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CHAPTER 1 GENERALINFORMATION

LH50DU SERVICE MANUAL 19.1

CHAPTER 1

GENERAL PAGE. 1- 2

1.1 IMPORTANT INFORMATION

PREPARATION FOR REMOVAL PROCEDURES

1.

Remove all dirt, mud, dust and foreign material before removal and disassembly.

2.

Use proper tools and cleaning equipment.

3.

When disassembling the machine, always keep mated parts together. This includes gears and
other parts that have been ”mated ”through normal wear. Mated part must always be reused or
replaced as an assembly.

4.

During machine disassembly, clean all parts and place them in trays in the order of disassembly.
This will speed up assembly and allow for the correct installation of all parts.

5.

Keep all parts away from any source of fire.

REPLACEMENT PARTS

Use only genuine parts for all replacements. Use recommended oil and grease for all lubrication
jobs. Other brands may be similar in function and appearance, but inferior in quality.

LOCK WASHERS/PLATES AND COTTER PINS

Replace all lock washers/plates and cotter pins
after removal. Bend lock tabs along the bolt or
nut flats after the bolt or nut has been tightened
to specification.

BEARINGS AND OIL SEALS

Install  bearings  and  oil  seals  so  that  the
manufacturer’s  marks  or  numbers  are  visible.
When installing oil seals, apply a light coating of
lightweight  lithium  base  grease  to  the  seal  lips.
Oil  bearings  liberally  when  installing,  if
appropriate.

①

oil seal

CAUTION:

Do not use compressed air to spin the bearings
dry. This will damage the bearing surfaces.

①

Bearing

CIRCLIPS

1.

Check all circlips carefully before reassembly.
Always replace piston pin clips after one use.
Replace distorted circlips. When installing a
circlip

①

, make sure that the sharp-edged

corner

②

is positioned opposite the thrust

③

it receives. See sectional view.

④

Shaft

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Содержание Crossfire E5 2022

Страница 1: ...ent types variants versions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each ATV model for spare parts information and service General Informat...

Страница 2: ...LH50DU SERVICE MANUAL 19 1 LH50DU 19 1...

Страница 3: ...ig nificant changes in specifications or procedures will be forwarded to all authorized Linhai dealers and will appear in future editions of this manual where applicable NOTE Designs and specification...

Страница 4: ...CONTENTS CHAPTER1 General Information CHAPTER2 Maintenance CHAPTER3 Chassis CHAPTER4 Final Drive CHAPTER5 Brakes CHAPTER6 Electrical...

Страница 5: ...s It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Always keep alert and wear protection Crate of the UTV and parts in the UTV maybe have sharp edge always pa...

Страница 6: ...1 GENERAL INFORMATION The parts of different types variants versions maybe un interchangeable even some parts have almost same appearance Always refer to Parts Manual of each CUV model for spare parts...

Страница 7: ...ded oil and grease for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality LOCK WASHERS PLATES AND COTTER PINS Replace all lock washers plates and cotte...

Страница 8: ...d reinset the terminal into the connector 6 Connect Connector NOTE The two connectors click together 7 Check for continuity with a tester NOTE If there is no continuity clean the terminals Be sure to...

Страница 9: ...SION TABLE METRIC TO IMP Known Multiplier Result Torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb In lb ft lb In lb Weight kg g 2 205 0 03527 lb oz Distance km h km m m cm mm 0 6214 0 621...

Страница 10: ...CHAPTER 1 GENERALINFORMATION LH50DU SERVICE MANUAL 19 1 CHAPTER 1 GENERAL PAGE 1 5 1 2 V I N NUMBER The vehicle identification number is stamped 1 into the front of the frame tube...

Страница 11: ...CHAPTER 1 GENERALINFORMATION LH50DU SERVICE MANUAL 19 1 CHAPTER 1 GENERAL PAGE 1 6 1 3 VEHICLE DIMENSIONS...

Страница 12: ...CHAPTER 1 GENERALINFORMATION LH50DU SERVICE MANUAL 19 1 CHAPTER 1 GENERAL PAGE 1 7 NOTES...

Страница 13: ...angeable even some parts have almost same appearance Always refer to Parts Manual of each CUV model for spare parts information and service 2 1 PERIODIC MAINTENANCE 2 2 THROTTLE PEDAL INSPECTION 2 3 C...

Страница 14: ...aintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 16km h 10 miles per hour Vehicles subjected to severe use such as operation in wet or dusty...

Страница 15: ...Monthly C Gear case Oil 150 annually R General Lubrication all fittings pivots cables etc 25 3 months L Shift linkage 50 hrs 6 months I A R if necessary DL Transmission belt 50 hrs 6 months I R if nec...

Страница 16: ...at 100 hours 4 Rear Axle Bearing on swing arm model Grease Locate fittings and grease Every 3 months or 50 hours 5 Steering system Grease Lubricate the pivoting and sliding parts Every 3 months or 50...

Страница 17: ...CHAPTER 2 MAINTENANCE LH50DU SERVICE MANUAL 19 1 CHAPTER 2 MAINTENANCE PAGE 2 5...

Страница 18: ...not open fully If the throttle pedal has no play the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal play periodically in accordance with the Periodic Maint...

Страница 19: ...on is not obtainable inspect choke cable for kinks or sharp bends in routing 2 4 TOE ALIGNMENT METHOD STRAIGHTEDGE OR STRING Be sure the steering wheel in a straight ahead position NOTE String should...

Страница 20: ...and looseness Check surface condition of the disc BRAKE PAD INSPECTION Pads should be changed when friction material is worn to 3 64 1mm HOSE FITTING INSPECTION Check braking system hoses and fittings...

Страница 21: ...one on the lever and apply the lever While adjusting it is important you apply the lever back and forth for operation free play and the locking of the parking position 7 Make sure the rear wheels turn...

Страница 22: ...n 1 Maximum Hard position 5 2 7 WHEELS Inspect all wheels for runout of damage Check wheel nuts and ensure they are tight Do not over tighten the wheel nuts WHEEL REMOVAL 1 Stop and lock the parking b...

Страница 23: ...a tire always use original equipment size and type and replace in pairs especially in 4X4 model The use of non standard size or type tires may affect CUV handling and cause machine damage especially i...

Страница 24: ...TER 2 MAINTENANCE PAGE 2 12 2 9 FRAME NUTS BOLTS FASTENERS Periodically inspect the tightness of all fasteners in accordance with the maintenance schedule Check that all cotter pins are in place Refer...

Страница 25: ...CHAPTER 2 MAINTENANCE LH50DU SERVICE MANUAL 19 1 CHAPTER 2 MAINTENANCE PAGE 2 13 NOTES...

Страница 26: ...even some parts have almost same appearance Always refer to Parts Manual of each CUV model for spare parts information and service 3 1 FRONT A ARM REPLACEMENT 3 2 REAR A ARM REPLACEMENT 3 3 REAR STABI...

Страница 27: ...nuts NOTE Tighten the nuts only finger tighten at this time They will be tightened to the final torque after the front wheels are installed and the vehicle is on the ground DO NOT reuse old bolts Ser...

Страница 28: ...CHAPTER 3 CHASSIS LH50DU SERVICE MANUAL19 1 CHAPTER 3 CHASSIS PAGE 3 3 3 2 REAR A ARM REPLACEMENT...

Страница 29: ...e and safely support vehicle with weight removed from the rear wheel s 2 Remove the wheel nuts and wheel NOTE To ease the removal of the spindle bolt remove the hub cap and loosen the spindle bolts be...

Страница 30: ...off of the axle 6 Remove the bolt that secures the shock and coil to the lower A arm 7 Loosen two bolts that secure the A arm to frame by alternating each about 1 3 of the way until A arm can be remo...

Страница 31: ...to 44 ft lbs 60 Nm DO NOT reuse old bolts Serious injury or death could result if fasteners come loose during operation 13 Attach A arm to rear knuckle Tighten upper and lower bolts to 44 ft lbs 60 Nm...

Страница 32: ...STALLATION 1 Elevate and safely support vehicle with weight removed from the rear wheel s 2 Remove the rear wheel to gain access to the stabilizer bar each side 3 Remove the stabilizer bar nut from th...

Страница 33: ...bilizer bar Inspect the bushings and replace if needed 7 Inspect the stabilizer joint and replace if needed 8 Reverse the procedure for installation Torque the stabilizer bolts to 23 ft lbs 32 Nm 3 4...

Страница 34: ...e sure CUV is secure before beginning this service procedure 3 Remove wheel nuts and wheels 4 Remove cotter pin from ball joint 5 Remove castle nut and separate A arm from ball joint stud 6 Remove scr...

Страница 35: ...ing the rest of the removal process The box is not as stable with the hinge pin removed 7 With the hinge pins removed remov the box from the frame Two people maybe needed to remove the bed from the fr...

Страница 36: ...CHAPTER 3 CHASSIS LH50DU SERVICE MANUAL19 1 CHAPTER 3 CHASSIS PAGE 3 11 3 7 STEERING ASSEMBLY REMOVAL INSTALLATION...

Страница 37: ...ring wheel 2 With the steering wheel holder nut removed remove the steering wheel holder 3 Remove the steering column bolts 4 Remove the upper of the steering column 5 Remove the cotter pins and the t...

Страница 38: ...CHAPTER 3 CHASSIS LH50DU SERVICE MANUAL19 1 CHAPTER 3 CHASSIS PAGE 3 13 NOTES...

Страница 39: ...TORQUE TABLE 4 2 FRONT HUB EXPLODED VIEW 4 3 FRONT HUB REMOVAL INSPECTION 4 4 FRONT HUB INSTALLATION 4 5 FRONT HUB BEARING REPLACEMENT 4 6 FRONT DRIVE AXLE REMOVAL INSPECTION 4X4 4 7 FRONT DRIVE AXLE...

Страница 40: ...other fasteners CAUTION Locking nuts and bolts with pre applied locking agent should be replaced if removed The self locking properties of the nut or bolt are reduced or destroyed during removal 4 2...

Страница 41: ...hub cap cotter pin front spindle nut and washer 7 Rotate each bearing by hand and check for smooth rotation Visually inspect bearing for moisture dirt or corrosion or roughness is evident 4 4 FRONT H...

Страница 42: ...o specified torque 4 5 FRONT HUB BEARING REPLACEMENT 1 Remove outer snap ring 2 Form the back side tap on the outer bearing race with a drift punch in the reliefs as shown 3 Drive bearing out evenly b...

Страница 43: ...5 Stopper Ring 6 Plunging Joint 7 Circlip 8 Bearing 9 Stopper ring 10 Inboard boot NOTE Always order and replace 6 and 8 together REMOVAL 1 Place the vehicle on level ground and set the parking brake...

Страница 44: ...s chapter 2 Move each end of the drive shaft in a circular motion and also a reciprocate for inner one and check the drive shaft joints for excessive wear or play 3 This inner CV joint inboard pivot j...

Страница 45: ...e boot A onto the drive axle and off the inboard joint 3 Wipe out all of the molybdenum disulfide grease within the inboard joint cavity 4 Remove the stopper ring from the inboard joint 5 Remove the i...

Страница 46: ...for wear or damage and replace the joint if necessary 8 Inspect the snap ring groove on the inboard joint for wear or damage 9 Inspect the splines on the inner CV joint for wear or damage 10 Check th...

Страница 47: ...isassembled assemble the bearing as follows a Position the bearing race and install the race into the bearing case Align the steel ball receptacles in both parts b Install the steel balls into their r...

Страница 48: ...band onto the boot Bend down the tab on the boot band and secure the tab with the locking clips and tap them with a plastic hammer Make sure they are locked in place 15 Install the large boot bands on...

Страница 49: ...by the brake line Use wire to hang the caliper to prevent possible damage to the brake line 5 Remove hub cap cotter pin front spindle nut and washer 6 Remove the upper and lower control arm bolts 7 Sl...

Страница 50: ...at of the steps in the REAR HUB AND KNUCKLE REMOVAL section 2 Slide the rear drive axle out of the knuckle by pulling the hub and knuckle assembly outward and down 3 Pull the rear drive axle straight...

Страница 51: ...e rear drive axle into the knuckle 4 Lift knuckle into place and install bolt to upper and lower control arm Torque bolt to 44 ft lbs 60 Nm 5 Install the washer and the spindle retainer nut 6 Install...

Страница 52: ...E EXPLODED VIEW 1 SOCKET HEAD BOLT M8X70 2 SEAL 25X47X7 3 SEAL 30X50X13 5 4 BOLT M8X50 5 DRAIN SCREW 6 WASHER 7 LEFT CASE 8 DOWEL PIN 9 WASHER 18 10 BOLT M18x1 5 11 VENT NOZZLE 12 CLAMPS 13 VENT PIPE...

Страница 53: ...HAFT 7 MID GEAR 8 CLIP 30 9 BEARING 110 10 HEXAGON FLANGE BOLT 11 DIFF CASE 12 OUTPUT GEAR 13 BEARING 6210 14 CLUTCH GEAR 15 Shift Yoke 16 Shift Return Spring 17 Shift Bar 18 Shift Pin 19 Shift Lever...

Страница 54: ...drain from the gearbox Important Clean the plug carefully and Replace the Washer B before Its assembled Fig 1 Fig 1 2 Remove the three Socket Head Bolts A and six Bolts B and Left Case C Fig 2 Fig 2 3...

Страница 55: ...1 CHAPTER 4 FINAL DRIVE 4 17 4 Remove two Bearing 6205 A two Bearing 6304 B Input Gear C and Mid Gear Shaft D Fig 4 Fig 4 5 Remove the Diff Solenoid A Shift Yoke Assembly B Shift Pin C Fig 5 Fig 5 6 R...

Страница 56: ...Spring A and the Shift Lever B and Shift Lever Spring C and Shift Bar D and Shift Yoke E Fig 7 Fig 7 8 Remove the Bearing 6210 A and Bearing 110 E Then remove eight Bolts D remove Output Gear B from...

Страница 57: ...E MANUAL 19 1 CHAPTER 4 FINAL DRIVE 4 19 10 First turn Diff Pinion Mate Gear B 90 and then remove Pinion Mate Thrust Washer A and Diff Pinion Mate Gear B and Side Gear Thrust Washer C and Diff Side Ge...

Страница 58: ...CHAPTER 4 FINAL DRIVE 4 20 4 16 REAR GEAR CASE ASSEMBLY 1 Mount Pinion Mate Thrust Washer A and Diff Pinion Mate Gear B and Side Gear Thrust Washer C and Diff Side Gear D and Diff Case E as shown the...

Страница 59: ...f Cross Pin B Then mount the Diff Roll Pin A Fig 12 Fig 12 3 Mount Output Gear B to Diff Assembly C mount eight Bolts D Then mount the Bearing 6210 A and Bearing 110 E PS Apply Loctite 271 evenly on t...

Страница 60: ...VICE MANUAL 19 1 CHAPTER 4 FINAL DRIVE 4 22 4 Mount the Shift Return Spring A and the Shift Lever B and Shift Lever Spring C and Shift Bar D and Shift Yoke E as shown Fig 14 Fig 14 5 Mount the Clip A...

Страница 61: ...H50DU SERVICE MANUAL 19 1 CHAPTER 4 FINAL DRIVE 4 23 6 Mount the Diff Solenoid A Shift Yoke Assembly B Shift Pin C Fig 16 Fig 16 7 Mount two Bearing 6205 A two Bearing 6304 B Input Gear C and Mid Gear...

Страница 62: ...and Diff Case Assembly C and Clutch Gear D and Coupler E and Nut F Fig 18 PS Apply Loctite 271 evenly on the Bolt F screw thread Tighten the Bolt to a torque of 80 90Nm Fig 18 9 Mount the three Socket...

Страница 63: ...CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19 1 CHAPTER 4 FINAL DRIVE 4 25 10 Mount the oil Drain Screw A and Washer B Add 825 25mL oil 85W 90GL 4 from C Fig 20 Fig 20...

Страница 64: ...CHAPTER 5 FINAL DRIVE LH500U 2 LH500U 2A SERVICE MANUAL16 0 CHAPTER 4 FINAL DRIVE 4 26 NOTES...

Страница 65: ...mation 5 1 SPECIFICATIONS 5 2 TORQUE 5 3 BRAKE SYSTEM SERVICE NOTES 5 4 BURNISHING PROCEDURE 5 5 BRAKE BLEEDING FLUID CHANGE 5 6 PARKING BRAKE AND BRAKE LINE INSPECTION 5 7 PARKING BRAKE ADJUSTMENT 5...

Страница 66: ...sc Thickness 0 177 0 187 4 496 4 750m m 0 167 4 242mm Brake Disc Thickness Variance Between Measurements 0 002 0 051mm Brake Disc Run out 0 005 0 127mm 5 2 TORQUE Item Torque ft lbs except where noted...

Страница 67: ...king effectiveness Braking distance will be extended until brake pads are properly burnished To properly burnish the brake pads use the following procedure 1 Choose an area large enough to safely acce...

Страница 68: ...clear hose to the fitting and place the other end in a clean container Be sure the hose fits tightly on the fitting 6 Slowly pump foot pedal until pressure builds and holds 7 Hold brake pedal on to ma...

Страница 69: ...servoir cover 13 Field test machine at low speed before putting into service Check for proper braking action and pedal reserve With pedal firmly applied pedal reserve should be no less than 1 2 1 3cm...

Страница 70: ...ehicle should not roll while parked 3 If the vehicle moves adjustment is necessary 4 Adjust the parking brake where the cable attaches to the lever assembly on the rear brake caliper Parking Brake Adj...

Страница 71: ...rly 1 Loosen the two brake caliper bolts in equal increments Remove the bolts from the bracket and lift park brake assembly out 2 Measure the thickness of the caliper parking brake pads Replace pads i...

Страница 72: ...ury may occur if machine tips or falls 2 Remove the front wheel 3 Remove the two caliper bolts and caliper from mounting bracket 4 Push caliper piston into caliper bore slowly using a C clamp or locki...

Страница 73: ...ing Bolts Torque 18 ft lbs 25 Nm 4 Slowly pump the brake lever until pressure has been built up Maintain at least 1 2 13 mm of brake fluid in the reservoir to prevent air from entering the brake syste...

Страница 74: ...56 mm Brake Disc Thickness Variance Service Limit 0 002 0 051 mm difference between measurements 3 Mount dial indicator as shown to measure disc runout on the dial indicator Replace the disc if runout...

Страница 75: ...fluid draining INSPECTION Inspect caliper body for nicks scratches or worn Replace caliper as an assembly if any problem exists INSTALLATION 1 Install caliper on hub strut Apply Loctite 242 to screw...

Страница 76: ...line 4 Push caliper piston into caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir...

Страница 77: ...ine 2 Use a wrench to remove the brake line Place a container to catch brake fluid draining from brake lines 3 After the fluid has drained into the container remove the caliper mounting bolts and remo...

Страница 78: ...pad contact surface using a 0 1 micrometer and a dial indicator Replace disc if worn beyond service limit Brake Disc Thickness New 0 150 0 164 3 810 4 166 mm Service Limit 0 140 3 556 mm Brake Disc Th...

Страница 79: ...CHAPTER5 BRAKES LH50DU SERVICE MANUAL19 1 CHAPTER 5 BRAKES PAGE 5 15 NOTES...

Страница 80: ...CHAPTER5 BRAKES LH50DU SERVICE MANUAL19 1 CHAPTER 5 BRAKES PAGE 5 15...

Страница 81: ...CHAPTER 6 ELECTRICAL CTRICAL PAGE6 1 CHAPTER 6 ELECTRICAL 6 1 PARTS INSPECTION AND SERVICE 6 2 BATTERY 6 3 Vehicle travel system 6 4 CHARGING SYSTEM 6 5 LIGHTING SYSTEM 6 6 SPEEDOMETER SYSTEM 6 7 MAI...

Страница 82: ...tally except the light on handlebar 2 Place the vehicle on a level surface with the headlight approximately 25 7 6m from a wall 3 Measure the distance from the floor to the center of the headlight and...

Страница 83: ...produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEER OUT OF REACH OF CHILDREN WARNIN...

Страница 84: ...contactor 5 Emergency stop switch 11 Wiring connection 6 Motor controller 1 Fuse NO CONTINUITY Replace the fuse CONTINUITY replace the DC DC Voltage Converter Refer to DC DC Voltage Converter INSPECT...

Страница 85: ...o the 60V power supply as shown in the figure above there is a 12 V 13 8V voltage between terminal and terminal Measuring with a multimeter CORRECT 4 Charger Check the charger Confirm the Charger Char...

Страница 86: ...switch Normal working state State of emergency note When a vehicle is in danger the user should press the emergency stop switch at the first time The vehicle will not be able to drive or charge after...

Страница 87: ...tor encoder Check whether the encoder wiring is correct 4 sounds one long and four short Motor Controller Overheating Turn off the Main switch Cooling Controller 5 sounds one long and five short The r...

Страница 88: ...Motor check Connections with the controller are normal and when you tap the accelerator you find that the car doesn t move or it jitters at a very slow speed The motor encoder is normal but the motor...

Страница 89: ...HAPTER 6 ELECTRICAL CTRICAL PAGE6 9 8 Main switch check 9 accelerator 1 Accelerator switching signal 2 Acceleration control signal 3 Accelerator power supply negative pole 4 Accelerator power supply p...

Страница 90: ...ove press the pedal to the termination position lightly and check the voltage value of terminal 2 and 3 with the multimeter It fits the figure below 10 DC contactor The DC contactor terminal C and ter...

Страница 91: ...CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19 1 CHAPTER 6 ELECTRICAL CTRICAL PAGE6 11 Travel system CIRCUIT DIAGRAM...

Страница 92: ...CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19 1 CHAPTER 6 ELECTRICAL CTRICAL PAGE6 12...

Страница 93: ...UIT DIAGRAM Connecting positive and negative poles of battery pack Red Wire Connecting Positive Pole 1 Charging interface 2 Charger socket 3 Charger body 4 Charging display lamp 5 Battery temperature...

Страница 94: ...on Normal working state State of emergency 2 Wiring connection Check the connection of the changing system Refer to CIRCUIT DIAGRAM 3 Charging display lamp Charging capacity 80 flashing interval of re...

Страница 95: ...ing system 1 Fuse NO CONTINUITY Replace the fuse CONTINUITY 2 Battery Check the battery condition INCORRECT Clean battery terminals Recharge or replace the battery Refer to BATTERY INSPECTION CORRECT...

Страница 96: ...re lighting system POOR CONNECTIONS correct 6 6 LCD Meter 1 Engine working hour counter and The odometer 7 Turn indicator light L 8 Turn indicator light R 2 Voltmeter 9 Reverse indicator light 3 gear...

Страница 97: ...CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19 1 CHAPTER 6 ELECTRICAL CTRICAL PAGE6 17 6 8 WIRING DIAGR...

Страница 98: ...CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19 1 CHAPTER 6 ELECTRICAL CTRICAL PAGE6 18 NOTES...

Страница 99: ...CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19 1 CHAPTER 6 ELECTRICAL CTRICAL PAGE6 19...

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