remove the nut from the quadrangular rod head, using tool 1, tool 5, tool 6, and
tool 7. Screw the thread of tools with the thread of wheel hub nut, use the tool 5
against the steering knuckle, and then rotate the tool 5. The wheel hub can be
removed by this method.
Use tool 4 to lock the inner ring of the inner bearing, fasten the clasp on the tool
4, use tool 5 and 7. Rotate the tool 4 and remove the inner bearing.
When assembling:
Put the inner bearing of wheel hub and wheel hub assembly on the steering
knuckle, screw the thread of tool 3 on the thread of steering knuckle.
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Tighten tool 1 inside the thread of wheel hub cap, use tool 5 and 6 to tighten 7
inside the thread of nut 6, tighten the bolt of the thread bar 5 inside the thread hole of
small end of tool 3. Attention: tighten all thread more laps to make sure that all
threads of tools and parts should not be damaged.
Fix the tool 5, use tool 7 to rotate the tool 1, install the wheel hub and bearing
assembly in right position. Fasten the nut of axle head, after adjusting the
pre-tightened force of wheel hub and bear lock the hexagonal bolt.
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Use tool 2 to fasten the wheel hub cap with regulated tightening force.
Section Two Steyr mid-rear driving axles

Steyr mid-rear driving axles are developed under the technology of design and
manufacturing from the Steyr axle. They are with planet inter-wheel reducer and they
are two-stage reduction driving axles. The lubricant oil of their reducer should be the
same as the high speed gears. Their maintenance circle and lives are longer. Punching
axle housing and electron beam welding technology of axle head can guarantee the
intensity and rigidity of the axle assembly. After continuous manufacturing and
technical improvements, many models were developed, like standard model, enforced
model, quenching model, enforced quenching model, widened model, and so on.
Their loads are mainly 13 t and 16 t. their main characteristics are heavy load, wide
range of ratio, good reduction ability. They are more advanced in the domestic market.
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They are mainly used in the fields of military force, petroleum, projects, road
transportation, forestry and field working departments. They are mainly used in the
dump trucks, tractor trucks, off-road trucks and project trucks, in which the payload
are over 20 tons. The ABS system, braking clearance auto adjustment arm, central
inflation and deflation system and air suspension system can be optional according to
the requirements of end users.
1.the structure and parameters of Steyr mid-rear driving axles
Chart 3-1 the outline of STR mid-rear driving axle
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Chart 3-2 mid driving axle picture
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Chat 3-3 rear driving axle picture

Table 3-1 the basic parameters of STR mid-rear driving axles
ITEMS Parameters
Rated load(kg) 13000(technical feasible load:16000)
tread(mm) 1800
span of spring 960
size of section 150×130×16
output flange θ180 θ165 θ150
Max. input rotation speed(rpm) 3500
Max. input toruqe(Nm) 25560 23540 19620 17170 14220 12260 10300
Ratios 4.386 4.80 5.73 6.72 7.49 8.40 9.49
The size of brake θ420×185 θ410×220(optional)
Braking type sub air chamber braking, cam type
Brake torque(N.m) 29400
Kerb mass(kg) 870
the ratio of inter-wheel reducer 3.479
Stop braking model spring energy storage deflation braking
The lubricant oil(Liter) Main reducer 10 inter-wheel reducer each 2
the model of wheels installation the center hole position of wheel hub， wheel bolt 10
－M22×1.5，pitch circle θ335
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2. The structure and operation principles of STR middle driving axles
As shown in the chart 3-2, middle driving axle is composed of central one stage
reducer plus planet gear inter-wheel reducer. The ratio of the inter-wheel reducer is
3.478. Combined with central master and slavery taper reducer with different gears
they can form main ratios for option. The most used ratios in the domestic market are
4.8, 5.73 and 6.72. Its structure is complicated. As shown in the chart, the power is
transferred to flange assembly 3 from transmission shaft, make reducer rotate through
spline shaft of inter-wheel 166 reducer. The planet gears of 十 shape shaft inside the
reducer gets into mesh with two half shafts and then rotate. The gear 13 of rear shaft moves the
hollow shaft 25 through spline and hollow shaft have a linkage with mastery column gear 26
through spline. The power is transferred to mastery taper gear through slavery gear, and then to
main differential by the rotation of mastery and slavery taper gears. The rotation of planet gear and
half shaft gear inside the main differential transfer the power to left and right half shafts and rotate
the inter-wheel reducer to move the vehicle.
Inter-wheel differential is used to automatically adjust speeds of left and right
wheels when the vehicle is turning. The inter-axles differential is used to
automatically adjust the speeds of middle axle and rear axle when the vehicle is
running on the rugged roads. When vehicles are running on the rugged roads, they
need the different moment speeds of middle axle and rear axle to adapt the need the
road surface requires from the wheels. If the connection between the middle axle and
rear axle is rigid, any moment the rotation speeds of middle axle and rear axle are
absolutely the same. This can consume the power as well as wear the tires. Sometime
it can damage the parts. The inter-axle differential can automatically adjust the
rotation speeds of middle and rear axles to satisfy the needs of roads.
When vehicles are trapped in the muddy roads, the inter-axle differential should
be engaged. When the switch of inter-axle differential is pressed down, the
electromagnetic valve will be opened and then the compressed air enters into the
working cylinder of inter-axle differential lock and pushes the piston rod. The folk 22
of differential lock will insert the pin 18 of differential lock into the pin hole of front
half shaft gear 15 to make the housing of differential lock the half shaft gear. The
differential has no function of differential any more. The transfixion shaft 28 and
hollow shaft have a complete rigid connection between them. The middle and rear
axle, the left and right shafts have also complete rigid connection to enforce the
vehicle to get out the rugged road. After this please remove the inter-wheel and
inter-axle differential locks in time to recover its normal functions. Otherwise, that
will cause the wear or damage to the parts.
3.the main points of assembling and maintenance for the main parts of
middle axles
1) The assembling of inter-wheels and inter-axles differentials: clean the half housing of
differentials and then put the washer of half shaft gears inside the half housing. Put some lubricant
oil and put the half shaft gear inside. Put combination of the 十 shape shaft, planet gears and
washer inside the half housing. Put some lubricant oil on the rotation parts of 十 shape shaft and
planet gears and check its rotation situation. Turn the 十 shape shaft a few rounds and engage it
naturally with half shaft gears. If shaken, the planet gears should have clearance and the clearance
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should be even. Put another half housing with half shaft gears and washers with this one according
to the machining marker and then tighten 8 bolts on it with the torque of 210 n.m.
Measuring the gear side clearance of half shaft gears and planet gears: use dial
indicator to test on the small end of half shaft gears with clearance required by
technical 0.25-0.45mm. If not in this range, the thickness of half shaft gear washer
should be adjusted. Turn the differential assembly 180 degrees, install the bolts with
hands onto the assembly and spin 3 circles. Afterwards, tighten all 16 bolts. The
tightening force should be around 325±25Nm. At last, press the inner ring of one
column taper roller bearing of differential into the space between the two half housing
shafts.
2) Adjustment of pre-tightening force for the bearing of differential assembly:

put the assembled differential assembly into the housing of main reducer, install the
outer ring and adjustment nuts of differential (attention for thread), assemble the
cover of bearing of differential and tighten the self lock nut. Rotate the differential
and adjust the nut. Meantime, use the copper rod to strike the bearing cover to
eliminate the clearance, and adjust the pre-tightening force of differential bearing to
13.6-36.4N. as shown in chart, use spring balance to pull any bolt of passive wheel
and get the moment data when differential is rotating.
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The assembling of inter-axle differential 166 assembly: the assembling technology

requirements of 166 assembly are basically the same as the main reducer. The differences are
that the front half housing should be amounted with differential lock ring and lock pin, the
bearing washer of front half shaft of differential housing, and that the rear half housing should
be installed with bearing 6019 with anti dust coer.
3) The assembling of cross axle box: press two roller bearings 31311 into
bearing seat. Make sure that bearings must be pressed in flat position. Shake the
bearing seat lightly to make sure that the bearing should be smoothly rotating. Press
oil flake and row-steep roller bearing NU314 into active taper gear.
Put the screw adhesive inside the thread holes of cross axle box; install
double-head bolt and positioning pin. Turn the cross axle box, press bearing 6312
installed with steel ring and stop slot and install column active gears with inclined
gears into cross axle box( attention: the numbers of gears, different numbers, different
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ratios). Use press machine to press hollow shaft, and then tighten the round nut and
make sure the tightening force should be 300 N.m.
Put some screw adhesive into screw holes of bearing seat of cross axle box, and
then tighten the stud and assemble passive wheel adjusting washer and then assemble
the isolating ring into the tapered passive gears. Press the active wheel from the top of
cross axle box. Meantime put spline in right position and press into column passive
gears and then press into combination parts of bearing seat. Install the pre-tightening
adjusting washer and external ring onto the bearing seat; install the bearing inner ring
and three hex bolts on the face of active gears with the tightening force of 200 N.m.
Adjusting the pre-tightening force of active gears: shake the active taper gears
and make them rotate and adjust their pre-tightening force by increasing or decreasing
the thickness of the washers; meantime lock the circle nut of hollow shaft.
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4) turn the main reducer 180 degree. The pre-tightening force of bearing of
differential of main reducer should be adjusted well. And then put some screw
adhesive into screw hole and tighten the stud; clean the connection surface and put the
Letai sealant on it. After that install the cross axle box, spring washer and nuts. The
nuts should be tightened according to opposite line and the torque should be 120 N.m.
Adjusting the gear clearance of active and passive tapered gears and gears’
engagement situation: adjust the nuts of both sides (the screw-in depth should be the
same, otherwise it will affect the pre-tightening force of differential) and change the
position of passive gears. The gear clearance should be between the 0.20 and 0.40 mm.
put the Hongdan powder evenly on the three adjacent gears of the passive gears, and
then rotate the passive gears to check its engagement situation.
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Rotate the passive gear and measure it on three points and make sure that its
gears clearance should be less than 0.15mm. The gears’ clearance and engagement
situation will affect directly the life of gears and its noises during running. So in
routine maintenance it must be adjusted very well. Big gears’ clearance will increase
the noise and some time causes the gear-collision troubles. Attention: after assembling
and maintenance, the cover of bearing should be tightened with the torque of 210 N.m,
meantime lock the lock plate to prevent nuts from getting out of it.
Assemble the fixed engagement cover, locking washer, circle nuts respectively
on the spline parts of the differential and tighten the circle nuts. Use screwdriver to
turn down the bolt of the lock and attach it to the underside of the circle nut. Remove
three bolts from the active taper gear and put adhesive on it. And then tighten the nuts
with the torque of 170-180 N.m.
5) Assembling of the cross axle box cover: install the o seal ring onto the
bushing, and then put them on the arm axle of shifter fork. After that assemble the
flexible ring used for axles and then put the seal glue outside the bushing. Install the
shifter fork sliding block inside the cross axle box after installing it on the shifter fork.
Turn the cover of cross axle box, spin the thread positioning pin inside and
wedge it in the trapeziform slot of bushing and fasten it. Turn the axle of shifter fork
arm to make sure it can run smoothly. Press the annular ball bearing 6312 into the
bearing hole of box cover.
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Put some sealant on the upper side of the cross axle box cover and install the
well-assembled axle seal ring in right position, tighten the bolts, and press the
inter-axle differential assembly using press machine from the underside. The bearing
6312 should be in right position. And then press the flange. Attention: the spline
should be in right position and the side of oil seal should not be damaged.
Put sealant on the connection surface of cross axle box and assemble the cover of
cross axle box to the cross axle box. Fasten the bolts diagonally. Screw on the flange
nut with torque of 750±50Nm. Make it alignment with the pin hole and put pin inside
and lock it.
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6) Assembling lying axle: clean the axle housing, put the oil drain hole upward,
install two column pins into the left and right bracket and the hole of base plate, align
the lower traction rod bracket spring sliding plate and assemble them, and tighten
them with 8 bolts with torque of 570±20Nm.
Put half shaft with two splines inside, install the O-ring seal onto shifter fork
shaft, smear some anti-block material, put the shifter fork in right position from the
outer hole of axle housing, fix the shifter fork on the operating rod and then fix the
curved plate with hex nuts. Install the sliding engagement cover onto the half shaft
and make sure it can be sliding very well. Install the shifter fork block into
engagement cover.
Smear some sealant on the root of the arc fixing thread and install it in the hole
of axle housing and fix it. Drop some screw adhesive into another four thread holes on
the surface of axle housing and fasten the stud. And then smear some sealant on it.
Requirements: smearing the sealant evenly; the root of the thread should be smeared
with sealant; the hole of bolts should be filled with sealant. Assemble the main
reducer assembly into the axle housing, align the holes and make sure the installation
is in right position. And then tighten the self-lock nuts with the torque of 120Nm.
Turn the flange to check if the mobile parts are intervene with the fixed parts.
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Install the bearing 6212 and perforation shaft inside the bearing seat of axle
housing, smear the sealant evenly on the surface of bearing seat, and then install the
bearing seat in the right position with torque of 60Nm. Align the output flange
assembly with the spline and then install it onto the perforation shaft, fasten the flange
nuts with torque of 750-800Nm. Align it with pin hole and get the pin inside and lock
it.
Clean the installation surface of air chamber bracket, align the air chamber
bracket with thread holes and install it. Requirements: bolts must be smeared with
screw adhesive; after fasten it a few laps with hand, use spanner to tighten it
diagonally with torque of 600Nm.
7) The assembling of wheel border: clean the flange surface of axle housing, fill
some screw adhesive into screw holes, align the brake base plate with screw holes and
install them in right position. Requirements: tighten it diagonally with torque of 300
Nm and pay attention to installation angle.
Smear some sealant in the holes of brake base camshaft and holes of camshaft
support, install a washer onto the camshaft, put it in the hole of base plate, install
another washer, clamp spring, camshaft support and clearance auto adjustment arm,
and then install the flexible ring for axle, adjust the washer and clearance to make the
adjustment assembly and camshaft support have a clearance of 0.5-0.8. use washer
under the camshaft support, install camshaft support, and make sure the camshaft can
turn smoothly. Smear some screw adhesive on the fixing bolts and fasten the camshaft
support with the torque of 160Nm. Check again the turning and return of camshaft to
make sure it is running smoothly.
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Fix the shifter fork shaft of inter-axle differential, protect the engagement cover
from dropping, take the pre-installing half shaft out, clean the inner holes of both ends
of axle housing, smear some lubricant oil and install the oil seal of half shaft in right
position by using special tools. Attention: the oil seal spring and oil seal edge should
not be damaged.
Smear some anti-stagnant lubricant on the contact areas of stop pin and brake
hoof, assemble the brake hoof assembly onto the stop pin, hitch the return spring, fold
the brake hoof assembly and hitch another return spring to the slot of return spring pin.
Smear some anti-stagnant lubricant on the installing slot of rolling wheel and arc
surface of brake camshaft and install the rolling wheel in right position.
Smear some lubricant oil on the separating ring with installed o-ring and use
special sleeve tools to install it into the shaft head of axle housing, and then warm the
bearing 322222 to 70 degree to 80 degree and assemble it. Attention: the surface of
separating ring must be smooth and have no knock trace; its inner ring must match the
outer ring of bearing of wheel hub assembly.
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Install the wheel hub assembly with tire bolts, wheel hub oil seal and the outer
ring of bearing onto the axle head. Attention: distinguish the spinning directions of
left and right( oil seal is with oil-return line, which can solve the oil leakage problem).
For one-edge oil seal facing with oil-return line, its spinning direction is right;
conversely, the direction is left. When assembling oil seal, clean the inner hole of
wheel hub oil seal, smear some sealant, put the oil seal straight and press it inside.
The one-edge oil seal should be pressed first and then the double-edge oil seal. Press
the tire bolts inside diagonally and put the head cut aligning with stop cut side of
wheel hub.
Two outer rings of bearing should match the inner ring of bearing the bearing
bracket and bearing installed. Get the bearing bracket installed with the inner ring of
shaft 30222, align the spline of axle head and press into right position.
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Install respectively the anti-thrust washer, lock slip and circle nut of axle head.
When tightening, use the copper stick to shake the bearing bracket and wheel hub,
eliminate the bearing clearance and fasten the nuts of axle head with torque of
350-400Nm. Requirements: the thickness of adjustment washer inside the nuts of axle
head should not be more than 3.5mm;the tightening force should be guaranteed and
the washer should be pressed closely.
The locking part for the new type axle head is the anti-loosing double-nut
structure. As shown in the right chart, there are two nuts, one thin, and one thick.
Thick one is inside and its chamfer is outward. After reaching its tightening torque,
back one sixth lap. And then adjust the pre-tightening force, after reaching
requirement; assemble lock slip and thin nut with its chamfer inward. After tightening,
press the lock slip and lock bolt down the slot of two nuts.
The adjustment of the pre-tightening force of wheel hub bearing: after fastening
the axle head nuts, turn the wheel hub a feel round, eliminate the clearance, use spring
balance to hitch the tire bolts and pull in direction of wheel hub tangent, and make a
record when wheel hub rotating. The requirement is 70 to 90Nm. If the digit is not in
this range, it should be adjusted again( old model can be adjusted by increasing or
decreasing the thickness of the washer; new model can be adjusted by increasing or
decreasing the forward or backward of the nuts; shake the wheel hub; after
eliminating the clearance, its pre-tightening force should be measured again). After
adjusting, the lock slip and lock bolts should be put inside the slot of axle head nuts.
Assembling planet hub reducer assembly: clean the hub reducer housing, press
planet wheel shaft and rolling ball inside, assemble the planet wheel washer and
column rolling needle bearing onto the planet wheel shaft, install the planet gears,
assemble another planet wheel washer, align the planet wheel bracket with original
machining position and install it in right position. Use the bolts with screw adhesive
to tighten the planet wheel bracket with required torque of 220Nm and check the
rotating of planet gears to make sure it is very smoothly rotating.
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Install inner gear ring, and put the flexible ring inside the groove. Install the left
and right half shaft (attention: when installing double spline shafts, actions should be
gentle and prevent sliding engagement cover from changing or dropping) in right
positions, smear some lubricant oil on the groove of seal ring of wheel hub assembly,
install the o-ring inside the groove, align the hub reducer with holes and install it in
right position. Install sun gear washer and sun gear and put the axle flexible ring
inside the groove. Align the brake drum with hole, install it in right position, fasten
the flat head screw. Turn the brake drum and check if there are any interventions with
brake hoof and other parts. Clean the head and cover of hub retarder, smear some
sealant on the connection part of the cover, spread some screw adhesive on bolts and
install it on the hub planet reducer assembly.
4.the assembling and repairing points of main parts of rear axles
The assembling points of Steyr rear driving axle are similar to the middle driving
axle, so we here only discuss the differences.
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3-4 main reducer of rear axle
As shown in the chart 3-4, the transmission shaft transfer the power to flange
assembly 1 and driving the axle drive bevel pinion 5. After passing axle driven bevel
pinion 20, the power goes into differentials. The differential is composed of cross
shaft 19, four planet gears 18, two half axle gears 17 and 23, and differential half
boxes 15 and 21. The connecting bolts connect two half housings 15 and 21, so when
the differential is rotating, the cross shaft is rotating and the planet gears are rotating.
Meanwhile, the left and right half shafts 17 and 23 are driven to rotate and transfer the
power with the same torque to left and right wheels. When vehicle is turning, the
inner wheel should run fewer circles than the outer wheel. Due to the balance relation
of torque, planet gears not only revolve but also rotate around the cross shaft, so the
two half shaft gears have different speeds. The circles the inner wheel run less than
the outer wheel is the same as the circles the outer wheel run more than the inner
wheel. So this can achieve the different speeds to guarantee the smooth turning of the
vehicle. Inside the differential, the rear part of planet gears is installed with ball
washer to increase the life of mechanical parts and decreasing the noise. The
adjustment washer 16 and 22 are installed to lower part of half shaft gears to adjust
the engagement clearance of half shaft gears and planet gears. Axle drive bevel pinion
5 is stalled inside the bearing seat 4 and supported by taper rolling bearing 3 and 6.
Adjustment washer 29 is used to adjust the pre-tightening force of bearing.
The differential assembly is supported by two taper roller bearings 9 and 24 at

the ends of differential; adjust the pre-tightening force of differential bearing and
relative position of axle driven bevel pinion by differential adjustment nuts 18 and 28.
Its adjusting method and adjusting values are the same as the engagement of middle
axle differential and axle drive and driven bevel pinions.
From the chart we can see that compared with middle axle the main reducer of
rear axle has no one pair of column driven gears. Its structure is relatively simple. It
achieves different ratios by the gears numbers of taper gears. Different gears numbers
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can make different ratios. When changing ratios for rear axles, we should replace
taper gear as well as the axle drive bevel pinion’s bearing seat, differential housing
and differential bearing.
The following is the table for the gear numbers of gear when having different
ratios:
Ratio I 4.8 5.73 6.72

Taper driving gear 17 17 15
Mid
Taper driven gear 28 28 29
Column driving gear 31 35 35
axle
Column driven gear 26 35 35
Rear Taper driving gear 21 17 15
Taper driven gear 29 28 29
axle
1) The assembling of main reducer bearing seat of rear axle: clean the bearing
seat, use press machine to install the bearing into the bearing hole of bearing seat, turn
the bearing seat and install another bearing, heat the inner of bearing by 80 Degree
and press it into the shaft of active tapered gear, and then put the active tapered gear
into the bearing seat, install the adjustment washer and adjust the pre-tight force of
bearing.
Measure the rotating torque of bearing seat by its tangent direction and make
sure the torque range is between the 8 to 16 Nm. if not in this range, adjust the
thickness of adjustment washer.
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install the oil ring assembly installed with differential oil seal into the bearing
seat. Attention: smear sealant inside the hole of bearing seat and protect the blade of
oil seal and install it.
press the input flange assembly into right position, fasten the nuts of flange and
make sure the tightening force is in range of 750 to 800NM, put it right against the
hole of open pin, put the open pin and lock the second rotating flange and check the
pre-tightening force of bearing again.
Fix the adjustment washer of reducer onto the bearing seat, assemble the o-ring
and smear the sealant at the end of it, and then put it into the housing of main reducer.
Drop some screw thread adhesive into the screw thread hole of main reducer and
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fasten the bolt with the force of 120Nm.
Turn the main reducer; adjust the engagement of its gears. The adjusting method
is the same as the main reducer of mid axle. After achieving requirements, lock the
lock washer, install the fixing engagement sleeve and lock it with locking washer.
The assembling of wheel border and axle housing is the same as the driving mid
axle.
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If the oil seal is aging or wearing and check if the surface of isolation ring is
smooth and wearing. If the oil seal is nice and there is still a heavy oil leakage, the air
circulation device of axle housing should be checked. If the inlet of axle air is blocked
by oil smear, when running the heat produced by axle housing increase the air
pressure and force the oil to go out from the oil seal.
Oil leakage from the differential oil seal: there are three kinds of differential oil
seal, one is from middle axle input, one is from middle axle output and the last one is
from the input of rear axle. If there is a oil leakage from the input shaft, the is
commonly caused by the damage or wearing of oil seal of input axle shaft or caused
by spring loose of oil seal. When repairing, if the oil leakage is from the outer ring of
oil seal, this is maybe caused by the loose between the oil seal outer ring and outside
housing.
When re-installing, please clean the oil seal outer ring and oil seal seat hole and
smear Letai 603 adhesive on the outer ring of oil seal and then put the oil seal into the
oil seal seat hole. If the oil seal is completely good and there is still a oil leakage,
check if the air circulation device of axle is blocked; secondly check if the flange nut
is loose or the surface of flange is smooth or not. If they don’t meet the needs, please
replace them with the new one. Check if there is any wearing and loose of bearing and
the partial wearing of oil seal caused by imbalance of driving shaft. The oil seal of
half shaft is damaged and leak oil, which can make oil get into the main reducer from
the wheel reducer. And this can cause too much oil in the main reducer and increase
its pressure and consequently cause oil leakage; and overheating of axle and wheel
can be accompanied. If oil leakage is from output shaft, the check contents are the
same as the one from input shaft.
Oil leakage from combination surface or welding line of axle housing: if the oil
leakage is from the top cover of axle head, this is maybe caused by unclose contact
between the planet wheel bracket and top cover. The connection between the top
cover and top surface of shaft head is the connection without washer. After
disassembling them, clean the top cover and planet bracket and then smear Letai 587
adhesive on them and then re-assemble them. The continuous adhesive belt should be
used. Regarding the middle axle, the combination surface of cross axle box is more
and there is a big possibility of oil leakage. when disassemble them and repair, the
combination surface should be well protected and wild disassembling is refused.
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Where there is some knock or damages, they should be recovered and sealant should
be used. The combination surface of axle housing and main reducer is easy to have a
oil leakage, the reason are many. The distortion of parts, the loose of bolt can cause
combination surface oil leakage. When repairing, the combination surface should be
recovered first and smear Letai 587 sealant. The oil leakage from the welding line of
axle housing is mostly caused by too much pressure on the axle housing and make too
much stress on the welding line, which can cause cracks and oil leakage. so, overload
is refused.
Oil leakage from the sand hole and loose of casting parts. some oil leakages
happen on the non-combination surface and we should make a clear judgment. The
sand hole and cast defects can be solved by re-welding or replacement.
2) Burn damage of wheel differential: the lubrication on the main reducer of
middle axle and transiting wheel box is splash lubrication; but the position of wheel
differential is highest, so the lubrication condition of wheel differential is worse. Any
oil shortage can cause threats to wheel differential. When filling oil for new vehicles
or changing gear oil, new oil must be filled from the oil filling mouth of wheel
differential housing and should be added continuously before they reach the check
point of transiting box of middle axle.
After some failures, after changing new differentials, the burn damages are
continuing, even burning the planet gears and cross shaft together. There are two main
reasons which cause the differential burn damages: one is shortage of oil, another is
the wrong ratio of middle axle and rear axle. Here the gear numbers of taper and
column driving and driven gears should be checked. Some users change the driving
and driven tapered gears of middle or rear axle and ignore the ratio of the vehicle,
which makes the different ratio after replacement. This can cause differences between
the middle axle and rear axle and then cause the high speed rotating of wheel
differential when running, which can soon cause burn damages to differential together
with worse lubrication condition.
3) Abnormal sound of axle drive: if there are some abnormal sounds from axle
housing, please stop the vehicle and check immediately. Abnormal sounds are mostly
from the damaged parts.
the falling apart of differential support bearing, heavy rust or wearing on bearing,
the loose or falling off of the bolt of driven gears, the loose of differential lock
engagement and the collision of drive gears or differential gears can cause heavy
abnormal sound.
If there is a continuous sound of gear wearing, and it becomes bigger and bigger
with the accelerating of vehicle speed, this is mostly caused by spot erosion of
bearing, wear of drive gears or damages and spot erosion of gear surface. If there is no
obvious sound in normal driving and there is obvious sound when decelerating, this is
mostly caused by pull of drive gears, spot erosion. There are 7 bearings in middle axle,
the falling apart of bearings can cause obvious sound. The part of abnormal sound
should be checked and then disassembled and checked. If there are no abnormal
sounds when vehicles running in beeline, but if there are some abnormal sounds when
turning, this is caused by damages or burn damages of differential gears. the loose of
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the engagement sleeves of wheel differential lock can cause the sound from the
collision of two sleeves. The abnormal movement of wheel differential lock pin can
also cause the knocking sound. This kind of abnormal sound is from the irregular
mechanical beating.
If there is a continuous sound after changing with new driving and driven gears
and it becomes bigger and bigger with the acceleration of vehicles, the engagement
clearance of driving and driven gears should be checked. Because the driving and
driven gears are matched pairs, so if changed with a pair of gears which are not
matched, it can cause the abnormal sound and this sound cannot be removed. Please
make sure that the driving and driven gears are matched pairs.
When disassembling the driving and driven tapered gears, protect the installing
clearance adjustment washer. When re-assembling, recover the washer. Otherwise due
to the warp of adjustment washer, there is a possibility to cause the noise of
engagement of driving and driven gears. When replacing the driven tapered gears,
Taile 262 adhesive must be smeared on the connection thread of bolt and fasten them
according to regulated torque.
If there is no abnormal sound during normal driving and there is abnormal sound
during deceleration, this is mostly caused by pull of gear back or spot erosion. If the
sound is tiny, it is normal. But if it is big, it must be checked. Too much gear
clearance can cause abnormal sound during quick start or acceleration.
Distortion of axle housing can also cause abnormal sound of rear axle. when
checking, please pay attention to this point.
If abnormal sound appears, please stop and check. Because falling apart of
bearings, loose of fixing bolts, the damages to gears can cause serious consequence if
they cannot be fixed.
4) Overheat of axle. There are three reasons for axle overheat: too much
lubricant oil, less lubricant oil, too much pre-tightening force for bearings. If the
lubricant oil is too little, the mechanical parts cannot be lubricated and the parts will
be heating. Sometime it can cause burn damage to parts. if there is too much lubricant
oil, it can also cause overheat of axles. For differential support bearing, driving gears
support bearing, if the pre-tightening force is too much, they will produce too much
heat. This can be solved by adjusting the thickness of washers.
5) Failure of differential lock: when switching on the switch of differential lock,
the indicator light is not on. First check when pressing down the button if the piston
handspike of differential working cylinder works well or not. If the handspike cannot
reach its normal position, this means that the gears don’t engage well. Moving the
vehicle forward and backward can solve this problem. If the working cylinder doesn’t
work completely, there should be some problems with the electronic and pneumatic
control system of magnetic valve. Loosen the output connector of magnetic valve and
observe if there is some air coming out. If no, the problems should be with the
electronic control of magnetic valve or the magnetic valve itself. If there is some air
coming out, the problems are with the working cylinder.
After pressing down the switch of differential lock, if the handspike of working
cylinder makes the differential lock in right position but the indicator light is still not
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on, the problem should be with the switch of indicator or the bulb. This can be
distinguished by testing lights.
6) overheat of hub. This kind of overheat is caused by too much pre-tightening
force for hub bearings and mainly after maintenance. In maintenance tightening the
nuts not according with regulation, too much tightening force can cause too much
pre-tightening force. The hub should be re-assembled according with the regulations.
of course, damaged bearings of hub can also cause overheat of hub.
7) Overheat of brake drum. There are many reasons for overheat of brake drums.
Some are from mechanical parts. some are from brake control pneumatic system.
First check if brake chamber can quickly return back after check. If not or slowly
back, remove the chamber handspike from the brake adjustment arm and then check if
the brake chamber can return quickly. If slowly back again, the problem is obviously
with the brake chamber and brake control pneumatic circuit. After adjustment arm
away from the chamber, if return is smooth, check if the brake camshaft is flexible.
Distortion of brake camshaft, heavy lack of oil for shaft sleeve or wrong position of
the bracket of brake camshaft can result in abnormal return and then overheat of brake
drum. The broken or loose return spring of brake shoe can cause not only overheat of
brake drum but also friction noise.
In normal driving, the brake friction disc and brake drum should have a certain
clearance. Too big clearance can cause brake effects; small clearance can cause
overheat.
So the radiating conditions of brake drum is bad and frequent brake can soon
make overheat on brake drum, even burn air inlet of tires and cause leakage of tires.
So if the vehicles work normally in the mountain areas, when they are driven down
long distance slopes, the engine exhaust brake are suggested to reduce the speed and
service brake should be avoided to prevent the overheat of brake drum.
8) ABS trouble. The failure of ABS is mainly from the following reasons: the
increasing clearance of hub bearings makes the clearance between the ABS probe and
gear rim bigger than regulated value, the normal value within 0.7 mm; there is some
filth on the probe and this can make the decreasing sensitivity; the wiring of ABS are
damaged when their position are changed during driving and short circuit occurs; the
failure of ABS sensor can also cause this problem.
6. The usage and maintenance of Steyr driving mid-rear axle
1) If the vehicles are driven around 2000-3000 km, the compulsory maintenance
must be carried out. During the maintenance, the gear lubricant oil for central drive
and wheel reducer should be changed. After this maintenance, for every 20000km, the
oil must be changed. When filling oil for middle part of middle axle, the oil should be
filled from the filler neck on the differential housing of wheel. The oil for central
drive and wheel reducer of middle-rear axle should be in APIGL-4 grade, in
SAE85W/90 viscosity. keep the oil in some level and check the oil level of wheel
reducer and axle main reducer frequently during usage.
There are two oil necks on the wheel reducer. Oil drain neck is set up at the end
of shaft head; oil inlet neck is located in the central part of top cover. The normal oil
position of wheel reducer should be the horizontal position of oil inlet neck when the
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oil drain neck is in the highest position. Here open the oil inlet neck and put the
fingers into the hole of nut. If the fingers can touch the oil, the position is ok.
Generally speaking, the oil for rear axle housing should be 6 liters; the oil for middle
axle housing should be 10 litters; the oil for each wheel reducer should be 2 liters.
2) The operation of differential lock. If installed with wheel differential lock
and axle differential lock on middle-rear axle, the vehicles can smoothly get out the
troubled road. The purpose of differential lock is to help the vehicles out of the
troubled roads when the vehicles are in the muddy or smooth roads. There are two
switches for differential locks on the panel board, one is wheel differential lock switch,
and another is axle differential lock switch. When the vehicles are driven into muddy
road, if one wheel slides, please press down the clutch and wheel differential lock
switch. When the indicator for wheel differential lock is on, the differential locks for
middle and rear axle are effected at the same time. But if the clutch pedal is up, the
wheels on one wheel slide at the same time, but the other wheel stays still. So the
vehicles cannot get out. Press down the clutch pedal and axle differential lock switch.
The indicator light should be on. Then put into gear, move foot from clutch and the
vehicles can get out of troubled road. After getting out the troubled road, the
differential locks should be immediately closed.
When the vehicles are turning, the wheel differential lock of driving rear axles
can automatically make different speeds for left and right wheels to protect the tires
and vehicle parts. When one wheel of vehicles runs into a muddy or smooth road,
engage the differential lock. After this, left and right half shafts become one
connection shaft and the vehicles can get out the troubled road. After getting out
troubled road, the differential lock should be closed. Otherwise it can cause great
damage to tires and differential.
3) In maintenance, when the half shafts needs to be removed, something should
be paid attention to. If the half shafts are located in the side without differential lock,
they can be disassembled at random; If the half shafts are located in the vehicle side
with differential lock, before removing them, the differential lock should be engaged.
To prevent differential lock engagement sleeve from dropping, iron wire should be
used to fix the handspike of working cylinder of differential lock to seal the working
cylinder.
4) Avoiding heavy overload: The designed load of Steyr rear axle is 13 ton. The
thickness of housing for axles made in China is 16mm. Heavy overload and focused
load can cause distortion and crack of axle housing. To prevent this serious
consequence, load must be regulated by the driving conditions.
5) the adjustment of brake clearance adjustment arm. Before adjusting the hand
clearance adjustment arm, all brakes should be loosened. Turn the hexagon bolt
clockwise until there is no clearance. And then turn it anti-clockwise until three
sounds are heard. And then run the vehicles and check the brake.
Before adjusting the Clearance auto adjustment arm, all brakes should be also
loosened. In the adjustment arm the arrow direction should be the same as the brake
direction. Turn the hexagon bolt clockwise to make the brake arm be into the U fork
of brake chamber handspike. Right against the hole position, use flat-head pin, washer
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and open pin to connection. Push the adjustment arm to its end, fasten the positioning
bracket, and then use the bolts and nuts to fix the bracket and adjustment arm. Turn
the hex bolts on the arm clockwise to make zero clearance between the brake shoe
and brake drum and then turn anti-clockwise the nuts by 3/4 loop. Finally try the
brake a few times.
6) In repairing if re-assembling the differential and driven gear is needed, Letai
262 screw adhesive should be smeared on the connection screws with regulated
torque to make sure the connection bolts are fixed.
7. Axle No.
The nameplate for Hande Axle
Axle No. This is the model of axle, which can indicate the specifications of
axle. To make convenience to sales and services, the Assy No. of axles should be
clearly regulated. The colors of nameplates may have some differences according to
different models and ratios, but there formats are the same.
Manufacture No. Manufacture No. can indicate the production date and
assembling No. This no can be used to find the production and supplying unit of axle
parts, which can be used to supply proofs for guarantee claim and troubled parts
analysis. According to Manufacture No, the axle no can be found and clear the states
of troubled axles and their specifications.
But axle no can not be used to find the manufacture no. Meanwhile, the axles
with same no can be millions.
The position of nameplate on axle. The nameplate is fixed on the right slope of
connection board of axle housing air chamber bracket. It is shown on the chart below.
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If nameplate is lost during usage, as shown in the picture, there is steel stamp of
axle manufacture no in the inner side of spring sliding board of the upper side of the
left axle housing.
The meaning of axle manufacture no. (made of ten digits)
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The axle manufacture no. before June of year 2006.
Needed by the production state, after June of year 2006, the manufacture no of
axles were changed as follows:
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Chapter 3 Air loop line of whole truck

Section 1 summary
There are much more new technology and craft being adopted in the Shaanxi
truck Euro 3 series .new functional valves using, hose and pipe be reasonable fixing
caused the performance be more economical and reliable .now we expatiate the whole
truck from followed parts : air source part , breaking air pipe line ,assistant air pipe
line , emergency braking part , parking breaking and trailer braking part .
Section 2 valves
1.chief pump of breaking
function: controlling the braking power which from the double loop line ,if one
side is not available, other side should work as usual.
Theory:
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When mandril “a” bearing force, piston“c ” was below down ,then exhaust valve
closed and input valve open .The pressed air is from No.11 port , passed chamber “A”,
after that , arrived pipe “I”. Meanwhile , airflow get to chamber B through port“D”，it
forced piston“f” moving down ,then exhausting valve closed , and input valve opened
again, the pressed air from port“12” get to pipe“Ⅱ”through port“22”.
When braking released ,the pressed air discharge from port 21,22.
When the first loop line action halt, valve“e” force piston“f” moving down,
caused the exhausting valve closed and input valve opened ,then 2rd loop line be
starting ,at same time ,1st loop line can working as well .
faults & solutions
Faults description Faults reason Faults solution

Exhausting valve of Up chamber Clean or change the
not available , or it be polluted valve
Gasket of up chamber is not Cleaning or change the
available , or it be polluted seal of valve
Air leaking from spring of up chamber be distorted Change the spring
exhausting port when Exhausting valve of doen chamber Clean or change the
the truck brake not available , or it be polluted valve
Gasket of down chamber is not Clean or change the
available , or be polluted valve
Spring of down chamber be Change the up chamber

distorted spring
Input valve of Up chamber not Clean or change the
available , or it be polluted valve
Spring of up chamber be distorted Change the up chamber
spring
Air leaking from
Gasket of up guided ring is not Clean or change
exhausting port when
available , or it be polluted
the truck works
Input valve of down chamber not Clean or change the
available , or it be polluted down chamber valve
Gasket of down guided ring is not Clean or change the
available , or it be polluted gasket
Head nodding or tail Pipeline not in order or signing Arranging pipes in
waving when the brake force on axles was excessive order or adjusting the
truck brake brake force
Rubber spring is in low Change the spring or

Weak breaking flexibility or flow in pipe be lower arrang pipes in order
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1.Spring type compound power-storing brake chamber
(1) function: supply power to the wheel, the cavity of chamber use for normal
braking , the spring cavity use for emergent & parking braking , these two cavity is
separate .
Theory ：
When moving braking ,the pressed air which controlled by foot brake valve enter
“A” chamber via port 11, meanwhile, spring c be pressed by disc a ,then lever b be
pushed out ,by this ,the braking torque come out.
When the truck is on emergent & parking braking , operate the hand brake valve,
by that , pressed air release out from chamber B via port12 , the spring f also put out
the power , bring the braking torque by piston e , disc d , plate a and lever b .
You can also free the parking brake by loosening the bolt g , when there are no
pressed air on chamber.
3 )Faults & solutions:

Air leak from Disc splited or aging Change the disc
Moving braking disc
Hoop loosening Fasten the hoop
chamber
Air leak from spring Gasket of guided canister is not Change gasket or clean
chamber when the available or intermixed by impurity away the impurity
truck moving The gasket of Tub Y is not available
or intermixed , or air leak from the Change gasket or clean
breathing pipe away the impurity
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The gasket between tub and flange Change gasket or clean
not available or intermixed , or joint away the impurity ,then
bolt is loosening fasten 8 bolts
Gasket between guided canister and

pushing plate is not available or Change gasket or clean
intermixed , it lead air leaking from away the impurity
the bolt loosening place
Braking force not The power of big spring be lower or

Change the big spring
enough or can not it cut down
parking Adjusting the length of
Joint fork fit in wrong position
lever
Caution : spring chamber must disassembled by special implement and for special
worker !
3.4-loopline protecting valve
1) Function ：charge to 4-looplines,if some one is not available ,the valve will
protect other loop working normally .
2) Theory :
Pressed air get to chamber A&D,C&D from port 1, when the pressure achieve a
certain level ,the valve be open . then pressed air get to storing canister via port
21,22,23,24 . when one loop is not available ,the pressed air in other loops not leaking
because the valve is single-way type. Meanwhile,the air pressure in these loops acted
on the plate , charging the normal loops from port 1 .the pressed air will leak only
even as the pressure is equal or more than the unavailable loop ,even this , the
pressure is also keeping enough.
3) Faults & solutions
Air leaking from the joint
Plate not available Change the plate
gap
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Can not charge to Change spring or
Valve can not open by reason of
uncertain loop line or be adjust the chamber
excessive spring force , or
hitched caused by output bolt in
spring locked
pressure lower counterclockwise-way
Can`t park by the braking Change spring or
force of front or rear axle. Pressure for close be lower. adjust the chamber
bolt in clockwise
4.Trailer breaking valve
1) Action : this valve fixed on tractor truck chassis which in double pipe breaking
system , use for breaking the air-cut type or emergent breaking type trailer . when pipe
ruptured or air leaks , the truck will brake automatically if it fixed a throttle .
2) Theory
3522CF1 series
In normally working , the pressed air entered from port 43, input valve“h” be
closed and exhausted valve “c” opened , no pressure output from port 2 . when
parking break, the pressed air from 1st loop enter chamber “A” via port 41,pushing
piston “a”, making exhaust valve ”c” closed and input valve ”h” open , the air output
from port 2, the pressure between this and port 41 is a direct ratio .
If loop 1 is not available, there are no pressure coming from port 41, the pressed
air from 2nd chamber enter chamber ”E” via port 42 , pushed plate “e” , then
exhausting valve ”C” closed and input valve “h” open, the pressed air go out from
port 2. When braking release, the pressure on port 41,42 be lower but 43 be
higher ,then input valve “h” closed ,exhausting valve ”C” open, air go out from
port ”2” .
Adjust the bolt ”j” to alter the extend arrange .
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3522CF2 series
In normally working , the pressed air entered from port 11 , make plug “i”
moving up , all the paths of throttle be open , pressure via port 21 be outputted to
trailer charging port , charge to trailer , and go to chamber “c” via port “c”.
When braking pipe of trailer loosening or breaking, there are no pressure setup ,
the pressed air enter chamber “G” via port 41, then plug ”i” move down , throttle
aperture be plug up , lead the air flow which passing port 11,21 be weaker ,
meanwhile, input valve “C” be open , then the pressure go out via port12 ,22 .
working theory of other parts are same with normal trailer breaking valve.
3) Faults & solutions
1 The point which joint 1 Take the valve from kit and
Air leaking from valve assy and up-piston change it ,or repair the seal line
exhausting port when be broken of up-piston
service or parking
2 The point dirtied by 2 Clean all the parts
breaking
scraps
3 Gasket broken 3 Change gasket (take from kit)
Braking force no Pressure in output port be Change the gasket (take from kit)
strong when parking lower or the gasket
brake broken
1The point which joint 1 Take the valve from kit and
valve assy and mid-piston change it ,or repair the seal line
Exhausting port of
be broken of up-piston
service brak leaking
2 The point dirtied by 2 Clean all the parts
air
scraps
3 Gasket broken 3 Change gasket (take from kit)
Port 42 leaking air 1 Plate break 1 Change plate (take from kit)
when normally work 2 Nut loosen 2 Fasten nut
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5.Relay valve
l )Function : make the braking and releasing time shorter . normally fixed on rear
axle.
2) Theory :
When the truck works normally, pressed air comes from the canister via port1 ,
then input valve “d” closed because air pressing and spring returning ,there are no
pressure in chamber ”C” .
When brakes , the pressed air from braking valve enter chamber B via 4 , drive
the big piston moving down , that making valve “e” closed , and pushing valve
base ”c” , then input valve “d” open , the air pressure get balance between chamber
“A” and “C” , so exhausting and input valve both closed .
There are no pressure in chamber ”B” when braking release , the pressure make
piston 7 moving up , then exhausting valve “e” open , but input valve “d” closed , the
pressed air release quickly via exhausting valve “e”. this function is emergent
releasing .
3) Faults & solutions：

Faults
Faults reason Faults solution
description
Gasket of input valve not If gasket ”6” broken or dirty ,
available , or be polluted change or clean.
Checking quadrate seal 4 and the

Air leaking from
exhausting port Gasket of exhausting port sealing line of valve-1, change
when the truck not available , or be quadrate seal 4 if it broken ; if
polluted sealing line incised, polished by
works
emery cloth , both be cleaned .
Focre of valve spring is not Change the spring

enough
Air leaking from
Gasket of exhausting valve Change the valve or clean
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SHACMAN
not available , or be
exhausting port polluted
when the truck Gasket of exhausting port
Change or clean the gasket of
brakes not available , or be
exhausting port
polluted
Slow reaction of O-ring gasket not Checking O-seal 12 , if bad , change
brake available , or be polluted or clean
6. Differential relay valve
Differential relay valve

Function : if in the un-normal situation that service & parking braking operated
at same time , the compound spring endure the double force of break chamber , that
avoid other parts overloading, also make the spring cylinder charging rapidly , this
way can release park baking , keep the service park activity
41 -controlling port(joint the service braking loop)
42 -controlling port(joint the hand braking loop)
1 -cinput port (joint pressed air canister)
2 -output port
Indication : this valve use for take the place of trailer braking relay valve , when
it replacing , main relay valve and other cable are not changing , but the cable of
service braking joint with port 42 by a three-port connector
In normally works, air charging to chamber “A” via the port 42 which controlled
be hand brake. That press piston a&b move down , exhausting valve closed , and the
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valve lever be pushed down , then input valve “d” opened , the pressed air output to
rear chamber of spring brake chamber , so that , braking released , truck works
normally .
If operate the main braking during truck working , the pressed air enter chamber
B via port 41, it pressed piston ”b” down , for the reaction of chamber “A”&”C” , the
pressure in chamber “B” can not influence differential-relay working . pressed air
flow to rear chamber of spring braking chamber , keep park braking releasing ,
If operate the hand braking during truck working , air in chamber “A” will
exhaust partly or completely. Then no pressure on piston “a” , but pressure in chamber
“C” push piston “b” up , lead exhaust valve “e” open , meanwhile lever “c” moving
up, input valve closed .By this ,spring braking cylinder can brake in different force
range by adjusting the position of ever.
If braking by hand brake , exhausting valve be closed after air exhaust , then air
pressure in chamber “A” and ”C” be higher , differential relay valve is in balance
position at this time .
7. Hand brake valve

l)function and theory
When handle “a” on the range of 0°～10° , cam assy ”b” push the piston assy
“c” , by that Spring “l” be pressed , it push valve assy ”h” down , then exhausting
valve closed and input valve open, meanwhile , the spring “n” pushed the extra valve
“m” , input valve closed . the pressed air come from port 11, get chamber”A” via “A” ,
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SHACMAN
then go out from port21. Because chamber “A” is connected with chamber “E”, so air
enter chamber ”C” through extra valve “m” , out from port 22 , then whole truck is in
complete releasing situation.
When handle “a” on the range of 10°～55° , cam assy ”b” move up , by the
action of piston spring 1 , piston ”e” be up, exhausting valve open, same time, by the
action of valve spring “g”, valve assy ”h” move up , so input valve closed, the air
enter chamber “A” from port “21” , go out from port 3 via Valve assy “h”. Because
chamber “A” is connected with “E”, also air come from port 22 but out from port3 .
By the pressure on port21 be lower , then keep balance by spring “d” , and output
pressure P21 , P22 be lower in 0 , because of handle moving .when the handle get to
the reining point, the tractor truck is in completely braking .
When the handle get to the locking position (73°) , handle be lockup , then whole
truck is in completely braking , also input valve closed and exhausting valve open.
When the handle get to the checking position (85°) , cam “b” push the pipe
assy ”i” ,make the valve assy moving down , on extra valve , the exhausting valve
closed but input one open, air pressure come from port11,via chamber ”B” , channel
“D”, chamber ”C” then out from port22,trailer braking released . this way for
checking grade ability braking when in parking brake . when loosening the handle , it
return to parking brake lock point.
2) Faults & Solution
Exhausting valve gasket be
Air leaking from Change or clean the valve
polluted or not available
Valve gasket be polluted or not
in servicing position Change or clean the gasket
available
Input valve gasket be polluted
Air leaking from Change or clean the valve
or not available
Valve gasket be polluted or not
in parking position Change or clean the gasket
available
Bolt loosening or spring not Fasten the bolt or adjust
Torpidly operating
balance spring
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Section 3 air pipeline theory
1. air pipeline of 4x2 trucks
Part of air source analyse : air enter pressing equipment via filter. When air
pressed yet, be sent to the drier, after that , dry air be sent to 4-loopline valve.
Braking loop line of Front axle : pressure adjusting valve in drier adjust the
normal pressure as 7.5～8.0bar, the pressed air be output to 4-loopline valve , then
come to air canister “1” via port21 , then got to port12 of main pump . pressure value
of canister1 showed on the meter who link with a sensor set at port 12 . when braking
pedal be stepped on, air from port 22 pressed the plate of 2 separate chamber , then
caused braking.
Braking loop line of rear axle : pressed air be output from 4-loopline valve via
port 22 , enter canister “2” , then go to port 11 , there is a tee joint which join with a
pressure sensor , the pressure value showed on a meter . when braking pedal be
stepped on , air from port 21 go to the front chamber and supply service braking . the
same pressed air also effected on port41 of Differential Relay valve. If not draw up
the hand brake , this pressure not act on Differential Relay valve but air from port 2
keep the Rear Chamber Spring pressed .
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Parking and emergent braking loop : air from port 24 of 4-loopline be separated
as two line , one get to canister3 , other one go to port 1 of hand brake valve . First
line go to port 11 of trailer brake valve from canister 3, second one became 2 parts
after through a union tee: one go to hand brake valve , other one get to port 1 of
Differential Relay valve . so when put down the hand brake lever and works normally ,
air go from port 21 to 42 , open the Differential Relay valve , release the parking
brake by pressing the rear chamber spring. When draw up the hand brake valve , air in
the loopline releasing completely from port 3 , and air in spring chamber also release
out from port3 , force the spring lever achieving parking brake .
If do parking brake and hand brake at same time , that will hurt the transfer parts
because of overload , the Differential Relay valve will avoid that , the function is
ensuring supplying air to rear chamber although parking brake going with hand brake
at same time. Likewise , if stepping pedal and drawing up the hand brake
simultaneity , only main brake available , but hand brake not .
Double pipe trailer brake: air from trailer brake canister 3 supply to trailer brake
valve , there are two ports , one in red joint for charging , charge to trailer canister ,
the other yellow joint for controlling .there are also 3 controlling port : 41-front axle
braking port ,42-rear axle controlling port ,43-hand braking controlling port .if any
signal input , trailer will be braked .
Assistance air supplying loop: the output port 23 will supply assistance air , for
clutch branch pump assisting , air pressure horn controlling , Differential lock
controlling, flameout and exhaust valve braking ,HI-LO gear controlling, clutch
braking etc .
clutch branch pump assisting :step down the pedal , hydraulic oil from main
pump control the assist pump valve , then supply assistance by pushing the lever .
Electronic air pressure horn : press the horn thumb switch , then push the horn
cover which set on the steering wheel , meantime , horn magnetic valve started , and
air supply to double side horn , they sounds .
Differential lock : press the lock thumb switch , magnetic valve started , then
assisting loop supply air to differential lock cylinder , locking the synchronal setting
of driven axle, that avoid truck slipping.
Flameout and exhaust valve braking : step on the Flameout switch , start the
magnetic valve , then open the halting cylinder of one air loop , by that ,engine
working stopped, then other loop supply air on butterfly valve of WEVB ,
exhausting pipe be plugged up , so speed be slow down.
HI-LO step of gear box :air go from assisting loop via Decompress & Filter
valve , then supply to double H valve , convert the gear between HI - LO .
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SHACMAN
Clutch brake : taking air pressure from LO gear pipe, when step on clutch pedal
for braking , the brake button valve open , air loop connect with the braking cylinder
which on gear box side , then make the gear speed cutting down ,that`s good for
changing the gear when start .
2. 6X4 air loop chart
Air source part : air be filtered then enter the air presser , after be pressed , go to
drier , when drying , the air be send to 4-loop valve .
Braking loop of front axle: booster valve which set in air drier adjust the pressure
as 7.5～8.0bar , the pressure be output to 4-loop valve ,via port21 to air canister 2 ,
then be send to port 12 on main brake pump . there is a union tee connect with a
sensor , which shows the pressure of canister 1 by a meter . when step on the brake
pedal , air from port22 go to 2 braking separate chamber , then brakes.
Braking loop of rear axle : air go from 4-loop valve port 22 to canister1 , then
separate by 2 lines , one goes to port 11 of main braking pump, to a union tee ,
connect with a pressing sensor , it shows the pressure of rear axle canister . Air form
other line go to port1 of Service Braking relay valve. when step on brake pedal , 1st
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SHACMAN
output pipe line via port 21 go to trailer brake valve port 41 , it supply the signal
pressure to trailer ; air from other pipe go to Service Braking relay valve then go to
front of the spring chamber of mid & rear axle.
Parking and emergency braking loop : when air go out of 4-loop valve , via port
24 , it be separated by two line. Line 1 enter air canister 3 , air in other line also be
separated as two part , Part 1 go to port 1 of hand brake via single line valve , Part 2
go to port 1 which set on parking brake relay valve . if put down the hand brake and
move the truck , air go from hand brake port 21 to parking relay valve port4 , force
this valve open , release the brake by press rear chamber spring . when draw up the
hand brake lever for parking brake, air in pipe release out from hand brake valve
port3 . and air in branch spring chamber also release from parking brake relay valve
port3 , then spring lever be pushed out , it`s in parking Brake.
Spill valve: there is a check valve in series with Service brake and Parking brake
valve port. The function is : port21,22,and port 23,24 be separated by two check
valve ,when the pressure which in the front & rear axle braking loop get to the the
value of 7.0bar , it will charge to port23,24 . but for the main braking loop , 6.5bar is
enough for charging . so in order to ensuring the main braking reliable , and
shortening the charging time , we design this Spill valve. If pressure in main brake
loop at the value of 6.5bar ,this valve open , the front & rear axle braking loop
reversely charge to parking brake , promote his valve get to 4.5bar rapidly , then
4-loop valve and assistance pressure loop be open , they charge to the loop , then
truck in normally working.
Double pipeline braking of trailer :air from trailer canister 3 go to trailer brake
valve . There are two output port on this valve , the red one is usual charging port ,
always charge to trailer canister , other yellow one is an controlling port, use for
output air pressure to trailer after the truck braking .there is a input port and 3
controlling port as front axle controlling port 41, rear axle port 42 and manual
controlling port 43 . no matter input signal to each port , trailer is braking .
Assistance air loop part : air from 4-loop valve port 23 go to assistance air pipe
line , this part include clutch branch pump assistance , electronic horn , wheel
differential lock , axle differential lock , flameout and Exhaust Valve Braking , Hi-Lo
gear of transmission ,clutch braking device.
Clutch power assistance : when steps on clutch pedal ,the hydraulic oil push
clutch assistance pump for controlling the valve , then the pressure which come from
assistance air loop force the lever to supply assistance power .
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Wheel Differential lock : press the lock thumb switch , magnetic valve started ,
then assisting loop supply air to differential lock cylinder , locking the synchronal
setting of driven& rear axle, that avoid truck slipping.
Axle Differential lock : press the lock thumb switch , magnetic valve started ,
then assisting loop supply air to differential lock cylinder which set on mid-axle,
locking the synchronal setting of driven & rear axle, that avoid truck slipping.
3.Air pipeline chart of 8x4 trucks
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Part of air source analyse : air enter pressing equipment via filter. When air
pressed yet, be sent to the drier, after that , dry air be sent to 4-loopline valve.
Braking loop line of Double Front axle : pressure adjusting valve in drier adjust
the normal pressure as 7.5～8.0bar, the pressed air be output to 4-loopline valve , then
come to air canister “1” via port21 ,when going out from canister “1” ,it be separated
by two lines , Line 1 supply air to the brake relay valve of Double Front axle . other
line 2 go to port 12 of clutch main pump. At this port , there is a union tee that
connect with a pressure sensor , the sensor shows pressure value of canister 1 by a
meter . when step on braking pedal , port 22 on braking main pump send the air to
relay valve port of Double front axle ,then air from the relay valve go to four eparate
braking chamber , that caused braking.
Braking loop line of rear axle : air go from 4-loop valve port 22 to canister1 ,
then separate by 2 lines , Line 1 goes to port 11 of main braking pump, to a union tee ,
connect with a pressing sensor , it shows the pressure of rear axle canister . air go
from Line 2 to brake relay valve port 1 , when step on brake pedal ,air via brake pump
port 21 go to service brake valve , cause service braking by pressing the front spring
chamber .
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Parking and emergency braking loop : when air go out of 4-loop valve , via port
24 , it be separated by two line. Line 1 enter air canister 3 , air in other line also be
separated as two part , Part 1 go to port 1 of hand brake via single line valve , Part 2
go to port 1 which set on parking brake relay valve . if put down the hand brake and
move the truck , air go from hand brake port 21 to parking relay valve port4 , force
this valve open , release the brake by press rear chamber spring . when draw up the
hand brake lever for parking brake, air in pipe release out from hand brake valve
port3 . and air in branch spring chamber also release from parking brake relay valve
port3 , then spring lever be pushed out , it`s in parking Brake.
Spill valve: there is a check valve in series with Service brake and Parking brake
valve port. The function is : port21,22,and port 23,24 be separated by two check
valve ,when the pressure which in the front & rear axle braking loop get to the the
value of 7.0bar , it will charge to port23,24 . but for the main braking loop , 6.5bar is
enough for charging . so in order to ensuring the main braking reliable , and
shortening the charging time , we design this Spill valve. If pressure in main brake
loop at the value of 6.5bar ,this valve open , the front & rear axle braking loop
reversely charge to parking brake , promote his valve get to 4.5bar rapidly , then
4-loop valve and assistance pressure loop be open , they charge to the loop , then
truck in normally working.
Assistance air loop part : air from 4-loop valve port 23 go to assistance air pipe
line , this part include clutch branch pump assistance , electronic horn , wheel
differential lock , axle differential lock , flameout and Exhaust Valve Braking , Hi-Lo
gear of transmission ,clutch braking device.
Clutch power assistance : when steps on clutch pedal ,the hydraulic oil push
clutch assistance pump for controlling the valve , then the pressure which come from
assistance air loop force the lever to supply assistance power .
Wheel Differential lock : press the lock thumb switch , magnetic valve started ,
then assisting loop supply air to differential lock cylinder , locking the synchronal
setting of driven& rear axle, that avoid truck slipping.
Axle Differential lock : press the lock thumb switch , magnetic valve started ,
then assisting loop supply air to differential lock cylinder which set on mid-axle,
locking the synchronal setting of driven & rear axle, that avoid truck slipping.
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PTO operation: pressing the PTO thumb switch , by the action of normally open
magnetic valve and a normally closed valve , by Line 1, the pressure output to the
hydraulic pump through transmission box. Other Line2 , the pressure shift the gear
which on assistance transmission box ,that ensure the truck no sliding when take
power by shifting the gear .
Page 138

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English Repair Manual WP12

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Service Manual

Chapter 1 Engine (WP12)

Section 1 General introduction

4. WP12 series diesel engine outline drawing (see picture 1-2)

Section 2 Technical and performance specifications

1.Main technical specifications of WP12

2.Main performance specifications of WP12

Unit WP12 Euro Ⅲengine

3. Main specifications of accessories

S. No Name Item WP12 series

idler gear bolt pin M121.5-10.9 105Nm 90

Standard M6 bolt 8.8 8Nm 10.9 13Nm

Section 3 Introduction on engine main structure

Pistons are grouped on weights. Weight difference in same group piston is

When installing engine, mass difference in same connecting rod group is

5. Crankshaft and flywheel

6.Gear system and air distribution structure

1.1 gear systerm drawing

1.2 air valve and EVB clearance adjustment

Piston locates on upper stop position.

●Please choose adherence degree of lubrication according to environment

●Weichai special lubrication is recommended.

1.2 oil basin

8. Oil supply system

Fuel injection and oil supply system

High pressure electric control common rail is newly designed

1.1 Fuel return

1.2 Internally connected high-pressure connection

1.3 Fuel coarse filter components

The capability of coarse filter is limited by minimum filtration temperature.

S. No Name Specifications Descriptions

Exhaust the system by manual pump

Steps: (as illustration 3-9)

1. Stop engine 2. Loose air discharge bolts

4. Refasten air discharge bolts

Drain water out before getting frozen.

Steps (see illustration 3-10)

2. Refasten fuel discharge plug

Replacing water collector

Steps (shown in illustration 3-11)

1. Stop the engine

3. If possible, manually dismantle the bolts of water collector. If it is too tight,

4. Deal with it properly, do not throw.

6. Install bolts manually and screw it with tool.

7. If water utensile will be used on a new spinning filter, check if there is

8. Use torque spanner to install. Torque is 20Nm.

When installing, do not damage spinning filter

Fuel leakage will pollute environment.

The following steps shall by complied to remove filter:

1. Stop the engine

2. Remove the old spinning filter

3. If the utensile is still usable, put it away.

The installation of Spinning filter according to following steps:

1. Lubricate the seal

2. Manually screw filter until seal combined with interface.

4. Exhaust until no air bubble appears

5. Carry out leakage test

Maintenance item Time interval Remarks

Table 9 installation instruction of fuel secondary filter

Only apply to fuel filter

Do not install damaged filter

Clearance under filter cap:262.5mm+length of screw connector

Wipe oil membrane on washer

Put the filter under filter cap