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Linhai Crossfire E5 2022 Service Manual
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Linhai Crossfire E5 2022 Service Manual

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SERVICE MANUAL
19.1
LH50DU
WARNING
The parts of different 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 Information
※
Maintenance
※
Electrical
※
Chassis
※
Final Drive
※
Brakes
※

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Summary of Contents for Linhai Crossfire E5 2022

  • Page 1 SERVICE MANUAL 19.1 LH50DU WARNING The parts of different 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 Information ※ Maintenance ※...
  • Page 2 LH50DU SERVICE MANUAL 19.1 LH50DU 维修手册欧标英文 版本 19.1...
  • Page 3 NOTICE This manual was produced by the Linhai Group primarily for use by Linhai dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Linhai vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle repair.
  • Page 4 CONTENTS CHAPTER1 ……………………………………………………….General Information CHAPTER2 ………………………………………….……………………Maintenance CHAPTER3…………………………………………..…………………………Chassis CHAPTER4………………………………………………….……………….Final Drive CHAPTER5………………………………………………………………………Brakes CHAPTER6………………………………………………….….……………..Electrical...
  • Page 5 Battery electrolyte is poisonous. 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 pay attention and wear protection.
  • Page 6 CHAPTER 1 GENERALINFORMATION LH50DU SERVICE MANUAL 19.1 CHAPTER 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 information and service. 1.1 IMPORTANT INFORMATION 1.2 V.I.N NUMBER 1.3 VEHICLE DIMENSIONS...
  • Page 7 CHAPTER 1 GENERALINFORMATION LH50DU SERVICE MANUAL 19.1 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.
  • Page 8 CHAPTER 1 GENERALINFORMATION LH50DU SERVICE MANUAL 19.1 CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect:  Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three. 4.
  • Page 9 CHAPTER 1 GENERALINFORMATION LH50DU SERVICE MANUAL 19.1 CONVERSION TABLE How to use the CONVERSION TABLE Use this table to convert METRIC unit data to IMPERIAL unit data. METRIC MULIPLIER **mm 0. 3937 **in **cm 0.03937 **in CONVERSION TABLE METRIC TO IMP Known Multiplier Result...
  • Page 10 CHAPTER 1 GENERALINFORMATION LH50DU SERVICE MANUAL 19.1 V.I.N NUMBER The vehicle identification number is stamped ○ into the front of the frame tube. CHAPTER 1 GENERAL PAGE. 1- 5...
  • Page 11 CHAPTER 1 GENERALINFORMATION LH50DU SERVICE MANUAL 19.1 VEHICLE DIMENSIONS CHAPTER 1 GENERAL PAGE. 1- 6...
  • Page 12 CHAPTER 1 GENERALINFORMATION LH50DU SERVICE MANUAL 19.1 NOTES CHAPTER 1 GENERAL PAGE. 1- 7...
  • Page 13 CHAPTER 2 MAINTENANCE LH50DU SERVICE MANUAL 19.1 CHAPTER 2 MAINTENANCE 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 information and service. 2.1 PERIODIC MAINTENANCE 2.2 THROTTLE PEDAL INSPECTION 2.3 CHOKE ADJUSTMETN...
  • Page 14 CHAPTER 2 MAINTENANCE LH50DU SERVICE MANUAL 19.1 2.1 PERIODIC MAINTENANCE GENARAL CAUTION Mark on the following chart DL ： Due to the nature of the adjustments marked with a DL on the following chart, it is recommended that service be performed by an authorized dealer. ▲：...
  • Page 15 CHAPTER 2 MAINTENANCE LH50DU SERVICE MANUAL 19.1 Headlamp Inspection Daily apply dielectric grease to connector when replaced Tail lamp inspection Daily apply dielectric grease to socket when replaced ▲ Transmission Oil Level Monthly change annually Battery Terminals Monthly Battery fluid level Monthly Brake pad wear Monthly...
  • Page 16 CHAPTER 2 MAINTENANCE LH50DU SERVICE MANUAL 19.1 ▲ Ball joint (A arm- strut) 10 hrs monthly I, (for damage, wear, and play) R. Replace if necessary LUBRICANT AND FLUID Item Lube Rec Method Frequency  1. brake pedal Grease Grease, inspect Monthly hours 2.Brake Fluid...
  • Page 17 CHAPTER 2 MAINTENANCE LH50DU SERVICE MANUAL 19.1 CHAPTER 2 MAINTENANCE PAGE. 2-...
  • Page 18 CHAPTER 2 MAINTENANCE LH50DU SERVICE MANUAL 19.1 LUBRICATION RECOMMENDATIONS NOTE: 1.More often under severe use, such as wet or dusty conditions. 2.Grease: Light weight lithium-soap grease. 3.Grease M：Molybdenum disulfide (MoS ) grease (water resistant). 4.When suspension action becomes stiff or after washing. 5.Hours are based on 10 mph(16Km/h) average.
  • Page 19 CHAPTER 2 MAINTENANCE LH50DU SERVICE MANUAL 19.1 2.3 CHOKE ADJUSTMENT If the choke knob does not stay out when pulled, adjust the choke tension by tightening (clockwise) the chock cable boot until the choke slider freely but stays out when pulled. If smooth choke operation is not obtainable, inspect choke cable for kinks or sharp bends in routing 2.4 TOE ALIGNMENT...
  • Page 20 CHAPTER 2 MAINTENANCE LH50DU SERVICE MANUAL 19.1 2.5 BRAKING SYSTEM INSPECTION The following checks are recommended to keep the braking system in good operating condition. Service life of braking system components depends on operating conditions. Inspect brakes in accordance with the maintenance schedule and before each ride Keep fluid level in the master cylinder reservoir to the indicated level on reservoir.
  • Page 21 CHAPTER 2 MAINTENANCE LH50DU SERVICE MANUAL 19.1 2. If the rear wheels are locked, it is adjusted properly. 3. If the wheels are not locked, it must be adjusted. To adjust (set up) the mechanical parking brake, use the following procedure Note: The adjusting on the caliper is for the wear out of the pads.
  • Page 22 CHAPTER 2 MAINTENANCE LH50DU SERVICE MANUAL 19.1 necessary. REAR SUSPENSION Compress and release rear suspension. Damping should be smooth throughout the range of travel. Check all rear suspension components for wear or damage. Inspect shock for leakage Shock spring preload can be adjusted using the shock spanner wrench.
  • Page 23 CHAPTER 2 MAINTENANCE LH50DU SERVICE MANUAL 19.1 Torque listed in the table. On wheel nuts, Make sure tapered end of nut goes into taper on wheel. Wheel Nut Torque Specifications Bolt Size Specification Front M12X1.25 69Ft.Lbs 95Nm Rear M12X1.25 69Ft.Lbs 95Nm CAUTION: If wheels are improperly installed it could affect Vehicle handling and tire wear.
  • Page 24 CHAPTER 2 MAINTENANCE LH50DU SERVICE MANUAL 19.1 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 to specific fastener torques listed in each chapter. CHAPTER 2 MAINTENANCE PAGE.
  • Page 25 CHAPTER 2 MAINTENANCE LH50DU SERVICE MANUAL 19.1 NOTES CHAPTER 2 MAINTENANCE PAGE. 2- 13...
  • Page 26 CHAPTER 3 CHASSIS LH50DU SERVICE MANUAL19.1 CHAPTER 3 CHASSIS WARNING 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 information and service. 3.1 FRONT A-ARM REPLACEMENT 3.2 REAR A-ARM REPLACEMENT 3.3 REAR STABILIZER BAR REMOVAL/INSTALLATION...
  • Page 27 CHAPTER 3 CHASSIS LH50DU SERVICE MANUAL19.1 3.1 FRONT A-ARM REPLACEMENT 1. Elevate and safely support vehicle with weight removed from front wheel(s). 2. Remove cotter pin from ball joint stud at wheel end of A- arm and loosen nut until it is flush with end of stud.
  • Page 28 CHAPTER 3 CHASSIS LH50DU SERVICE MANUAL19.1 3.2 REAR A-ARM REPLACEMENT CHAPTER 3 CHASSIS PAGE. 3-...
  • Page 29 CHAPTER 3 CHASSIS LH50DU SERVICE MANUAL19.1 1. Elevate 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 before removing the wheel.
  • Page 30 CHAPTER 3 CHASSIS LH50DU SERVICE MANUAL19.1 4. Remove the brake caliper. Suspend the brake caliper from the frame with a wire. NOTE: Do not let the brake caliper hand from the brake line or damage may occur. 5. Loosen two bolts that secure the rear knuckle to the A-arm.
  • Page 31 CHAPTER 3 CHASSIS LH50DU SERVICE MANUAL19.1 11. Insert new A-arm bushings and new A-arm shaft into new A-arm. 12. Install new A-arm assembly onto vehicle frame. Apply Loctite™ 242 to screw threads of the A arm bolts and torque bolts to 44 ft. lbs. (60 Nm ). DO NOT reuse old bolts.
  • Page 32 CHAPTER 3 CHASSIS LH50DU SERVICE MANUAL19.1 3.3 REAR STABILIZER BAR REMOVAL/INSTALLATION 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 the lower A-arm, each side.
  • Page 33 CHAPTER 3 CHASSIS LH50DU SERVICE MANUAL19.1 5. Remove the stabilizer from the fram. 6. Inspect the stabilizer 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).
  • Page 34 CHAPTER 3 CHASSIS LH50DU SERVICE MANUAL19.1 4. Remove coil spring and collapse strut body. 5. Remove two pinch bolts from strut body. 6. Remove strut body. 7. Install front shock cartridge until bottomed in strut casting. 8. Install pinch bolts with clamp(s). Torque pinch bolts to 15ft.lbs.(21Nm). 9.
  • Page 35 CHAPTER 3 CHASSIS LH50DU SERVICE MANUAL19.1 machine. 3.6 BOX REMOVAL/INSTALLATION Box Removal 1. Disconnect the license light coupler. 2. Lift the box into the dump position. 3. Remove the box shock pin from the frame (both sides). 4. Remove the shocks from the shock brackets. Let the shocks fully extend.
  • Page 36 CHAPTER 3 CHASSIS LH50DU SERVICE MANUAL19.1 3.7 STEERING ASSEMBLY REMOVAL/INSTALLATION CHAPTER 3 CHASSIS PAGE. 3- 11...
  • Page 37 CHAPTER 3 CHASSIS LH50DU SERVICE MANUAL19.1 1. With the steering wheel cover bolts removed, remove the steering wheel cover and the steering wheel. 2. With the steering wheel holder nut removed, remove the steering wheel holder. 3. Remove the steering column bolts. 4.
  • Page 38 CHAPTER 3 CHASSIS LH50DU SERVICE MANUAL19.1 NOTES CHAPTER 3 CHASSIS PAGE. 3- 13...
  • Page 39 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 CHAPTER 4 FINAL DRIVE WARNING The parts of different types/ variants/ versions maybe un-interchangeable, even some parts have almost same appearance. Always refer to Parts Manual of each UTV model for spare parts information and service.
  • Page 40 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 4.1 WH E E L , H U B , AND SPINDLE TORQUE TABLE Item Specification heel Nuts 69 Ft.Lbs 95 Nm Front W heel Nuts 69 Ft.Lbs 95 Nm Rear W Front Hub Nut on Spindle/ outer CV joint 101 Ft.Lbs 137 Nm Rear Hub Retaining Nut...
  • Page 41 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 tire/Wheel firmly and checking for movement. 3. Grasp the top and bottom of the tire. The tire should rotate smoothly without binding or rough spots. 4. Remove wheel nuts and wheel. 5. Remove the two brake caliper mounting bolts. CAUTION: Do not hang the caliper by the brake line.
  • Page 42 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 spindle in different directions. Install hub cap. 7. Rotate hub. It should rotate smoothly without binding or rough spots or side play. 8. Install brake caliper using new bolts. (Apply Loctite™ 242 to threads) Tighten bolts to 18 ft.lbs (24 Nm) CAUTION: New bolts have a pre-applied locking agent which is destroyed bolts upon removal.
  • Page 43 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 damage. Replace housing if damaged. 4.6 FRONT DRIVE AXLE REMOVAL/INSPECTION (4X4) NOTE: The outer CV joint cannot be disassembled or repaired, if damage or faulty the drive axle assembly must be replace. 1.
  • Page 44 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 3. Hold the drive shaft straight out. 4. Place a tire lever between the inner CV joint and the differential housing, with a small piece of wood against the housing to help get "leverage" and protect the casting.
  • Page 45 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 ring has locked into the front differential side gear groove. 4. Carefully install the outer CV joint (spindle) into the strut，install the front hub and wheel. 5. Install the ball joint on the A arm, the steering tie rods, the hubs and the wheels as described in this Chapter and Chapter 4.
  • Page 46 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 bearing race for wear or damage. 3. Check for wear or damage to the inner splines of the bearing race. 4. If necessary, disassembly the bearing assembly for further inspection. Carefully remove the steel balls from the bearing cage then remove the bearing race from the bearing cage.
  • Page 47 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 NOTE: Inner CV joint must be replaced with the bearing as an assembly. 4.9 FRONT DRIVE AXLE ASSEMBLY (4X4) 1. The rubber boots are not identical and must be installed on the correct joint. The boots are marked as follows: a.
  • Page 48 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 11. After the stopper ring is in place, fill the inboard joint cavity behind the bearing assembly with additional molybdenum disulfide grease. 12. Pack each boot with the following amounts of molybdenum disulfide grease: a.
  • Page 49 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 4.11 REAR HUB AND KNUCKLE REMOVAL/INSPECTION 1. Elevate rear end and safely support machine under main frame area. CAUTION: Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service...
  • Page 50 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 7. Lower the vehicle. Torque the spindle retaining nut to 101 ft.lbs. (137 Nm). Install a new cotter key and the hub cap. 8. Install brake caliper using new bolts. (Apply Loctite™ 242 to threads) Tighten bolts to 18 ft.lbs (24 Nm) 4.13 REAR DRIVE SHAFT REMOVAL 1.
  • Page 51 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 2. Reinstall the rear driveshaft into the rear gearcase. Be sure the circlip is securely fit into the rear gearcase. Use a rubber mallet to tap on the outboard end of the driveshaft if necessary. 3.
  • Page 52 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 4.15 REAR GEAR CASE DISASSEMBLY REAR GEARCASE EXPLODED VIEW SOCKET HEAD BOLT M8X70 SEAL 25X47X7 SEAL 30X50X13.5 BOLT M8X50 DRAIN SCREW WASHER LEFT CASE DOWEL PIN WASHER 18 BOLT M18x1.5 VENT NOZZLE CLAMPS VENT PIPE DIFF SOLENOID...
  • Page 53 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 BEARING 6205 INPUT GEAR COUPLER NUT M16X1.5 BEARING 6304 MID GEAR SHAFT MID GEAR CLIP 30 BEARING 110 HEXAGON FLANGE BOLT DIFF CASE OUTPUT GEAR BEARING 6210 CLUTCH GEAR Shift Yoke Shift Return Spring Shift Bar Shift Pin Shift Lever Spring...
  • Page 54 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 1. Remove the oil Drain Screw A and let the oil drain from the gearbox. Important: Clean the plug carefully and Replace the Washer B before Its assembled. →Fig 1 Fig 1 2.
  • Page 55 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 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.
  • Page 56 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 7. Remove the Shift Return 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 Diff Assembly C.
  • Page 57 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 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 Gear D and Diff Case E. →Fig 10 Fig 10 CHAPTER 4...
  • Page 58 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 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, then turn Diff Pinion Mate Gear B 90 °.
  • Page 59 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 2. Mount the Diff 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.
  • Page 60 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 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 and Bearing 206 B. →Fig 15 Fig 15 CHAPTER 4...
  • Page 61 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 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 Shaft D. →Fig 17 Fig 17 CHAPTER 4...
  • Page 62 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 8. Mount the Input Gear A and Mid Gear Shaft B 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.
  • Page 63 CHAPTER 4 FINAL DRIVE LH50DU SERVICE MANUAL 19.1 10. Mount the oil Drain Screw A and Washer B. Add 825±25mL oil(85W/90GL-4) from C →Fig 20 Fig 20 CHAPTER 4 FINAL DRIVE. 4- 25...
  • Page 64 CHAPTER 5 FINAL DRIVE LH500U-2/LH500U-2A SERVICE MANUAL16.0 NOTES CHAPTER 4 FINAL DRIVE. 4- 26...
  • Page 65 CHAPTER5 BRAKES LH50DU SERVICE MANUAL19.1 CHAPTER 5 BRAKES WARNING The parts of different 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. NOTE: Also See Chapter 2 for Maintenance Information.
  • Page 66 CHAPTER5 BRAKES LH50DU SERVICE MANUAL19.1 5.1 SPECIFICATIONS Front Brake Caliper Item Standard Service Limit Brake Pad Friction material 0.157"/ 4mm 0.04"/ 1mm Thickness B rake Disc Thickness 0.150- 0.164"/3.810- 4.166mm 0.140"/ 3.556mm Brake Disc Thickness Variance 0.002 "/ .051m m Between Measurements Brake Disc Runout 0.005 "/ .127mm...
  • Page 67 CHAPTER5 BRAKES LH50DU SERVICE MANUAL19.1  Check and adjust master cylinder reservoir fluid level after pad service.  Make sure atmospheric vent on reservoir is unobstructed.  Adjust foot brake after pad service.  Test for brake drag after any brake system service and investigate cause if brake drag is evident.
  • Page 68 CHAPTER5 BRAKES LH50DU SERVICE MANUAL19.1 This procedure should be used to change fluid or bleed brakes during regular maintenance. 1. Clean reservoir cover thoroughly. 2. Remove cover from reservoir. 3. If changing fluid, remove old fluid from reservoir with a brake fluid pump or similar tool. 4.
  • Page 69 CHAPTER5 BRAKES LH50DU SERVICE MANUAL19.1 calipers. 11. Add brake fluid to MAX level inside reservoir. Master Cylinder Fluid Level Between the MIN line and the MAX line of reservoir. 12. Install master cylinder reservoir cover. 13. Field test machine at low speed before putting into service.
  • Page 70 CHAPTER5 BRAKES LH50DU SERVICE MANUAL19.1 2. Inspect the parking brake cable at the parking brake lever assembly on the brake caliper. 3. Inspect the brake lines and brake line connections for possible leaks or loose lines. 5.7 PARKING BRAKE ADJUSTMENT Parking Brake Inspection 1.
  • Page 71 CHAPTER5 BRAKES LH50DU SERVICE MANUAL19.1 5.8 PARKING BRAKE REAR CALIPER REMOVAL / INSTALL Park Brake Caliper Disassembly / Pad Inspection NOTE: Do not get oil, grease, or fluid on the park brake pads. Damage to the pads may cause the pads to function improperly.
  • Page 72 CHAPTER5 BRAKES LH50DU SERVICE MANUAL19.1 5.9 FRONT PAD REMOVAL / INSPECTION / INSTALLATION NOTE: The brake pads should be replaced as a set REMOVAL 1. Elevate and support front of CUV safely. CAUTION: Use care when supporting vehicle so that it does not tip or fall.
  • Page 73 CHAPTER5 BRAKES LH50DU SERVICE MANUAL19.1 INSPECTION Measure the thickness of the pad friction material. Replace pads if worn beyond the service limit. Service Limit 0.3/64"(1 mm) INSTALLATION 1. Lubricate mounting bracket pins with a light film of All Season Grease, and install rubber dust boots.
  • Page 74 CHAPTER5 BRAKES LH50DU SERVICE MANUAL19.1 REMOVAL / REPLACEMENT 5.10 FRONT DISC INSPECTION / INSPECTION 1. Visually inspect the brake disc for nicks, scratches, or damage. 2. Measure the disc thickness at 8 different points around the pad contact surface using a 0-1" micrometer and a dial indicator.
  • Page 75 CHAPTER5 BRAKES LH50DU SERVICE MANUAL19.1 5.11 FRONT CALIPER REMOVAL/ INSPECTION / INSTALLATION CAUTION: The caliper is a non-serviceable Component; it must be replaced as an assembly. NOTE: If any special service needed, contact the CUV manufacture via the agent for the parts and special instruction.
  • Page 76 CHAPTER5 BRAKES LH50DU SERVICE MANUAL19.1 5.12 REAR BRAKE PAD REMOVAL/ INSPECTION / INSTALLATION NOTE: The brake pads should be replaced as a set. REMOVAL 1. Elevate and support rear of CUV safely. CAUTION: Use care when supporting vehicle so that it does not tip or fall.
  • Page 77 CHAPTER5 BRAKES LH50DU SERVICE MANUAL19.1 been built up. Maintain at least 1/2 ". (13 mm) of brake fluid in the reservoir to prevent air from entering the brake system. 5. Install wheels, burnishing procedure should be performed. 5.13 REAR CALIPER REMOVAL/ INSPECTION/ INSTALLATION CAUTION: The caliper is a non-serviceable Component;...
  • Page 78 CHAPTER5 BRAKES LH50DU SERVICE MANUAL19.1 recheck assembly and installation. 11. Install the rear wheel and wheel nuts. Carefully lower the vehicle. NOTE: If new brake pads are installed, it is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise.
  • Page 79 CHAPTER5 BRAKES LH50DU SERVICE MANUAL19.1 NOTES CHAPTER 5 BRAKES PAGE. 5- 15...
  • Page 80 CHAPTER5 BRAKES LH50DU SERVICE MANUAL19.1 CHAPTER 5 BRAKES PAGE. 5- 15...
  • Page 81 CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19.1 CHAPTER 6 ELECTRICAL PARTS INSPECTION AND SERVICE BATTERY Vehicle travel system CHARGING SYSTEM LIGHTING SYSTEM SPEEDOMETER SYSTEM MAIN SWITCH AND HANDLE SWITCH WIRING DIAGRAM CHAPTER 6 ELECTRICAL CTRICAL PAGE6...
  • Page 82 CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19.1 6.1　PARTS INSPECTION AND SERVICE A HEADLIGHT ADJUSTMENT 1. Use bulb 12V 35W/35W. 2. Pull the cable plug off the conducting strip in the socket, remove the clip① before dismounting the bulb. 3. Fit a new bulb into the socket, sitting properly in the three slots, install the clip as shown in the fig.
  • Page 83 CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19.1 TAILLIGHT / BRAKELIGHT LAMP REPLACEMENT 1. Remove the cover. 2. Turn the plug and remove it from the sockrt. 3. Fit the plug in the socket and reassemble the cover. 6.2 BATTERY Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing Antidote: External: Flush with water.
  • Page 84 CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19.1 6.3 Vehicle travel system Procedure Check: 1. Fuse (Main) 7.Motor 2. Battery 8.Main switch 9. accelerator DC-DC Voltage Converter 4.Charger DC contactor 5. Emergency stop switch 11.Wiring connection 6. Motor controller 1、Fuse NO CONTINUITY Replace the fuse. CONTINUITY 2.
  • Page 85 CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19.1 Connect the three-hole plug-in to the 60V power supply as shown in the figure above ，there is a 12 V-13.8V voltage between Ⅳ terminal and Ⅴ terminal(Measuring with a multimeter)。 CORRECT 4、 Charger  Check the charger Confirm the Charger Charging Lock Terminal A and Main Cable Connection Reliable （...
  • Page 86 CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19.1 acceleration signals） 。 Refer to " Charger INSPECTION" CORRECT 5、Emergency stop 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 pressing the emergency stop switch When the emergency stop switch is in normal working state, the terminals A and B are connected。...
  • Page 87 CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19.1 6.1 MOTOR Controller alarm MOTOR Controller alarm code No Alarm mode Alarm meaning Reasons for failure and treatment methods Motor Controller accelerator pedal 1、The accelerator has an acceleration Keep on ringing fault signal when Main switch is turned on。 Check whether the accelerator pedal is stuck 2、Poor contact with main cable...
  • Page 88 CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19.1 6.2 Check whether the three-phase wiring between motor and controller is reliable. Poor contact can cause damage to the controller. Motor Encoder 7、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.
  • Page 89 CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19.1 8.Main switch check 9. accelerator 1、Accelerator switching signal 2、Acceleration control signal 3、Accelerator power supply negative pole 4、Accelerator power supply positive pole Inspection methods and procedures CHAPTER 6 ELECTRICAL CTRICAL PAGE6...
  • Page 90 CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19.1 Connect the terminal 3 of the accelerator to the terminal 4 with 12 V DC power supply according to the figure above, 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.
  • Page 91 CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19.1 Travel system CIRCUIT DIAGRAM CHAPTER 6 ELECTRICAL CTRICAL PAGE6 11...
  • Page 92 CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19.1 CHAPTER 6 ELECTRICAL CTRICAL PAGE6 12...
  • Page 93 CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19.1 6.4 CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM Connecting positive and negative poles of battery pack (Red Wire Connecting Positive Pole) Charging interface： 1、 Charger socket 2、 Charger body 3、 Charging display lamp： 4、 Battery temperature sensor 5、...
  • Page 94 CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19.1 Inspection methods and procedures 1、Emergency stop switch Confident that the emergency stop switch is in normal working state, If not, pull out the switch button。 Normal working state State of emergency 2.Wiring connection Check the connection of the changing system, Refer to “CIRCUIT DIAGRAM”. Charging display lamp Charging capacity <...
  • Page 95 CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19.1 6.5　LIGHTING SYSTEM 1. Fuse (Main) 4.Lights switch 2. Battery 5. DC-DC converters 3. Main switch Wiring connection (entire lighting system) 1、Fuse NO CONTINUITY Replace the fuse. CONTINUITY 2. Battery  Check the battery condition. INCORRECT Clean battery terminals.
  • Page 96 CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19.1 replace the “ DC-DC Voltage Converter” 。 Refer to " INSPECTION" DC-DC Voltage Converter 6. Wiring connection (entire lighting system) Check the connection of the entire lighting system POOR CONNECTIONS correct 6.6 LCD Meter 1. Engine working hour counter 7.
  • Page 97 CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19.1 6.8　WIRING DIAGR CHAPTER 6 ELECTRICAL CTRICAL PAGE6 17...
  • Page 98 CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19.1 NOTES CHAPTER 6 ELECTRICAL CTRICAL PAGE6 18...
  • Page 99 CHAPTER 6 ELECTRICAL LH50DUSERVICE MANUAL19.1 CHAPTER 6 ELECTRICAL CTRICAL PAGE6 19...

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