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DongFeng DFA1101GZ5AD6J-907 Service Manual

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DFA1101GZ5AD6J-907
SERVICE MANUAL
DONGFENG AUTOMOBILE CO.,LTD
2006.05

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Summary of Contents for DongFeng DFA1101GZ5AD6J-907

  • Page 1 DFA1101GZ5AD6J-907 SERVICE MANUAL DONGFENG AUTOMOBILE CO.,LTD 2006.05...
  • Page 2 INDEX General Principles Clutch Gearbox Propeller Shaft Steering System Front Axle Rear Axle Suspension System Brake System Electric System...

  • Page 3: Table Of Contents

    General Principles Table of Conntents General Principles...................GL-1 Operational Instruction ...................GL-2 Standard Terms....................GL-2 Standard Tightening Torque ................GL-2 Maintenance Rule ...................GL-3 Recommended Fuel and Lubricant..............GL-6 Protective Measures while Repairing .............GL-8 Cleaning......................GL-9 Generic Inspection ..................GL-9 Trouble Analysis...................GL-10...

  • Page 4: General Principles

    Maintenance method varies with different skill level, methods, tools and available parts that serviceman adopts. Any serviceman should firstly take into consideration no harm personal safety and vehicle safety when working. As for the maintenance of engine, please refer to service documents offered by DongFeng Cummins Engine Co., Ltd. GL-1...

  • Page 5: Operational Instruction

    General Principles Operational Instruction You can neglect the structural differences between the part in the manual and the corresponding one of your vehicle, because the manual is just teaching you principles for your operation. Standard Terms Vehicle direction Vehhicle direction referred in the manual is marked as the right picture.

  • Page 6: Maintenance Rule

    General Principles Maintenance Rule Maintenance Schedule It's necessary for periodical inspection and maintenance of truck to prolong its service life, improve its power performance and fuel economy, so periodical inspection and maintenance should be carefully carried out accord- ing to the following items. Then it will achieve the max economic and social benefits. The following schedule is not only for maintenance items of 80,000km, but also for normal maintenance items after 80,000Km.
  • Page 7 General Principles Clutch Maintenance Mileage Interval( × 1,000km） Maintenance Item △ 4 8 12 16 20 24 28 32 36 40 44 48 80 Check the working conditions of clutch ☆ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ Check the free travel of clutch pedal ☆...
  • Page 8 General Principles Axle and Wheel Maintenance Mileage Interval( × 1,000km） Maintenance Item △ 4 8 12 16 20 24 28 32 36 40 44 48 80 Clean alxes and wheels ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ ★ Check the oil leakage of final drive ☆...

  • Page 9: Recommended Fuel And Lubricant

    General Principles Braking System Maintenance Mileage Interval( × 1,000km） Maintenance Item △ 4 8 12 16 20 24 28 32 36 40 44 48 80 Check the fastening conditions of brake back plate ☆ ★ ★ ★ ★ Check the wearing of brake drum and shoe, replace while ★...
  • Page 10 General Principles Suitable temperature scope: For 15W-40: -10 ℃ ~-15 ℃； For 10W: -5 ℃ ~-20 ℃ ; For 5W-30: below -25 ℃ Lubricant for gears in driving axle Recommend to use sulfur-phosphor API GL-5 gear lubricant for heavy duty vehicle. Applicable environment temperatures for different classes are as follow: Gearbox oil Recommend to use sulfur-phosphor 85W/90 GL-4 gear lubricant for middle duty vehicle.

  • Page 11: Protective Measures While Repairing

    General Principles Volume Data Part Volume （L） Power steering gear Add between the upper and lower scale of oil tank Protective Measures while Repairing To assure safety in repairing, the following protective measures should be taken all the way: 1） Before reparation, you should ensure that the wheels can not turn.

  • Page 12: Cleaning

    General Principles Cleaning Because the parts may be covered by dirty oil and mud, cleaning is compulsive. Applicable cleaning methods include steam cleaning, pressure cleaning, light oil cleaning, acid or alkali cleaning, neutral medium cleaning, trichlorethylene steam cleaning, Magnus solution cleaning, etc. Part damages may be revealed during the cleaning, so great attention should be paid while cleaning.

  • Page 13: Trouble Analysis

    General Principles Trouble Analysis In a vehicle, a part is made up of many components. Some parts like clutch, transmission and rear axle are interactive functioning. Therefore, in order to find and examine trouble exactly, it is necessary to know the struc- ture of each part as well as the functional connection between various parts.
  • Page 14 General Principles Unstable running of vehicle Engine troubled Incomplete release of parking brake Incomplete release of brake Bumpy running of vehicle Clutch troubled Overload of propeller shaft Engine rubber mounting failed 4. During vehicle running Poor acceleration Clutch slipped Incomplete release of brake Incomplete release of parking brake Engine fuel system troubled Abnormal noise...
  • Page 15 General Principles Abnormal steering operation Heavy steering Steering system troubled Incorrect front wheel alignment Front axle troubled Over low pressure of front wheel Turning wheels not return Steering system troubled Incorrect front wheel alignment Front axle troubled Insufficient steering angle Steering system troubled Front axle troubled Abnormal gear shift...
  • Page 16 Clutch Table of Contents Main Parameter....................CL-1 Trouble Analysis..................... CL-2 Clutch Mechanical System ................CL-3 Adjustment of Clutch Pedal................CL-4 Clutch Cover and Flywheel ................CL-6 Usage and Maintenance.................. CL-7...

  • Page 17: Main Parameter

    Clutch Clutch Main Parameter Distributing diameter (mm) Φ 368.3 Bolt install hole size Aperture (mm) Φ 10.3 (+0.25) Number of holes 8 (4 pairs) Distributing diameter (mm) Φ 363.53 Φ 7.92 (0.03) Positioning pin hole size Aperture (mm) Φ 9.52 (+0.03) Number of holes Angle between positioning hole and installing bolt hole 15°...

  • Page 18: Trouble Analysis

    Clutch Trouble Analysis Trouble Cause Method Clutch pressure plate or driven disc lin- Change the pressure plate or driven disc ing distorted or cracked lining Release lever improper adjusted Disassemble and repair Clutch disengaged incom- Air in clutch hydraulic pressure control- Exhaust the air in the pipe plete or vehicle started ling system pipe...

  • Page 19: Clutch Mechanical System

    Clutch Clutch Mechanical System 1.Clutch pedal bracket assy 12.Front oil pipe assy 2.Lower fixed plate--pedal bracket 13.Free flowing coupling 3.Hose assy--oil reservior to master cylinder 14.Front hose assy--clutch 4.Clutch pedal welding assy 15.Rear oil pipe assy--clutch master cylinder to booster 5.Pedal sleeve 16.Clutch rear oil pipe bracket 6.Clutch pedal shaft...

  • Page 20: Adjustment Of Clutch Pedal

    Clutch Adjustment of Clutch Pedal 1.Adjust the height of the clutch pedal by adjusting the pedal setting bolt. The height of clutch pedal is about 160~170mm. 2.Adjust the free stroke of the clutch pedal. Release bearing Check the release bearing for any crack or wear. The release bearing must be smooth and turn without noise. Replace it if necessary.
  • Page 21 Clutch Check Check the degree of wear of the driven disc surface. Wear limit:(from friction surface to the rivet head) 0.3mm. Check the spline tooth clearance and the run out tolerance of driven disc. Check the driven disc for ablation, color changed, or contaminated by oil or grease.

  • Page 22: Clutch Cover And Flywheel

    Clutch Clutch Cover and Flywheel 1.Driving blade 6.Diaphragm spring 2.Rivet--pressure plate 7.Pressure plate 3.Rivet--cover 8.Clutch cover 4.Rivet--supporting ring 9.Balancing rivet 5.Supporting ring CL-6...

  • Page 23: Usage And Maintenance

    Clutch Flywheel check Check the working face of the flywheel for ablation or color changed, make use of the corundum paper to get rid of them if necessary. Check the plainness of the flywheel surface: <0.1mm Usage and Maintenance The diaphragm clutch which has two positioning holes and been con- nected by 8 M10 bolts, is made up by cover assy and driven disc assy.
  • Page 24 Clutch CL-8...
  • Page 25 Transmission Table of Contents Maintenance Standard ................... MT-1 Transmission Dismount ................. MT-2 Transmission Disassembly ................MT-3 Cleaning....................... MT-20 Check ......................MT-20 Reassembly ....................MT-24 Transmission Mount ..................MT-37...

  • Page 26: Maintenance Standard

    Transmission Maintenance Standard Maintenance Standard Nominal Sevice Repair Wear Dimension Standard Limit Limit Item Remark （mm） （mm） （mm） （mm） Clearance Gear shift lever － between gear 0.1~0.4 － shift lever and Gear select lever － select lever Radial clearance between gear shift lever and 0.05~0.11 －...

  • Page 27: Transmission Dismount

    Transmission Tightening Torque Item Tightening Torque （N.m） Clutch housing connecting bolt 142~186 fasten nut of propeller shaft connecting flange 333~549 Transmission upper cover fixed bolt and nut 32~42 Transmission cover fasten bolt 20~26 Reversing lamp switch and neutral position switch Power take-off housing connecting bolt Standard 47~63...

  • Page 28: Transmission Disassembly

    Transmission Transmission Disassembly Transmission housing and drive gear shaft 1.Small hex guide bolt 12.Cover board--power take-off 22.Speedometer driven gear hole 2.Spring washer 23.Rear bearing seat--mainshaft 13.Cover board spacer--power 3.Bearing cover--drive gear shaft 24.Skeleton oil seal assy take-off hole 4.Bearing cover spacer--drive 25.Small hex guide bolt 14.Oil screw plug assy gear shaft...
  • Page 29 Transmission Disassembly of transmission accessories 1.Remove the clutch housing assembly; 2.Remove the transmission upper cover assembly and spacer; 3.Dismantle the power take-off cover and spacer; 4.Measure the backlash of every pair of gear and take the records; Note: Take three points of every pair of gear to mea- sure.
  • Page 30 Transmission 5.Measure the axial clearance of every gear and take the records. Check point 1.Clearance between 6th speed gear and 6th speed gear thrust ring; 2.Clearance between 4th speed gear and 6th speed gear thrust ring; 3.Clearance between 3rd speed gear and 3rd and 4th speed gear fixed seat; 4.Clearance between reverse gear and reverse gear fixed seat;...
  • Page 31 Transmission 3.Remove the driven gear, flexible joint and bushing of the speedometer; 4.Remove the countershaft rear bearing cover and gasket; 5.Remove the drive gear shaft bearing cover and gasket; 6.Remove the oil seal from the bearing cover (if neces- sary); 7.Take out the drive gear shaft assembly;...
  • Page 32 Transmission 8.Remove the elastic collar and remove the ball bearing (only if it is necessary to replace the bearing); 9.Remove the mainshaft rear ball bearing elastic ring, set the extractor in the slot of the elastic ring, then take down the bearing; 10.Take down the synchronizer baulk ring of the 5th and 6th speed gear;...
  • Page 33 Transmission 12.Make use of the extractor to pull the reverse gear shaft; 13.Disassemble the reverse gear assembly; 14.Remove the countershaft rear locking nut; 15.Remove the elastic ring of the countershaft rear ball bearing, then set the extractor in the retainer ring slot, and pull the bearing out;...
  • Page 34 Transmission 16.Lift the countershaft out by using crane or hoist. Transmission mainshaft MT-9...
  • Page 35 Transmission 1.Front roller bearing--mainshaft 19.3rd, 4th gear sliding sleeve 35.3rd, 4th gear synchronizer lockpin 2.Lock nut 20.3rd, 4th gear synchronizer lockpin 36.Lockpin spring 3.Lock nut lock shim 21.Lockpin 37.Synchronizer push block 4.Direct gear synchronizer conical ring 22.Synchronizer push block 38.1st, 2nd gear baulk ring 5.5th, 6th gear baulk ring 23.3rd, 4th gear fixed gear seat 39.Needle bearing...
  • Page 36 Transmission 3.Pull out the bearing by the extractor, then remove the locking nut, locking spacer and the spacer sleeve in sequence; 4.Take down the 5th and 6th speed gear synchronizer assembly and the 6th gear; 5.Dismantle the 5th and 6th speed gear synchronizer assembly;...
  • Page 37 Transmission 7.Take down 6th speed gear needle bearing and the bear- ing seat ring; 8.Remove the thrust spacer, 4th gear, needle bearing and 4th speed gear bearing seat ring; 9.Take down 3rd and 4th speed gear fixed gear seat; 10.Take down 3rd and 4th speed gear synchronizer; MT-12...
  • Page 38 Transmission 11.Take down 3rd and 4th speed gear; 12.Remove the needle bearing, spacer sleeve; 13.Take down 2nd speed gear and needle bearing; 14.Take down the 1st and 2nd speed gear synchronizer assembly; 15.Remove the 1st speed gear and needle bearing. MT-13...
  • Page 39 Transmission Transmission countershaft, reverse gear shaft 1.Snap ring for shaft 10.Countershaft 3rd gear 19.Lock nut 2.Countershaft front roller bearing 11.Key 20.Reverse gear 3.Constant mesh gear thrust shim 12.Key 21.Reverse gear needle bearing 4.Countershaft constant mesh gear 13.Woodruff key 22.Reverse gear shaft 5.Countershaft 6th gear sleeve 14.Transmission countershaft 23.O-ring...
  • Page 40 Transmission 1.Take down the elastic ring and spacer sleeve; 2.Remove the roller bearing; 3.Make use of the oil pressure machine to press out the gear which fixed by keys, and remove the spacer sleeve at the same. Note: When pressing the countershaft, don't let it fall down.
  • Page 41 Transmission Transmission cover 1.Controlling shaft 16.Steel ball 29.Reverse gear guide 43.5th, 6th gear guide block block 2.Oil seal 17.Damping spring-- reverse gear 30.Steel wire rope 44.Cotter pin 3.Top cover 18.Lock shim--spring seat 31.Reverse gear fork shaft 45.Safety stop pin spring 4.Plain washer 19.Damping spring seat-- 32.Steel wire rope...
  • Page 42 Transmission Gear shift shaft and fork could be moved in any sequence. But however, the interlocked pin and steel ball are related to the transmission top cover. Therefore, if the interlocked pin is not set on the neutral position, you can't pull down the gear shift fork shaft.
  • Page 43 Transmission 5.Make use of tools to take out the gear shift fork of the reverse gear, 5th and 6th speed gear, and the spring pin of every guide block; 6.Knock down the 5th and 6th speed or reverse gear shift shaft, and then take down the interlocked pin, reverse gear or 5th and 6th speed gear shift fork and steel ball;...
  • Page 44 Transmission 2.Loose the screw and remove the locking spacer, then take out the spring and steel ball from the gear shift lever; 3.Make marks on the same place of the gear shift lever and gear shift shaft spline; 4.Knock out the straight pin by a hammer and then pull the gear shift shaft.

  • Page 45: Cleaning

    Transmission Cleaning Cleaning is compulsive because parts and components are often covered up with dirty oil and slurry. Appli- cable washing methods include vapor wash, Light oil wash, acid wash or alkaline wash, neutral agent wash, trichloroethylene wash, Magnus solution wash, etc. Some damages may be exposed during washing, so keep an eye on the parts and components during washing.
  • Page 46 Transmission loose, abnormal noise (bearing), discolored, eroded, deteriorate (friction lining), etc. All the rubber pieces, such as O-rings, oil seals, washers, cannot be further used after disassembled. Transmission top cover 1.Measure the clearance between gear shift lever and gear select rocker arm; Repair standard: 0.1~0.4mm Wear limit: 0.8mm 2.Measure the clearance between gear shift shaft and...
  • Page 47 Transmission Transmission upper cover 1.Measure the clearance between gear shift fork and gear slide sleeve slot; Note: Measure the gear slide sleeve slot, it has to be above than 3 points or 5 points. Repair standard: 0.10~0.18mm Wear limit: 1.0mm 2.Measure the free length and stiffness of the gear shift fork shaft self-locked spring.
  • Page 48 Transmission Synchronizer Lockpin type Check the pretravel between synchronizer conical ring and cone disc. (A) Note: Measure the average value between two points by 180°. Repair standard: 0~0.5mm Wear limit: 2.0mm Slide block type 1.Measure clearance between baulk ring and synchro- nizer conical ring;...

  • Page 49: Reassembly

    Transmission 4.Measure radial clearance between fixed gear seat and synchronizer backing block (E); Repair standard: 0.05~0.35mm 5.Measure the free length and stiffness of the synchro- nizer spring. Free length: 15mm When press to 12.5mm: Stiffness repair standard: 0.6~1.0kg Wear limit: 0.4kg Reassembly When assembling the parts, please make sure that the installing direction of the gear thrust washer needle bearing and spacer sleeve.
  • Page 50 Transmission 5.Assemble the 3rd and 4th speed fixed gear seat and synchronizer assembly; 6.Press the needle bearing seat ring of the 4th speed gear, then install the needle bearing and 4th speed gear; 7.Install the thrust spacer; 8.Install the 6th speed gear needle bearing seat ring and needle bearing;...
  • Page 51 Transmission 10.Install the synchronizer backing block, spring seat, spring and lockpin in sequence; 11.Install the synchronizer lockpin assembly into the slot of the fixed gear seat; Note: Be sure to make the wide face of the synchronizer accord to the turning direction of the fixed gear seat. 12.Install the 5th and 6th speed gear slide sleeve;...
  • Page 52 Transmission 15.Install the mainshaft front bearing; 16.Set the elastic ring in the slot of the mainshaft end to block off the bearing; 17.Set the front end of the mainshaft downward, and install the 1st and 2nd speed synchronizer assembly, needle bearing, 1st speed gear, reverse gear seat and reverse gear sleeve;...
  • Page 53 Transmission Countershaft 1.Install the 3rd speed gear woodruff key; 2.Install the 3rd speed gear; 3.Install the spacer sleeve; 4.Install the flat key of 4th and 5th speed gear; 5.Install the 4th and 6 the speed gear of the countershaft; 6.Install the spacer sleeve; 7.Install the constant engaged gear flat key of the coun- tershaft;...
  • Page 54 Transmission 8.Install the constant engaged gear of the countershaft; 9.Use a thickness gauge to measure, and make sure the clearance between spacer sleeve and gear is smaller than 0.05mm; 10.Install the roller bearing; 11.Install the elastic ring to the countershaft; Transmission upper cover 1.Press to install the gear shift fork shaft by the upper cover hole, and then install the 3rd, 4th and reverse...
  • Page 55 Transmission 2.Install the interlocked pin on the 5th and 6th speed gear shift fork shaft, and then press to install the 5th and 6th speed shift fork shaft by the upper cover hole, then assemble the gear shift fork and guide block; 3.Install the interlock steel ball;...
  • Page 56 Transmission 6.After install the interlocked pin to the reverse gear fork shaft, press to assemble the reverse gear fork shaft through the hole of the transmission upper cover, then install the reverse gear guide block and gear shift fork; 7.Install the guide bolt; Tightening torque: 40N.m 8.Assemble the plug and spacer on the two ends;...
  • Page 57 Transmission 10.Install the reverse lamp switch and neutral switch. Tightening torque: 20N.m Transmission top cover 1.Install the spacer sleeve and O-ring on the gear shift shaft; 2.Assemble the gear shift block on the gear shift shaft, and pay attention that you should align with the marks which made when disassembling;...
  • Page 58 Transmission 5.Install the O-ring into the slot of the gear select rocker arm, smear a layer of grease on the surface and then install it on the transmission top cover; 6.Install plain washer and elastic ring; 7.Install the steel ball and self-locked spring into the hole, and then assemble the top cover on the transmis- sion upper cover;...
  • Page 59 Transmission 3.Install the reverse gear shaft assembly, and then install the locking spacer on the shaft; Tightening torque: 20~26N.m 4.Measure the end clearance and backlash of the reverse gear, and you should assure the observed value among the repair standard; End clearance: repair standard: 0.3~0.6mm Backlash: repair standard: 0.15~0.25mm 5.Install the mainshaft assembly;...
  • Page 60 Transmission 8.Install the ball bearing, spacer sleeve, speedometer drive gear, gasket and bearing seat in sequence; Tightening torque: M12 59~79N.m M14 93~124N.m 9.Install the 5th and 6th speed gear synchronizer baulk ring; 10.Press to install the ball bearing onto the drive gear shaft, and then assemble the elastic ring;...
  • Page 61 Transmission 12.Assemble the bearing cover assembly; Tightening torque: 33~44N.m Note: You must assure the oil hole of the bearing cover align to the hole of the transmission housing. 13.Measure the end clearance of the 1st speed gear (clearance between 1st speed gear and its thrust spacer) and make it among the repair standard;...

  • Page 62: Transmission Mount

    Transmission Transmission Mount Before assemble gearbox onto truck, make sure that the corresponding parts is tightened. 1.Install transmission and bracket as a assembly into truck with transmission jack and steel wire, make sure that drive gear shaft spline align to the clutch driven disc hub spline. 2.Install clutch booster or clutch slave cylinder, return spring and dowel pin.
  • Page 63 Transmission MT-38...
  • Page 64 Propeller Shaft Table of Contents Technical Parameter..................PR-1 Maintenance Standard ..................PR-1 Tightening Torque ..................PR-1 Trouble Analysis..................... PR-1 Propeller Shaft ....................PR-2 Intermediate Propeller and Center Bearing ............ PR-3 Propeller Shaft Maintenance ................PR-3...
  • Page 65 Propeller Shaft Propeller Shaft Technical Parameter Open type, tubular propeller shaft, two segments. The front Type segment is midship shaft with bearing, the rear is double uni- versal joints with flange inner slide Universal joint type Spider type Center bearing Slide a little along lengthways in the center bearing seat Universal joint max oscillatory angle ±...
  • Page 66 Propeller Shaft Propeller Shaft Structure 1.Flange fork 6.Grease nipple 11.Oil seal spacer 2.Bolt 7.Snap ring for holes 12.Oil seal cover 3.Cross shaft needle bearing assy 8.Slip york assy 13.Propeller shaft assy 4.Dust collar 9.Grease fitting 5.Cross shaft 10.Slip york oil seal PR-2...
  • Page 67 Propeller Shaft Intermediate Propeller and Center Bearing Structure 1.Flange fork 7.Intermediate propeller shaft 12.Bearing seat--center bearing assy 2.Cross shaft needle bearing assy 13.Bearing--center bearing 8.Washer--center bearing seat 3.Dust collar 14.Flange--driving conic gear 9.Center bearing bracket assy 4.Cross shaft 15.Washer--driving conic gear nut 10.Upper cover board--center 5.Grease elbow 16.Hex slotted flat nut...
  • Page 68 Propeller Shaft Measure point of the propeller shaft (mm): A=155 B=165 C=185 3.If the radial runout is above the limit value, remove the connecting flange of one end of the rear axle, and turn it for 180° then install the propeller shaft. 4.Check the radial runout again, if it still beyond the limit value, replace the propeller shaft.
  • Page 69 Propeller Shaft Check Check teh radial runout of the propeller shaft, and if it is beyond the limit value, replace the propeller shaft. Check the axial freedom of the spider shaft If the axial freedom of the spider shaft is beyond the limit value, you have to replace the spider shaft assembly.
  • Page 70 Propeller Shaft 3.Knock the flange fork with a hammer, and don't dam- age the holes of the spider shaft and flange fork when disassembling the spider shaft. 4.Disassemble the spider shaft bearing of the other end in the same way. Make marks on the dismantled parts, and you may not change their original position when reassembling.
  • Page 71 Propeller Shaft 3.Eliminate the clearance between bearing and snap ring by knocking flange fork. 4.Check the flexibility and axial freedom of the spider shaft. Maintain Replace of the front oil seal Note: The adjusted spacer is used for the driveline. After the disassembly of the flange, it is necessary to adjust the pretightening force of the bearing, so the main retarder needs to be repaired.
  • Page 72 Propeller Shaft 5.Apply some grease on the lip cavity of the oil seal and then press it into the oil seal seat. 6.Assemble the flange disc and drive gear nut. 7.Assembly the propeller shaft. Disassembly and Assembly Disassemble Remove the propeller shaft. After removing the propeller shaft, plug the output port of the transmission by plug.
  • Page 73 Steering System Table of Contents Check ......................ST-1 Steering Wheel and Steering Column ............ST-2 Power Steering Hydraulic pressure System............ ST-5 Steering gear ....................ST-6 Trouble Analysis..................... ST-7...

  • Page 74: Check

    Steering System Steering System Note: Before disassembly, carefully clean the surface of the parts. Please do the disassembly in a cleaning invironment to avoid dust or any other filth enter the parts. Put the removed parts in order and it may be convenient to reassem- ble.

  • Page 75: Steering Wheel And Steering Column

    Steering System Steering Wheel and Steering Column 1.Steering wheel assy 10.Bolt--tighten immobility 21.Steering spanner universal joint fork--slide fork 2.Washer--steering wheel 11.Restoration spring 22.Oil seal--slide fork 3.Adjuster bolt 12. Limiting bush 23.Oil seal cover--slide fork 4.Steering column bracket welding assy 13.Steering column welding assy 24.Grease fitting distance limited piece 5.Plate,sliding...
  • Page 76 Steering System Steering column When assembling the steering column, tighten the bolt and clip of the lower supporter by hand first. then tighten the steering column under the condition that the steering column is out of force. When assemble the steering cross shaft, you must check if the locking bolt and the sunk part is aligned.
  • Page 77 Steering System Turning lock Remove the fixed bolt of the clip. Tighten the fixed bolt. Note: Take a look if the installing position of the steering lock is correct. Adjusting mechanism After assembling the steering shaft adjusting mechanism, check its moving condition.

  • Page 78: Power Steering Hydraulic Pressure System

    Steering System Power Steering Hydraulic Pressure System 1.Power steering gear assembly 7.Clip 13.Hose 2.Elbow assembly, inlet oil 8.Oil pump 14.Hose--steering gear to oil reservoir 3.Upper bracket 9.Bolt--joint of the oil pump 15.Oil reservoir assembly, steering 4.Elbow assembly, outlet oil, 10.Joint--inlet oil tubing 5.Bracket 11.Jacket 6.Clip...

  • Page 79: Steering Gear

    Steering System Steering Gear Basic parameter Basic parameter M11-3411010 Appropriate maximum load of front axle (kg) 3500 Max. output torque (N.m) 2150 Max. oil pressure (MPa) Recommended oil pump flow (L/min) Drive ratio 18：1 Number of total turns 4.78 Pitman arm shaft turning angle ±...

  • Page 80: Trouble Analysis

    Steering System Trouble Analysis Trouble Cause Method 1.Oil level in steering gear is not suffi- Add oil to the upper mark cient 2..The connecting part between the oil outlet and the engine, and between the oil Tighten oil pipe fitting or replace the seal- inlet of the steering oil pump and the ing part engine, and between the oil pump and the...
  • Page 81 Steering System 1.Too much flow of the oil pump Replace the oil pump Steering gear overheat 2.The bending radius of the oil pipe is (its temperature is over too small or the inner part is blocked and Replace the oil pump cause oil flowing difficult and heated 65°C of the environ- ment temperature)
  • Page 82 Front Axle Table of Contents Structure......................FA-1 Disassembly of the Front brake ..............FA-2 Maintenance....................FA-3 Assembly and Adjustment................FA-4 Trouble Analysis..................... FA-5 Appendix 1 Lubricanting Parts and Lubricant ..........FA-7 Appendix 2 Tighten Torque of the Bolts and Nuts ........FA-7 Appendix 3 Main Adjusting Data and Maintaining Standard .......

  • Page 83: Structure

    Front Axle Front Axle Structure Front axle, steering knuckle 1.Upper cover--steering knuckle 8.Grease elbow 13.Wedge cotter pin--steering knuckle pin 2.Spacer--steering knuckle upper 9.Adjusting spacer--steering cover knuckle 14.Front axle 3.Steering knuckle pin 10.Left Steering knuckle arm 15.Thrust bearing 4.Upper bushing 11.Double head bolt--upper steer- 16.Right steering knuckle ing arm 5.Left steering knuckle...

  • Page 84: Disassembly Of The Front Brake

    Front Axle Disassembly of the Front Brake 1.Front dustproof shield 8.Bush--air chamber bracket 16.Bush 2.Rubber plug 9.O-ring 17.Screw 3.Column pin--air chamber push- 10.Adjusting spacer 18.Pin 11.Front brake adjusting arm assy 19.Rivet 4.Front brake bracket assy 12.Washer--brake cam 20.Brake friction plate 5.Front brake air chamber assy 13.Adjusting washer 21.Front brake shoe...

  • Page 85: Maintenance

    Front Axle Maintenance Before using new axle, apply enough 2# lithium grease into every grease fitting. First maintain To assure the safe running of your vehicle and obtain a long service life, you have to do the first maintain after the first 1,500~2,500kmafter leaving factory. Please note the following items: 1.Dismantle and check the wheel hub for any abnormal wear (please go to the Assembly and Adjustment to see the reference) 2.Check the fastening piece.

  • Page 86: Assembly And Adjustment

    Front Axle Assembly and Adjustment Disassemble and asseble of the assembly Front wheel hub brake drum assembly 1.Fixed the front axle and remove the wheel hub end cover; 2.Take off the cotter pin, adjusting nut and spacer; 3.Turn the wheel hub brake drum a little and pull it, gently knock at the brake drum at the same time to loose the inner ring of the outer bearing, then take down the wheel hub brake drum, but you need to pay attention that the assembly is so heavy that may be fallen down or hurt someone, and the inner ring of the outer bearing need to care at the same time, don't fall it.

  • Page 87: Trouble Analysis

    Front Axle Shoe shaft end: 0.25~0.45mm; Cam shaft end: 0.40~0.70mm, the clearance should be corresponding and the clearance difference between the upper and lower shoe is ≤ 0.1mm. Trouble Analysis Trouble Cause Method Big pretightening force of the wheel hub Adjust pretightening force bearing Wheel hub bearing is...
  • Page 88 Front Axle Front wheel hub bearing worn Replace wheel hub bearing Kingpin and bush overworn Correct or replace troubled parts Pendulate Steering knuckle distortion Replace Improper wheel alignment Check and adjust Improper wheel alignment Check and adjust Front axle bent Correct or replace Pulling to one side Brake unsmooth...

  • Page 89: Appendix 1 Lubricanting Parts And Lubricant

    Front Axle Appendix 1 Lubricating Parts and Lubricant Lubricating parts Maintenance Interval Mileage ( × 1000km) Item First maintain 12 16 20 24 28 32 36 40 44 48 Steering knuckle kingpin ● ● ● ● ● ● ● ● ● ● ● ● ● Tie rod ball pin ●...

  • Page 90: Appendix 3 Main Adjusting Data And Maintaining Standard

    Front Axle Appendix 3 Main Adjusting Data and Maintaining Standard Main adjusting data Adjusting Item Adjusting Data Toe-in 0~4mm Turning angle of the inside wheel 40° Clearance between front axle fist surface and ≤ 0.1mm the steering knuckle Shoe shaft end 0.25~0.45mm Cam shaft end 0.40~0.70mm Clearance between front fiction plate and brake Clearance difference between two shoes of the same side is...
  • Page 91 Rear Axle Table of Contents Structure......................RA-1 Maintenance....................RA-3 Assembly and Adjustment................RA-4 Trouble Analysis.....................RA-8 Lubricating Parts and Lubricant ..............RA-7 Tightening Torque of Important Bolts and Nuts..........RA-7 Main Adjusting Data and Maintaining Standard ..........RA-8...

  • Page 92: Structure

    Rear Axle Rear Axle Structure Rear axle housing and half axle 1.Vent plug 7.Set pin 13.Rear axle half-axle gasket 2..Screw plug--oil level hole 8.Square slotted conical screw plug 14.Half-axle oil seal assy with glue 3.Gasket--axle housing rear cover 15.Rear axle half-axle 9.Gasket 4.Rear axle housing cover assy 16.Rear axle half-axle bolt...
  • Page 93 Rear Axle Disassembly of the brake 1.Cotter pin 13.Rubber plug 25.Screw 2. Brake adjusting arm 14.Dustproof shield 26.Roller pin shaft 3.Cotter pin 15.Brake bottom plate 27.Roller 4.Plain washer 16.Set screw 28.Clamp ring 5.U-fork 17.Steel lock wire 29.Dustproof shield 6.Flat pin 18.Supporting pin 30.Grease nipple 7.Locking nut...

  • Page 94: Maintenance

    Rear Axle Maintenance Before using new axle, apply enough 2# lithium grease into every grease fitting. First maintain To assure the safe running of your vehicle and obtain a long service life, you have to do the first maintain after the first 1,500~2,500kmafter leaving factory. Please note the following items: 1.Add or replace the gear oil for the reductor;...

  • Page 95: Assembly And Adjustment

    Rear Axle Assembly and Adjustment Disassemble and asseble of the assembly Rear wheel hub brake drum assembly 1.Fixed the rear axle and remove the half axle bolt by a spanner; 2.Pull out the half axle gently and when the spline passing the oil seal, turn the half axle slowly to avoid damage the half axle oil seal;...
  • Page 96 Rear Axle 6.Paint two or three engaged teeth of driven gear red to chaeck the contact zone, if the contact area is improper, increase or reduce the thickness of the adjusting spacer until it is proper; Sketch map of the contact zone is as follows: Gear contact zone Adjusting method Proper contact zone...

  • Page 97: Trouble Analysis

    Rear Axle Adjustment of the rear wheel bearing pretightening force 1.Remove the stop spacer first; 2.Tighten the adjusting nut by a special spanner with a torque of 150~180N.m; 3.Turn the wheel hub 2~3 circles, and make the bearing aligned correctly; 4.Fasten the adjusting nut with a tightening torque of 150~180N.m;...

  • Page 98: Lubricating Parts And Lubricant

    Rear Axle Improper gear space of the differential Replace spacer or gear Too big clearance between drive gear and Replace spacer or gear driven gear Abnormal noise while Drive gear bearing pretightening force too Adjust pretightening force driving small Half axle gear, planet gear, and cross shaft Correct or replace troubled parts worn or damaged Oil level too low...

  • Page 99: Tightening Torque Of Important Bolts And Nuts

    Rear Axle Tightening Torque of Important Bolts and Nuts Part Tighten Torque (N.m) 130 ~ 150 Oil drain screw plug 350 ~ 500 Big nut of the drive gear 156 ~ 206 Rear brake bottom plate bolt 55 ~ 70 Air chamber bracket fixed bolt 50 ~ 75 Air chamber fixed bolt...
  • Page 100 Suspension System Table of Contents Trouble Analysis..................... FA-1 Structure......................FA-2 Disassembly....................FA-4 Check ......................FA-7 Assembly ......................FA-8...

  • Page 101: Trouble Analysis

    Suspension Suspension Trouble Analysis Trouble Cause Repair Spring leaf damaged Replace the spring leaf Bumpy ride Overload Load as required Vehicle rocked severely Damper failed Replace the damper Spring leaf center bolt is broken U-bolt and nut loosed Replace center bolt Spring leaf is broken at the U-bolt and nut loosed Replace spring leaf...

  • Page 102: Structure

    Suspension Structure Front leaf spring 1.Front spring leaf assy 8.U-bolt 2.Inclined underplate with set sleeve assy 9.U-bolt 3.Center bolt 10.Cover board--front suspension 4.Bush 11.Limit block--front suspension 5.Fixed end bracket 12.Lifting eye bracket 6.Spring pin set bolt 13.Front lifting eye 7.Spring leaf pin--front suspension 14.Lifting eye oin set SP-2...
  • Page 103 Suspension Rear leaf spring 1.Fixed end bracket 8.Leaf spring pin 2.Wedge lock pin 9.Cover board 3.Leaf spring pin 10.U-bolt 4.Limit block assy 11.Sub-leaf spring assy 5.Sub-leaf spring bracket 12.Sub-leaf spring underplate 6.Bracket--lifting eye end 13.Rear leaf spring assy 7.Lifting eye with bush assy 14.Set pin sleeve 15.U-bolt underplate SP-3...

  • Page 104: Disassembly

    Suspension Disassembly Clean the suspension system before disassembling. Set the truck in brake state, and block up the front and rear wheel with wooden stand. Dismounting of front suspension 1.Wedge the rear wheel, lift the front axle and front part of the frame with a jack and the safety support, then take down the front wheel;...
  • Page 105 Suspension 7.Remove the fixed bolt of the leaf spring front enf spring pin, then take down the leaf spring pin and let down the jack and take out the leaf spring; 8.Loose the lifting eye locking nut, and take down the lift- ing eye pin and you can remove the lifting eye.
  • Page 106 Suspension 5.Slowly down the jack to fall the rear axle to the ground, and remove the sub leaf spring assembly and sub-leaf spring underplate; 6.Disassemble the the rear end of the the leaf spring. Remove the fasten bolt of the leaf spring pin and pull the spring pin out then you can disassemble the rear end of the leaf spring rear end;...

  • Page 107: Check

    Suspension Check 1.Measure the outer diameter of the spring pin and lifting eye pin Front suspension 17.5mm Wear limit Rear suspension 29.5mm 2.Inner diameter of the spring bush and lifting eye bush Front suspension 19mm Wear limit Rear suspension 31mm 3.Clearance between spring pin, lifting pin and bush: Spring pin and bush: Repair standard...

  • Page 108: Assembly

    Suspension Assembly Assembly of the sub-assembly Assemble the leaf spring by center bolt accord the sequence of the spring leaf; Note: Smear some black lead lime grease on the relative friction surface of the spring leaf. Clamp the leaf spring by a C-shape clip, and tighten the center bolt and nut; Take down the C-shape clip from the leaf spring;...
  • Page 109 Suspension 7.Assemble the U-bolt; 8.Lift the front axle by the jack, and then take down the support of the frame then own the jack; 9.Tighten the U-bolts and nuts; Tightening torque 200~250N·m 10.Install the damper to the bracket, then the plain washer, spring washer and nut, then tighten them;...
  • Page 110 Suspension 4.Install the rear end of the spring, align the lifting eye hole to t spring eye, insert the spring pin, then install the lock nut; Tightening torque 32~42N·m Note:When inserting the cotter pin, make the inclined face contact to the face of lifting eye pin. 5.Install the underplate, sub-spring and cover board to the upper of the rear spring, then install the U-bolt;...
  • Page 111 Brake System Table of Contents Technical Parameter..................BR-1 Tightening Torque...................BR-1 Trouble Analysis of Wheel Brake ..............BR-2 Structure......................BR-4 Front Brake .....................BR-6 Rear Brake ......................BR-8 Frame Brake Pipeline ..................BR-9 Cab Brake Pipeline ..................BR- Hand Control Valve Control System............BR-11...

  • Page 112: Technical Parameter

    Brake System Brake System Technical Parameter Structure type Air-pressure, with shoe, drum type Brake type S type cam roller type Front Pressing bottom plate Brake bottom plate Rear Foundry bottom plate Front Φ 310 × 120mm Brake specification Rear Φ 310 × 150mm Front Rectangle cam Brake cam type...

  • Page 113: Trouble Analysis Of Wheel Brake

    Brake System Trouble Analysis of Wheel Brake The trouble of brake system including insufficient braking effectiveness, brake being seized, or only one brake shoe expanded, and having abnormal sounding. The worn-out brake shoe lining and the overlarge clearance between the lining and brake drum cause the insufficient braking effectiveness. If you cannot find any causes in the whole brake system, you should consider the brake's condition.
  • Page 114 Brake System Insufficient brake Trouble Cause Repair Normal air pressure Brake valve travel is too short Check and replace the brake valve if necessary Cam shaft doesn't run (bush lacks Check and replace cam shaft if nec- lubricant) essary Improper push rod travel of the brake Adjust the travel air chamber Bad contact of relay valve...

  • Page 115: Structure

    Brake System Structure Front brake 1.Pin, cotter 13.Hex bolt-to fix dust shield 27.Roller shoe-brake shoe 2.Front brake adjust arm assembly 14.Washer, spring 28.Roller 3.Pin, cotter 15.Plug-rear dust shield 29.Lock ring--brake shoe roller 4.Washer 16.Front dust shield shaft 5.Pin shaft--chamber push rod 17.Front brake plate L.

  • Page 116: Rear Brake

    Brake System Rear brake 1.Pin, cotter 13.Rubber plug 25.Screw--to fix brake plate 2.Brake adjust arm 14.Rear dustproof tray--rear 26.Roller shaft--rear brake shoe brake 3.Pin, cotter 27.Roller--rear brake shoe 15.Rear brake plate 4.Washer 28.Lock ring--brake shoe roller 16.Screw--to fix brake shoe shaft 5.Fork,cotter 17.Wire, lock...
  • Page 117 Brake System Front Brake Disassembly Remove the brake drum and wheel hub assembly, take down the return spring, brake shoe, brake cam, air chamber bracket and brake bottom plate in sequence. Check 1.Make sure whether the brake drum is damaged or distorted, replace in necessary. 2.When the brake drum is worn out and becomes out of round, it is allowed to bore, but the accumulative machin- ing quantity should not exceed 4mm for the diameter direction.
  • Page 118 Brake System Adjust After the brake linings have been replaced, the brake bot- tom plates have been dismounted, causing the positions of the anchor pins and the camshaft changed, the normal contact of the brake linings and the brake drum is destroyed;...
  • Page 119 Brake System Rear Brake Disassembly After remove the rear axle half axle, take down the brake drum and wheel hub assembly, then dismount rear brake adjust arm, brake cam, air chamber bracket, brake shoe with bottom plate assembly, and dust shield in sequence.

  • Page 120: Frame Brake Pipeline

    Brake System Frame Brake Pipeline 1.Elbow fitting 15.Air line assembly 29.Air desiccator and unloader valve subassembly 2.Exhaust brake valve assembly 16.Nylon pipe assembly 30.double direction valve and 3.Air line assembly-- 17.Nylon pipe assembly Quick release valve subassembly electromagnetic valve toexhaust 18.Quick release valve brake valve 31.Hose assembly...

  • Page 121: Cab Brake Pipeline

    Brake System Cab Brake Pipeline 1.Brake valve assembly 5.Nylon pipe assembly--Brake 7.Nylon pipe assembly--Brake valve 22 connect hole to hose valve11connect hole to hose 2.Hose bracket bracket bracket 3.Bracket, upper 6.Nylon pipe assembly--Brake 8.Jacket 4.Nylon pipe assembly--Brake valve12 connect hole to hose 9.Transition tie-in valve 21 connect hole to hose bracket...

  • Page 122: Hand Control Valve Control System

    Brake System Hand Control Valve Control System 1.Air line assembly--hose bracket to hand control valve 1 connect hole 2.Air line --hose bracket to hand control valve 1 connect hole 3.Air line assembly--hose bracket to hand control valve 2 connect hole 4.Air line--hose bracket to hand control valve 2 connect hole 5.Hand control valve assembly BR-11...
  • Page 123 Brake System BR-12...
  • Page 124 Table of Contents Clip and Fastener .................... BF-1 Cab Front Panel ....................BF-2 Door ........................ BF-3 Instrument Panel ..................... BF-4 Cab Internal Trims and External Trims ............BF-4 Seat ....................... BF-11 Cab Mounting ....................BF-12 Cab........................ BF-13 Chassis Frame....................BF-14 Air-conditioner and Heater ................

  • Page 125: Clip And Fastener

    Precautions When removing or installing various parts, place a cloth or padding onto the vehicle body to prevent scratches. Disassemble or assemble the handle device, molding parts, instrument, inner trims and so on carefully not to soil or damage them. Apply seal glue on necessary place when assembling.

  • Page 126: Cab Front Panel

    Cab Front Panel Disassembling the front bumper ass'y: 1.Release off the six fixed nuts from the front bumper (each three on left and right side). 2.Release off the bumper ass'y. 3.Disassemble the connection device for right and left fog light. 4.Disassemble the clip and bolt.

  • Page 127: Door

    Door Front Door When disassembling the front door, it is better to disassemble the cover at front side first. Afler adjusting the door or door lock, check the door lock open and lock condit ion BF-3...

  • Page 128: Instrument Panel

    Instrument Panel Caution: Before disassembling the instrument panel, switch off the power-supply. Be careful not to scratch pad and other parts. These parts are made of plactic. Excessive force will damage them. The structune of the instrument panel in shown as below: •...
  • Page 129 ③ Disassemble the roof lamp ass'y. ④ Disassemble the handrail. ⑤ Disassemble the seats. ⑥ Disassemble the safely belt. ⑦ Disassemble the door guardrail. ⑧ Disassemble the rear window glass. Door trims Disassembly of the door trims: ① Disassemble lock knob. ②...
  • Page 130 ⑥ Disassemble inner guard board of door (front door). ⑦ Disassemble inner guard board of door (rear door) Roof trims Disassembly of the roof trims Single seater cab ① Remove part of headlining from corner and gradually peel headlining off. Double seater cab ①...
  • Page 131 Cab External Trims BF-7...
  • Page 132 ① Front upper cover ② Front lower cover and lower cover board ③ Side external cover board ④ Front and rear windows ⑤ Cab door seal strips ⑥ Door and window seal strips ⑦ Front pedal cover and pedal mat (option). Front upper finisher, Front grille, Front corner panel BF-8...
  • Page 133 Front and rear window Cab door seal strip BF-9...
  • Page 134 Door outside molding Foot step shield and mat BF-10...

  • Page 135: Seat

    Seat When assemble or disassemble the seat, it should be maintarined clean and well. Front seat Cab Safety Belt Notes: If the vehicle in severely dashed in an accident, whatever the nature of the accident is, the belt assembly must be replaced.

  • Page 136: Cab Mounting

    Cab Mounting Cab front mounting 1.Torsion bar arm assy 4.Left bracket--front mounting 2.Tilting bracket assy 5.Retainer lower assy 3.Torsion bar Cab rear mounting 1.Left connecting bracket assy--rear mounting 4.Rear mounting lower cushion assy 2.Upper cushion assy 5.Right connecting bracket assy--rear mount- 3.U-suppot welding assy BF-12...
  • Page 137 The following parts at least should be disassembled in the area of cab engine: Main electric system and wire harness. Sparate the engine part from steering transminsion device, brake system and clutch operation system. The following parts at least should be disassembled in the area of cab: 1.Transmission system and steering control system.

  • Page 138: Chassis Frame

    Chassis Frame Chassis Frame Chassis Frame 1.Front cross member assy 9.Lifting eye end bracket 18.Sub-spring bracket 2.2nd cross member 10.Rear leaf spring cross member 19.Stiffening plate--rear bracket of rear spring 3.Right bracket of rear mounting 11.Hook bracket 20.Stiffening plate--rear bracket of 4.Left side member 12.Right side member front spring...

  • Page 139: Air-Conditioner And Heater

    Air-conditioner and Heater Air-conditioner and Heater Exhaust the refrigerant of the air-conditioner Note: Don't exhaust the refrigerant directly, otherwise it will destroy the ozonosphere. Please take use of the reclaim device of the refrigerant when exhausting. Do remember wear the blinkers. Avoid to touch the refrigerant directly.
  • Page 140 Air-conditioner and Heater Remove and Install the Air-conditioner Note： Make sure that the pressure of the air-conditioning system is lower than the air pressure, then gradually loosen the exhaust pipe and remove it. Change and clean the component of the air-conditioner 1.Don't put the compressor sideward or convert it for more than 10 minutes, otherwise, the oil of the compressor will flow into the low-pressure chamber.
  • Page 141 Air-conditioner and Heater The Using of the Air-conditioner and Heater Control panel Fan switch： It is used to control the on-off and rotate speed of the bloer.Airflow Operating-mode chosen switch： It is used to control the directions of the airflow. Temperature slide switch：...

  • Page 142: Construction Of The Heater

    Air-conditioner and Heater Construction of the Heater 1.Left air pipe 8.Wind inlet channel ass'y 2.Wind channel ass'y 9.Plastic nut ass'y 3.Middle air pipe 10.Heater ass'y 4.Right air pipe ass'y 11.Air blower ass'y 5.Left door defroster hose ass'y 12.Heater control ass'y 6.Defroster nozzle ass'y 13.Water inlet tube 7.Right door defroster hose ass'y...

  • Page 143: Air Flowing Direction

    Air-conditioner and Heater Air Flowing Direction Note: The specific operate method refer to its maintenance tool manual. BF-19...

  • Page 144: Check The Leakage Of The Refrigerant

    Air-conditioner and Heater Check the Leakage of the Refrigerant Operational procedure In order to be convenient for checking the leakage of the refrirator, please follow the method below: 1.Start the engine; 2.Start the air-conditioner; 3.Adjust the fan switch to the "4" position; 4.Set the temperature to the lowest;...
  • Page 145 Air-conditioner and Heater Make sure the quantity of the filled refrigerant As for the quantity of the filled refrigerant, you can measure by inspecting the flow of the refrigerant from the window, and read the pressure gauge of the high and low pressure pipe. Procedure BF-21...

  • Page 146: Air-Conditioning System

    Air-conditioner and Heater Air-conditioning System 1.Evaporator assy 6.Pipe assy--connecting evaporator and com- pressor 2.Evaporator lower bracket 7.Pipe assy--connecting compressor and con- 3.Evaporator exhaust pipe densator 4.Bracket assy--evaporator inlet and outlet pipe 8.Compressor assy--with clutch 5.Pipe assy--connecting evaporator and conden- 9.Condensator assy--with drier and bracket sator BF-22...
  • Page 147 Air-conditioner and Heater Oil of the Compressor Keep enough oil in the compressor. The lubricating oil and the refriferant circulate in the inner system, when change the component or the oil leaks a lot, please add the oil to the requirement capacity. If the oil capacity is not proper, the compressor will be in abnormal condition.
  • Page 148 Air-conditioner and Heater 3.Check the inlet Move the switch to the position, the inner air of the cab will be used in the circulation. Move the switch to the position, the external fresh air will be blown into the cab by the blower. 4.Temperature lower checking Move the switch to the lowest position;...

  • Page 149: Schematic Circuit Of Air-Condition System

    Air-conditioner and Heater Schematic Circuit of Air-condition System BF-25...
  • Page 150 Air-conditioner and Heater BF-26...
  • Page 151 Electric and Instrument Table of Contents Specification ....................EL-1 Bulb Type ....................... EL-1 Trouble Analysis..................... EL-2 General Instruction ..................EL-5 Battery ......................EL-6 Alternator......................EL-7 Starting Division..................... EL-9 Electromagnetic Main Power Switch ............. EL-9 Exhaust Brake System .................. EL-10 Hazard Warning System ................EL-11 Accessories ....................

  • Page 152: Specification

    Electric and Instrument Electric and Instrument Specification Vehicle Model DFA1101GZ5AD6J-907 Wire system 24V, Single lead type, negative earth Nominal Voltage (V) Starter Nominal Power (kW) Specified voltage (V) Alternator Specified current (A) Battery (A · h) Bulb Type Light name...

  • Page 153: Trouble Analysis

    Electric and Instrument Trouble Analysis The trouble in the electric system is divided into line trouble, which caused by wire crack or circuit short, and parts trouble, which caused by parts wear or fire. On the other hand, according to the service and maintenance, the system that approaches the final life car easily has trouble.
  • Page 154 Electric and Instrument Front headlamp Trouble Cause Remedy Fuse burnt Check cause and replace The headlamp Circuit breaks Check and repair doesn't light Earth line hasn't good contact Get off rust and restring then the joint when turn on Lamp wire burnt Replace bulb the switch Lamp switch has trouble...
  • Page 155 Electric and Instrument Fog light doesn't go on Trouble Cause Remedy Fuse burnt Replace Fog light doesn't Earth line contacts not well Tighten go on Bulb burns out Replace Fog light switch damages Replace Position light doesn't go on Trouble Cause Remedy Position light...

  • Page 156: General Instruction

    Electric and Instrument General Instruction Constitution Power supply division: Alternator, battery Starting system Power supply warning system Instrument indicator system Lighting system Others: Wiper, horn, cigar lighter, radio cassette player Features Using integrated alternator Using electromagnetic main power switch Two fusible wires at starter 22-way fuse box The complete truck wiring The wires of 22-way fuse box of the complete truck are connected as follow...

  • Page 157: Battery

    Electric and Instrument Battery Specifications Battery Two batteries 6-QW-90DF are in series Type Less maintenance Nominal voltage (V) Nominal capacity (A · h) Check 1.Electrolyte density when fully charged: 1.26~1.285g/ cm³ ① Density meter ② Floater 2.Fill distilled water in time if the electrolyte is found insufficient.

  • Page 158: Alternator

    Electric and Instrument Alternator Alternator operation principle diagram 1.Battery 3.Charging indicator 2.Electric using equipment 4.Regulator Specification Vehicle model DFA1101GZ5AD6J-907 Nominal voltage (V) Adjusting voltage (V) 28 ± 0.3 Nominal current (A) 6000 Nominal revolution （r/min） Output current (A) 18-20 Starting revolution （r/min）...
  • Page 159 Electric and Instrument Trouble analysis Trouble Cause Method Short circuit or too large contact resistance Charging indicator does not Short circuit between the 3 phases and rotor winding and Check the circuit and extinguish and the truck casing repair or replace the starts difficultly during damaged parts Diode damaged...

  • Page 160: Starting Division

    Electric and Instrument Starting Division Starter Vehicle model DFA1101GZ5AD6J-907 Nominal voltage (V) Nominal power (kW) Pinion teeth Pinion module 2.54/2.1167 Brake torque (N · m) Brake current (A) Brake voltage (V) Starting relay Operating voltage (V) 18~32 Operating current (A)

  • Page 161: Exhaust Brake System

    Electric and Instrument Exhaust Brake System The exhaust brake is operative when the foot is removed from both the clutch pedal and the accelerator pedal; and the exhaust brake switch, clutch switch, accelerator switch and electromagnetic solenoid are all on. But the exhaust brake will be released when either the clutch pedal or the accelerator pedal is depressed.

  • Page 162: Hazard Warning System

    Electric and Instrument Hazard Warning System When the hazard warning switch is in the alarm position, the left and right turning signal lamps will flash simultaneously. EL-11...

  • Page 163: Accessories

    Electric and Instrument Accessories Wiper motor Power －2 Revolution Low speed ＋3 High speed 60 ± 6 EL-12...

  • Page 164: Horn

    Electric and Instrument Horn Horn Press the horn button, the normal-open contact of the horn relay is connected and make the electric horn work. Horn relay Decrease the current flowing through horn button via an iron core with high resistance so as to prevent the horn button from burning out.
  • Page 165 Electric and Instrument Electric wiring diagram EL-14...

  • Page 166: Fog Lamps

    Electric and Instrument Fog Lamps Double rocker switch in parallel is used as a fog switch. That is because when the front lamps go on, the tail lamps, license lamp, instrument and quartz clock illuminators should be all lighted simultaneously, while the foglamp is not included, but when the foglamp goes on, the front lamps, tail lamps, license lamp, instrument and quartz clock illuminator should be all lighted.

  • Page 167: Instruments

    Electric and Instrument Instruments Structure This part consists of air pressure meter, fuel meter, water temperature meter, tachometer and speedometer. Name of the indicators and warning lights EL-16...

  • Page 168: Instrument Panel

    Electric and Instrument Instrument Panel Technical parameter and function Technical parameter Speedometer (km/h) 0~140 Tachometer (r/min) 0~5000 Fuel meter 0-1/2-1 40-80-100-120 Water temperature meter ( ℃ ) Nominal voltage (V) Constitution and function The instrument panel assembly is consisted by speedometer, tachometer, water temperature meter, fuel meter, warning system (14 warning indicator), and matched with the sensor and warner.
  • Page 169 Electric and Instrument Disassembly Pull out connectors and the flexible shaft, and then detach wires connected with the electronic tachometer before removing the instrument panel assembly. 1.Remove the speedometer after detaching 3 tapping screw. 2.Pull out bulb when turning the bulb holder counter clockwise to make it aligned with the notch. 3.The voltage drop resistors of small meters are also tightened by tapping screws so that they can be removed.

  • Page 170: Speedometer

    Electric and Instrument Speedometer Dial description The speedometer needle indicates the vehicle speed in kilometers per hour. The odometer indicates the accu- mulated driving distance in kilometers. The trip odometer indicates the distance driven per day or driving distance between specified regions. Firmly press the reset knob to reset the meter indicator to zero and then release it before using this speedometer.
  • Page 171 Electric and Instrument Structure The speedometer is used to indicate the vehicle driving speed and the accumulated driving distance. It comprises a speed and a mileage unit which records vehicle driving mileage. These two units are inte- grated into one body and driven by the flexible shaft which is connected with transmission output shaft.
  • Page 172 Electric and Instrument Trouble analysis Trouble Cause Method Both the speed Flexible shaft core broken Replace division and the Odometer rotating shaft seized Replace the odometer distance count- ing division of the speedometer Square connector nut slackened Tighten again do not work Only the speed Needle deformed and seized with dial or glass Correct...

  • Page 173: Tachometer

    Electric and Instrument Trouble Cause Method Grease on the magnet Clean out the grease Hairspring deformed Replace meter The needle seized Wrong assembling of the needle (needle slack- or failed that can Tighten ened) not return to zero There are impurities absorbed on the magnet of the Clean indication board.
  • Page 174 Electric and Instrument Instrument assembly and disassembly Before disassembling the instrument, pull out needle 1, and then loosen two screws 2. When disassembling the printed-circuit board; pull it out directly after welding off two wires 9(the printed board and blade connector are directly connected together through a spring blade socket on the board).

  • Page 175: Water Temperature Meter And Fuel Meter

    Electric and Instrument Water Temperature Meter and Fuel Meter Dial description Water temperature meter The water temperature meter is used to indicate the temperature of the engine coolant. The temperature of the coolant will change because of the temperature of the atmosphere and vehicle running condition. If the indication of the meter is over its normal range, stop the vehicle as soon as possible.

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