DongFeng DFA1101GZ5AD6J-907 Service Manual Download

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Cab

BF-5

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

Disassemble inside seal.

③

Disassemble inside handle escutcheon rear door).

④

Disassemble pull handle.

⑤

Pull out regulator handle.

Summary of Contents for 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 Cab Electric System ...

Page 3: ...nciples 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: ... This is very important Due to continuous improvements on our vehicles maybe there are some instructions in the manual that do not accord with the actual vehicles 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 mainte...

Page 5: ...he specified repair limit Wear limit It means that if a component is overworn or exceeds its wear limit it must be replaced Unit Legal measure units are used in this manual Standard Tightening Torque To assure the safety and reliability of key vehicle parts this manual makes specific prescriptions to the tightening torque of the bolts and other fasteners on those parts As for the bolts and other f...

Page 6: ...nd move reliability Never prolong the intervals Dong Feng Cummins Diesel Engine Maintenance Item Maintenance Mileage Interval 1 000km 4 8 12 16 20 24 28 32 36 40 44 48 80 Clean engine assembly Check acceleration capability and decelerability Check exhaust status Check the leakage of eninge lubricant Check the cleanness and reserves of lubricant Check the leakage of fuel Check the leakage in coolin...

Page 7: ...rbox Maintenance Item Maintenance Mileage Interval 1 000km 4 8 12 16 20 24 28 32 36 40 44 48 80 Clean gearbox and vent plug Check the oil reserves in gearbox Check oil leakage of gearbox Replace gearbox lubricant Check the looseness of the linking parts of the con trol mechanism Check the working conditions of the bearings in gearbox Disassemble and check gearbox Suspension System Maintenance Item...

Page 8: ...ar Clean steering gear Check free travel and working conditions of hand wheel Check the fastening conditions of the ball heads of steering cross rod and tie rod Check fastening conditions of steering mechanism and its brackets Check fastening conditions of steering arm and steer ing knuckle arm Check and adjust front wheel toe in Check front wheel alignment Check and adjust steering gear Disassemb...

Page 9: ...SH 15W 40 Ideal standard CH 4 SJ 15W 40 Note Engine damages for using lubricants below CD15W 40 or CE15W 40 or even lower are not in our warranty scope Check the fastening conditions of brake back plate Check the wearing of brake drum and shoe replace while necessary Check the working conditions of air compressor Other Maintenance Item Maintenance Mileage Interval 1 000km 4 8 12 16 20 24 28 32 36 ...

Page 10: ...mend to use specially used shock absorber oil Clutch boosting liquid Recommend to use DOT 4compounded braking liquid Different classes of braking liquid can not be used together Note Braking liquid made by different manufacturers can not be used together Engine antifreeze liquid coolant Recommend to use long term antirust antifreeze liquid The freeze point of the antifreeze liquid used should be 8...

Page 11: ...ic circuit the negative pole should be disconnected 5 The jacks and brackets used should be strong enough for the load acting on them Method of mounting brackets is as the sketch map The supporting points of front axle for mounting jacks is as the sketch map The supporting points of rear axle for mounting jacks is as the sketch map 6 When disassemble or assemble the assemblies that have been taken...

Page 12: ...e mud Oil duct Make a metal wire to get through the oil duct to ensure it is not jammed Wash the oil duct with cleaning solution with high pressure nozzle Antirust After removing the oil grease on the parts clean grease should be applied to prevent the rusting of the parts General Inspection Check parts and components with special gauges or tools Decide whether a component can continue to serve ac...

Page 13: ...of disassembling the steering gear rashly then decide whether the trouble belongs to the steering gear or to the connection mechanism When disassembling the part to find the cause of the trouble proceed systematically and start from easy problem It is a very important way to find out the cause of the trouble according to the manifestation of the trouble such as abnormal noise vibration and failure...

Page 14: ...or gear troubled oil insufficient or deteriorate Wheel hub bearing troubled grease insufficient or improper Over low tyre pressure Noise Transmission troubled Reductor gear troubled Propeller troubled Noise when run on road bend Differential gear troubled Noise when brake Brake troubled Too heavy vibration Front and rear leaf spring troubled Shock absorber troubled Propeller shaft troubled Engine ...

Page 15: ...sufficient steering angle Steering system troubled Front axle troubled Abnormal gear shift Difficult gear shift Abnormal clutch disengagement Transmission troubled Transmission handling mechanism troubled Gear disengaged Transmission troubled Transmission handling mechanism troubled Abnormal braking operation Weak braking Brake system troubled Overwear of tyres Hub bearing clearance too large Brak...

Page 16: ...Clutch CL 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: ...he hydraulic pressure system After clean the clutch pressure plate dry it with the suction cleaner not the compression air Bolt install hole size Distributing diameter mm Φ 368 3 Aperture mm Φ 10 3 0 25 Number of holes 8 4 pairs Positioning pin hole size Distributing diameter mm Φ 363 53 Aperture mm Φ 7 92 0 03 Φ 9 52 0 03 Number of holes 2 Angle between positioning hole and installing bolt hole 1...

Page 18: ...n lining and pressure plate Disassemble and repair Readjust accord to the standard Check master cylinder push rod and booster oil seal Change the pressure platespring Replace the release bearing Disassemble and repair Abnormal sound of clutch Clutch release bearing worn or improper lubricated Clutch pressure plate or driven disc dis torted Transmission input shaft or driven disc spline worn Clutch...

Page 19: ...edal shaft 7 Clutch pedal return spring 8 Bush pedal assy 9 Pin 10 Clutch master cylinder assy 11 Oil reservior assy 12 Front oil pipe assy 13 Free flowing coupling 14 Front hose assy clutch 15 Rear oil pipe assy clutch master cylinder to booster 16 Clutch rear oil pipe bracket 17 Rear hose assy 18 Booster assy 19 Nylon pipe assy air pipe to four way protective valve 20 Bracket set clutch booster ...

Page 20: ...he release sleeve and release fork for wear damage or erode and replace if necessary Bearing lubricating Make use of the recommended lubricant for the connecting surface and the attrition surface of bearing and fork Note Overmuch lubricant may cause clutch driven disc damaged Clutch driven disc and pressure plate Clutch driven disc 1 Friction lining rivet 2 Friction lining 3 Wave spacer 4 Front da...

Page 21: ... phragm If the height is not in the range of the specific range you need to replace the pressure plate Shake the pressure plate gently listening and check the wear or dam age of the diaphragm supporting ring Or you can knock the rivet head gently to find if there is cracks Replace the pressure plate if necessary Check the surface of the pressure plate for any ablation or dirt make use of the corun...

Page 22: ...Clutch CL 6 Clutch Cover and Flywheel 1 Driving blade 2 Rivet pressure plate 3 Rivet cover 4 Rivet supporting ring 5 Supporting ring 6 Diaphragm spring 7 Pressure plate 8 Clutch cover 9 Balancing rivet ...

Page 23: ...ion lining is 2 1 8mm During the wearing time the distance between the toppest point of the release finger and the release bearing end has to be adjusted to 3 4mm and the largest release stroke of the release finger is 10mm The outside diameter of the driven disc friction lining isΦ325mm Its material may adopt to asbestos or non asbestos according to the need of the customer The original thickness...

Page 24: ...Clutch CL 8 ...

Page 25: ...Transmission MT 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: ...ssion body Backlash between mainshaft and countershaft 0 15 0 25 0 5 Axial clearance of the 2nd gear 0 3 0 5 0 7 Axial clearance of the reverse gear 0 3 0 6 1 0 Radial clearance between mainshaft spline hub and mainshaft 0 2 0 3 0 5 Radial clearance between slide sleeve and coupling gear 0 45 0 55 1 0 Axial clearance of ball bearing 0 5 Synchronizer Lockpin type Pretravel of synchronizer conical r...

Page 27: ...ame 6 Remove wire and tube 7 Disassemble the transmission with transmission jack and steel wire 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 20 Power take off housing connecting bolt Sta...

Page 28: ...Rear bearing transmission drive gear shaft 9 Transmission drive gear shaft 10 Spring washer 11 Hex bolt 12 Cover board power take off hole 13 Cover board spacer power take off hole 14 Oil screw plug assy 15 Sealing washer 16 Transmission housing 17 O ring transmission counter shaft 18 Rear bearing seat spacer mainshaft 19 Speedometer oil seal assy 20 Speedometer flexible joint 21 Sealing washer 22...

Page 29: ...emove 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: ...d 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 5 Clearance between 2nd speed gear and 3rd speed gear thrust ring 6 Clearance between 1st speed gear and reverse gear seat Transmission body 1 Remove the rear bearing cover of the mainshaft 2 Remove the speedometer drive gear and spacer ...

Page 31: ...le 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: ...ing 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 Note Make marks on the baulk ring in order to distin guish 11 Make use of a crane or hoist to lift the mainshaft out from the transmission housing and make the front end of the mainshaft uptilted ...

Page 33: ...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 MT 9 16 Lift the countershaft out by using crane or hoist Transmission mainshaft ...

Page 35: ...le bearing 17 4th gear bearing seat ring 18 4th gear baulk ring 19 3rd 4th gear sliding sleeve 20 3rd 4th gear synchronizer lockpin 21 Lockpin 22 Synchronizer push block 23 3rd 4th gear fixed gear seat 24 3rd gear baulk ring 25 3rd gear 26 Needle bearing 27 3rd gear bearing seat ring 28 Transmission mainshaft 29 2nd gear assy 30 Needle bearing 31 2nd gear bearing seat ring 32 1st 2nd gear baulk ri...

Page 36: ...ar synchronizer assembly and the 6th gear 5 Dismantle the 5th and 6th speed gear synchronizer assembly Note Be careful when dismantle the slide gear sleeve take care of the fixed gear seat lockpin and spring of the slide sleeve and other parts Do not miss any of them 6 Pull the reverse gear with an extractor to loose the shaft bush and every gear needle bearing seat ring ...

Page 37: ...eed 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 ...

Page 38: ... 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 ...

Page 39: ...ust shim 4 Countershaft constant mesh gear 5 Countershaft 6th gear sleeve 6 Countershaft 4th gear lock ring 7 Countershaft 5th gear 8 Countershaft 4th gear 9 Sleeve 10 Countershaft 3rd gear 11 Key 12 Key 13 Woodruff key 14 Transmission countershaft 15 Countershaft rear roller bearing 16 Steel ring for shaft 17 Lock nut washer 18 Lock nut lock spacer 19 Lock nut 20 Reverse gear 21 Reverse gear need...

Page 40: ...lastic 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: ...pring 22 Steel ball 23 Limiting stop pilot bolt 24 Spring washer 25 Switch assy 26 Spacer 27 Steel ball 28 Reverse shift fork 29 Reverse gear guide block 30 Steel wire rope 31 Reverse gear fork shaft 32 Steel wire rope 33 1st 2nd gear fork 34 Gear fork catch bolt 35 1st 2nd gear fork shaft 36 1st 2nd gear guide block 37 3rd 4th gear fork shaft 38 Interlock pin 39 Steel ball 40 3rd 4th gear fork 41...

Page 42: ...he interlocked pin is not set on the neutral position you can t pull down the gear shift fork shaft 1 Take down the top cover assembly and gasket 2 Take out the self locked spring and steel ball Note Look out the self locked spring and steel ball don t miss any of them 3 Take down the reverse lamp switch and neutral switch steel ball 4 Take down the guide bolt of the limit block ...

Page 43: ...th 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 7 Knock out the 1st and 2nd gear shift fork spring pin and then the 1st and 2nd gear shift fork and 3rd and 4th speed gear guide block shaft Transmission top cover 1 Take down the elastic ring and then remove the select rocker arm and O ring ...

Page 44: ...ve 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: ...off with neutralizing solution Rubber parts Don t wash with mineral oil Get rid of slurry or filth with alcohol or clean cloth Oil channel Let a wire go through the oil passage to unclog the passage then wash the passage by injecting washing solu tion into it with pressurized nozzle Anticorrosion After getting rid of the dirty oil on the component apply a layer of clean grease to prevent corrosion...

Page 46: ...assembled 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 gear shift lever spline Repair standard 0 05 0 11mm Wear limit 0 5mm 3 Measure the clearance between gear shift lever and every guide block Repair standard 0 1 0 4mm Wear limit 1 0mm ...

Page 47: ...m Repair standard 140 190N Repair limit 110N Gear 1 If the measured backlash is over the wear limit value check gear impression and working condition of the bear ing Repair standard 0 15 0 25mm Wear limit 0 5mm 2 Measure the clearance between fixed gear seat and gear slide sleeve engaged tooth including mainshaft Repair standard 0 2 0 3mm Wear limit 0 5mm 3 Measure the radial clearance between sli...

Page 48: ... 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 Repair standard 1 5 2 5mm Wear limit 0mm 2 Measure clearance between baulk ring and gear fixed seat C Repair standard 5 3 5 7mm 3 Measure axial clearance between baulk ring and back ing block D Repair standard 0 5mm ...

Page 49: ...s please make sure that the installing direction of the gear thrust washer needle bearing and spacer sleeve All the surface of the turning part should be smeared with clean gear oil According to the requirement all the self locked nut oil seal and O ring should be replaced Mainshaft 1 Install the needle bearing and 2nd speed gear Note Install the 2nd speed gear in the correct direction 2 Install t...

Page 50: ...chronizer 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 9 Install the 5th and 6th speed fixed gear seat ...

Page 51: ...chronizer accord to the turning direction of the fixed gear seat 12 Install the 5th and 6th speed gear slide sleeve Note The height of the synchronizer lockpin lower than the lockpin assembly is not allowed 13 Install the 5th and 6th speed gear synchronizer 14 Install the spacer sleeve and lock shim then tighten the locking nut with a special spanner Tightening torque 300N m Note Bend the relative...

Page 52: ...d synchronizer assembly needle bearing 1st speed gear reverse gear seat and reverse gear sleeve 18 Press in the reverse gear bearing seat ring and install the needle bearing and reverse gear and thrust spacer 19 Measure clearance between every gear of mainshaft Repair standard 0 3 0 5mm Wear limit 0 7mm Note Make use of the transmission housing and mainshaft assembly to measure the end clearance o...

Page 53: ...pacer 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 Note When installing the key pay attention that the face with a bigger chamfer should be set on the gear ...

Page 54: ...r 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 gear shift fork Remember to assemble the spring pin into the spring pin hole of the gear shift fork ...

Page 55: ... the upper cover hole then assemble the gear shift fork and guide block 3 Install the interlock steel ball 4 Install the interlocked pin to the 1st and 2nd speed gear shift fork shaft press to assemble the 1st and 2nd gear shift shaft by the transmission upper cover hole and then install the 1st and 2nd guide block and transmis sion fork 5 Install the steel ball ...

Page 56: ...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 9 Install the spring pin on every shaft Note When installing the spring pin to the gear shift fork shaft and the guide block shaft the gap of the spring pin has to align with the direction of the shaft ...

Page 57: ...haft 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 3 Make use of a hammer to knock the pin into the housing 4 Install the steel ball and spring into the gear shift block and make the screw plug on the gear shift block by a locking shim Note Bend the locking shim to lock the screw plug ...

Page 58: ...in 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 Tightening torque 20 26N m Transmission assembly Before installing smear some gear oil on the surface of bearing O ring oil seal and the fitted bolt 1 Install the countershaft assembly 2 Install the front bearing then the elastic ring ...

Page 59: ...d 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 6 Install the countershaft rear bearing cover and gasket Tightening torque 59 79N m 7 Install the flexible joint oil seal and the driven gear of the speedometer ...

Page 60: ...r 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 11 Assemble the drive gear shaft assembly ...

Page 61: ...standard 0 3 0 5mm 14 Measure the backlash of every gear Repair standard 0 15 0 25mm Transmission accessories 1 Install the propeller shaft connecting flange Tightening torque 340 560N m Note When tightening the locking nut first engaged the gear after tightening set to the neutral position 2 Install the power take off hole cover and sealing shim Tightening torque 47 63N m 3 Install the sealing sh...

Page 62: ...Install clutch booster or clutch slave cylinder return spring and dowel pin Adjust free running for clutch outer pull rod Free running for clutch outer pull rod 2 3mm 3 Install transmission operating lever 4 Install propeller shaft and center bearing Propeller shaft tightening torque 215 245N m Center bearing tightening torque 160 220N m 5 Connect all the lines and tubes 6 Made sure that drain plu...

Page 63: ...Transmission MT 38 ...

Page 64: ...PR 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: ...g 0 1 Axial clearance of center bearing 0 5 Center bearing bearing seat inside hole sur face worn 0 05 ItemItem Tightening Torque Propeller shaft flange fork connecting nut 90 110 Center bearing locking bolt and nut 901 10 Trouble Cause Method Abnormal vibration in the running Connecting bolts on the propeller shaft loosely Tighten bolts or nuts Propeller shaft vibration Propeller shaft has not be...

Page 66: ...cture 1 Flange fork 2 Bolt 3 Cross shaft needle bearing assy 4 Dust collar 5 Cross shaft 6 Grease nipple 7 Snap ring for holes 8 Slip york assy 9 Grease fitting 10 Slip york oil seal 11 Oil seal spacer 12 Oil seal cover 13 Propeller shaft assy ...

Page 67: ... point of the propeller shaft for its radial runout 1 Flange fork 2 Cross shaft needle bearing assy 3 Dust collar 4 Cross shaft 5 Grease elbow 6 Snap ring for holes 7 Intermediate propeller shaft assy 8 Washer center bearing seat 9 Center bearing bracket assy 10 Upper cover board center bearing 11 Oil seal center bearing 12 Bearing seat center bearing 13 Bearing center bearing 14 Flange driving co...

Page 68: ... the radial runout again if it still beyond the limit value replace the propeller shaft 5 Road tests Appearance check Check the surface of the propeller shaft for any cracks or pit If there were replace the propeller shaft Disassembly and assembly Make marks on the flange disc and remove the propeller shaft from the end of the rear axle Pull the propeller shaft out from the power train and plug th...

Page 69: ...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 Disassembly Disassemble the spider shaft 1 Make marks on the propeller shaft and flange fork 2 Remove the snap ring ...

Page 70: ...ake marks on the dismantled parts and you may not change their original position when reassembling Assembly Spider shaft 1 Install the spider shaft bearing apply some grease on the surface of the bearing inside face Never miss the needle of the needle bearing when assembling 2 Select a snap ring to make the spider shaft among the required axial clearance and install it The thickness of the selecte...

Page 71: ...der 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 1 Remove the propeller shaft 2 Loose the end face nut 3 Remove the connecting flange 4 Remove the front oil seal ...

Page 72: ...t 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 Remove the axle housing half axle Note Don t damage the spline sleeve flange fork and front oil seal when removing the propeller shaft Assemble Fill with recommended gear lubricant ...

Page 73: ...Steering System ST 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: ...eal spacer and O ring Avoid using the used spacer oil seal and O ring when assembling After assembly you must have a test run Check Check the free travel of the steering wheel Measure the free travel of the steering wheel when it is set on the cen ter Free travel 35mm If the measured value isn t in this range check the the steering gear clearance and the ball pin Check the center position of the s...

Page 75: ...en immobility spanner 11 Restoration spring 12 Limiting bush 13 Steering column welding assy 14 Bush Steering column 15 Steering column 16 Bearing 17 Fork universal joint 18 Fitting grease 19 Spider 20 Needle bearing assy 21 Steering universal joint fork slide fork 22 Oil seal slide fork 23 Oil seal cover slide fork 24 Grease fitting distance limited piece 25 Fitting grease 26 Joint with spline sh...

Page 76: ...f force When assemble the steering cross shaft you must check if the locking bolt and the sunk part is aligned Disassembly and Assembly When do the disassembly and assembly you have to unlock the steering lock by key Assure the surface of the spring lock ring is under the shaft Before insert the shaft into the sleeve first install the spring lock ring Assemble the spring lock ring on the upper hal...

Page 77: ...heck its moving condition Front rear 6 Up down L3 15mm Check If the steering wheel can t be turned flexibly please check the steering column by the following steps and replace the corresponding wearing parts Check the steering column bearing for any damage or wearness and lubricate the bearing with proper grease Replace the total steering column if necessary Check the steering column sleeve for di...

Page 78: ...embly 2 Elbow assembly inlet oil 3 Upper bracket 4 Elbow assembly outlet oil 5 Bracket 6 Clip 7 Clip 8 Oil pump 9 Bolt joint of the oil pump 10 Joint inlet oil tubing 11 Jacket 12 High pressure hose assembly 13 Hose 14 Hose steering gear to oil reservoir 15 Oil reservoir assembly steering ...

Page 79: ...ear drain off the remain oil in the oil pump and the oil reservoir idle the engine and turn the steering wheel left and right to the limit for several times till there is not oil flowing out 3 Tighten the oil outer bolt keep it clean and avoid dirt entered 4 Fill with new hydraulic pressure oil 5 Idle the engine turn the steering wheel left and right to its limit for several times until there is n...

Page 80: ...r oil pressure in the oil pump Replace oil pump 8 Vehicle overload too much Reduce load One way heavey steer ing 1 Tire pressure of one side isn t enough Inflating 2 Only one direction of the steering gear leak out too much Repair the steering gear 3 The rotary valve isn t in the nuetral position 4 The fixed pressure of left or right can t be set up Replace sealing part Heavey steering when quickl...

Page 81: ...steering gear Adjust the side cover bolt 4 Oil level of the oil reservoir is lower than the lowest mark Add oil 5 Front axle leaf spring fixed bolt loosed Tighten 6 Steering universal joint locking bolt loosed Tighten Steering wheel return failed 1 Insufficient tyre pressure Inflating 2 Too tight fit of the front axle parts Adjust 3 Improper alignment of the front wheel Steering wheel return too q...

Page 82: ...ly 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 FA 8 ...

Page 83: ...teering knuckle 6 Knuckle pin plug assy 7 Bolt knuckle pin plug 8 Grease elbow 9 Adjusting spacer steering knuckle 10 Left Steering knuckle arm 11 Double head bolt upper steer ing arm 12 Upper steering arm left steer ing knuckle 13 Wedge cotter pin steering knuckle pin 14 Front axle 15 Thrust bearing 16 Right steering knuckle 17 Right steering knuckle arm 18 Steering limiting bolt ...

Page 84: ...t assy 5 Front brake air chamber assy 6 O ring 7 Front brake cam 8 Bush air chamber bracket 9 O ring 10 Adjusting spacer 11 Front brake adjusting arm assy 12 Washer brake cam 13 Adjusting washer 14 Front brake bottom plate assy 15 Shaft brake shoe 16 Bush 17 Screw 18 Pin 19 Rivet 20 Brake friction plate 21 Front brake shoe 22 Return spring ...

Page 85: ...g the service life and assure the safe run ning of the vehicle If you follow the maintenance schedule to do the maintain your vehicle may obtain the best economic benefit The items of the periodical maintain are as following 1 Add some grease to the grease nipple 2 Avoid important nut loosed 3 Adjust wheel hub bearing pretightening force and toe in 4 Adjust the brake clearance Periodical Maintain ...

Page 86: ...justment of front wheel hub pretightening force 1 Apply some 2 lithium grease on the thread of the steering knuckle shaft end and the wearproof spacer 2 Tighten the locking nut by a torque of 120 150N m 3 Turn the wheel hub for 2 3 circles to correct the alignment of the bearing 4 Tighten the locking nut by a torque of 120 150N m 5 Unscrew the locking nut for 1 3 circle install the locking washer ...

Page 87: ...tion plate or the brake drum Cleanup the grease or replace friction plate Abnormal noise while braking Friction plate worn and rivet appeared Replace friction plate Friction plate surface hardening or deterio ration Replace friction plate Brake drum uneven worn or loose installed Correct brake drum or tighten the bolt Brake shoe and friction plate connected loosely Replace rivet Brake shoe fixed p...

Page 88: ...nment Check and adjust Front axle bent Correct or replace Brake unsmooth See the relative brake items Front wheel hub bearing nut loosed Tighten accord to the required torque Tire unevenly worn or earlier worn Improper wheel alignment Check and adjust Wheel hub bearing worn or damaged Replace wheel hub bearing Bearing nut loosed Tighten accord to the required torque Ball pin kingpin and bush overt...

Page 89: ...uckle kingpin lithium grease 2 Tie rod ball pin lithium grease 2 Wheel hub bearing lithium grease 2 Adjusting arm lithium grease 2 Cam bracket lithium grease 2 Part Tighten Torque N m Steering draglink arm nut 120 140 Nut of the left and right steering knuckle arm 120 140 Front brake bottom plate bolt 140 170 Air chamber bracket fixed bolt 55 70 Air chamber fixed bolt 55 70 Pin lock nut 55 70 Stee...

Page 90: ...mm Cam shaft end 0 40 0 70mm Clearance difference between two shoes of the same side is 0 1mm Item Maintaining Standard Wear Limit Remark Outside diameter of kingpin 31 9 32mm 31 9mm Clearance between kingpin and steering knuckle bush 0 025 0 077mm 0 20mm Clearance between kingpin and front axle hole 0 01 0 052mm 0 10mm Clearance between steering knuckle and front axle 0 05mm 0 15spacer adjustment...

Page 91: ...tents 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: ...e housing cover assy 5 Bolt fix the rear axle housing cover 6 Rear axle housing 7 Set pin 8 Square slotted conical screw plug with glue 9 Gasket 10 Bolt fix the differential 11 Heavy spring washer 12 Half axle bushing 13 Rear axle half axle gasket 14 Half axle oil seal assy 15 Rear axle half axle 16 Rear axle half axle bolt 17 Bracket sensitive valve ...

Page 93: ...m ring cage ring 11 Bolt 12 Spring washer 13 Rubber plug 14 Dustproof shield 15 Brake bottom plate 16 Set screw 17 Steel lock wire 18 Supporting pin 19 Rivet 20 Brake bush 21 Brake shoe 22 Return spring 23 Return spring pin 24 Spring washer 25 Screw 26 Roller pin shaft 27 Roller 28 Clamp ring 29 Dustproof shield 30 Grease nipple 31 Bush 32 Oil seal 33 Cam shaft 34 Brake friction plate ...

Page 94: ...llow the maintenance schedule to do the maintain your vehicle may obtain the best economic benefit The items of the periodical maintain are as following 1 Add some grease to the grease nipple 2 Avoid important nut loosed 3 Adjust wheel hub bearing pretightening force and brake clearance 4 Add and replace the gear oil for the reductor Periodical Maintain Schedule Item Maintenance Interval Mileage 1...

Page 95: ...bly and front outer bearing inner ring in sequence at the spline end of the gear 4 Measure the pretightening load of the drive gear bearing install the oil seal assembly thrust washer flange fork and washer then tighten the castle nut with a torque 350 500N m and measure the pretightening force at this time the starting force of pulling the flange hole of the bearing seat should be 12 30N 5 If the...

Page 96: ... t turn to make the clearance become zero then turn with the counter clockwise until you hear two sounds of steel ball and the middle part clearance of the brake friction plate is 0 4 0 7mm Gear contact zone Adjusting method 1 Proper contact zone No need to adjust 2 The drive gear the driven gear is too far The drive gear and the driven gear is too far reduce the thickness of the spacer 3 The driv...

Page 97: ...ondition Improper adjustment of the brake air chamber push rod travel Adjust travel Friction plate overheated or deterioration Replace friction plate Improper connceting condition of the friction plate Correct the joint position of friction plate Water enterred the brake drum Press down the brake pedal during running to exhaust the water Grease on the connecting face of the friction plate or the b...

Page 98: ...ighten bolt by the required torque Oil drain screw plug loosed or the gasket is damaged Tighten screw plug or replace gasket Axle housing distorted because of over load Correct or replace axle housing Vent is blocked or damaged Clean or replace vent plug Brake unstably Improper installation of the brake shoe or return spring is broken Tighten fixed pin lock screw or replace return spring Oil on br...

Page 99: ...le nut 70 95 Rear adjusting nut 150 180 Reductor housing and axle housing connecting bolt 140 170 Axle housing rear cover and axle housing connecting bolt 90 120 Adjusting Item Adjusting Data Tooth space 0 2 0 4mm Clearance between rear fiction plate and brake drum 0 4 0 7mm Item Maintaining Standard Wear Limit Remark Feedhole of the rear axle leaf spring worn Φ 27mm Φ 28mm Radial runout of left a...

Page 100: ...Suspension System FA Table of Contents Trouble Analysis FA 1 Structure FA 2 Disassembly FA 4 Check FA 7 Assembly FA 8 ...

Page 101: ...ng leaf damaged Overload Replace the spring leaf 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 center hole U bolt and nut loosed Replace spring leaf ...

Page 102: ...d underplate with set sleeve assy 3 Center bolt 4 Bush 5 Fixed end bracket 6 Spring pin set bolt 7 Spring leaf pin front suspension 8 U bolt 9 U bolt 10 Cover board front suspension 11 Limit block front suspension 12 Lifting eye bracket 13 Front lifting eye 14 Lifting eye oin set ...

Page 103: ...eaf spring pin 4 Limit block assy 5 Sub leaf spring bracket 6 Bracket lifting eye end 7 Lifting eye with bush assy 8 Leaf spring pin 9 Cover board 10 U bolt 11 Sub leaf spring assy 12 Sub leaf spring underplate 13 Rear leaf spring assy 14 Set pin sleeve 15 U bolt underplate ...

Page 104: ...e front damper dismantle the front damper lower end and take off the related parts 3 Loosen the set nut from the upper end of the damper dis mantle the front damper upper end and take off the front damper 4 After loose U bolts and nuts remove the U bolt cover board and limit block 5 Down the front axle by loose the jack and then the leaf soring is in a free condition 6 Remove the spring rear end l...

Page 105: ...fting eye Disassembly of the rear suspencion 1 Wedge the front wheel lift the rear axle and rear part of the frame with a jack and the safety support then take down the rear wheel 2 Unscrew the set nut from the lower end of the damper and take off the related parts 3 Loosen the set nut of the damper pin from the upper end of the damper remove the related parts and take down the damper 4 Loose the ...

Page 106: ...e threaded sleeve off a little then pull or you can use the pin puller with thread 7 Remove the cotter pin used to fix the front pin of the rear leaf spring then take down the front pin of the rear leaf spring down the jack then remove the rear leaf spring finally 8 Take down the cotter pin of the lifting eye pin and make use of an iron rod diameter 15mm went through the special hole used to remov...

Page 107: ... wear condition of the spring leaf if the wear value is over 15 of the standard thickness please replace the spring leaf Standard thickness of the front leaf spring is 9mm wear limit is 7 65mm Standard thickness of the rear leaf spring is 10mm wear limit is 8 5mm Standard thickness of the sub leaf spring is 8mm wear limit is 6 8mm Note If one of the leaf spring is broken you d better replace the w...

Page 108: ...the nut After tightening the clamp bolt rivet the connecting thread of the bolt and nut to lock Assembly of the front suspension 1 Smear a layer of grease on the spring bush and lifting eye bush before assembling 2 Install the lifting eye to its bracket and insert the pin then tighten the locking nut 3 Install the front leaf spring assembly cover board limit block to the front axle and lift the fr...

Page 109: ...on 1 Smear a layer of grease on the spring bush and lifting eye bush and install the lifting eye to its bracket then insert lifting eye pin then the cotter pin and tighten its lock nut Tightening torque 90 110N m Note When inserting the cotter pin make the inclined face contact to the face of lifting eye pin 2 Set the rear spring to the rear axle and lift the rear axle by the jack 3 Align the fixe...

Page 110: ...stall the underplate sub spring and cover board to the upper of the rear spring then install the U bolt 6 Lift the rear end of the vehicle by a jack take down the support under the frame then down the jack 7 Install the U bolt underplate and damper lower bracket 8 Install the U bolts and nuts and tighten Tightening torque 300 350N m 9 Add grease to the leaf spring pin and lifting eye pin 10 Instal...

Page 111: ...tents 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 10 Hand Control Valve Control System BR 11 ...

Page 112: ...ghtening Torque Fasten bolt of the front brake air chamber and its bracket 55 70 Fasten bolt and nut of the front air chamber and brake bottom plate 55 70 Fasten bolt of front brake bottom plate and steering knuckle 160 220 Lock nut of front brake anchor pin with conical sleeve 128 167 Fasten bolt of the rear brake air chamber and its bracket 55 70 Fasten bolt and nut of the rear air chamber and b...

Page 113: ...bolt protrude due to the wear of the brake lining The brake lining surface is harden The brake lining surface deteriorated Bad contact of brake shoe and brake lining Uneven wear of brake drum inner surface or incorrect installation Brake shoe supporting pin loosed The wheel hub bearing worn out The brake drum deformed Replace brake lining Replace brake lining Replace brake lining Rivet up the rive...

Page 114: ... friction lining Abnormal air pressure Air pipes leak air Air compressor doesn t work Improper adjustment of the unloader valve or it failed because of impurities Brake valve leaks air Repair Disassemble and repair the air com pressor Adjust or clean Disassemble and repair the brake valve Trouble Cause Repair Wheel seized Air in brake air chamber Improper lubricant of cam shaft or adjust ing arm r...

Page 115: ...shield 14 Washer spring 15 Plug rear dust shield 16 Front dust shield 17 Front brake plate L H 18 Screw 19 Wire lock 20 Anchor pin front brake 21 Rivet 22 Bushing brake shoe 23 Front brake shoe 24 Return spring rear brake shoe 25 Washer spring 26 Hex bolt 27 Roller shoe brake shoe 28 Roller 29 Lock ring brake shoe roller shaft 30 Pin shaft Washer spring 31 Front dust shield 32 Fitting grease 33 Bu...

Page 116: ...ke 15 Rear brake plate 16 Screw to fix brake shoe 17 Wire lock 18 Shaft shoe 19 Rivet 20 Bush rear brake shoe 21 Rear brake shoe 22 Return spring rear brake shoe 23 Pin return spring 24 Washer spring 25 Screw to fix brake plate 26 Roller shaft rear brake shoe 27 Roller rear brake shoe 28 Lock ring brake shoe roller shaft 29 Rear dustproof tray rear brake 30 Fitting grease 31 Bush brake plate 32 Se...

Page 117: ...There should not be any crack especially at the two end hooks 7 The diaphragm of the brake chamber should be in good condition It should not have any ageing crazing or crack It is not allowed to use the same size diaphragms of different hardness on one truck 8 Check clearance of all fitting surface Assembly 1 Install the assembled brake backing plate assembly on the front axle steering knuckle Tig...

Page 118: ...uld be Near the anchor pins 0 25 0 40mm Near the camshaft 0 40 0 55mm The difference of clearance at the same end of the two shoes 0 1mm When braking linings worn out and the push rod stroke of the chamber exceeds 40mm partial adjustment should be done immediately to reduce the clearance between the linings and the drum Never turn the anchor pins to destroy the good match of linings and drum When ...

Page 119: ...ends of the rear axle housing the tightening torque of the bolt is 130 160N m and then install the pressing dust shield 3 Install the air chamber bracket and fasten then set to the brake cam and assemble the adjusting spacer After that install the brake adjust arm to the brake cam and lock with a clamp ring connecting the air chamber push rod to the brake adjust arm with flat pin 4 The return spri...

Page 120: ... Nylon pipe assembly 18 Quick release valve subassembly 19 Nylon pipe assembly 20 Hose assembly 21 Hose assembly 22 Hose bracket 23 Hose assembly 24 Fitting elbow 25 Hose assembly 26 Nylon pipe assembly 27 Hose assembly 28 Air line assembly desiccator to dampAir tank assembly 29 Air desiccator and unloader valve subassembly 30 double direction valve and Quick release valve subassembly 31 Hose asse...

Page 121: ...r 4 Nylon pipe assembly Brake valve 21 connect hole to hose bracket 5 Nylon pipe assembly Brake valve 22 connect hole to hose bracket 6 Nylon pipe assembly Brake valve12 connect hole to hose bracket 7 Nylon pipe assembly Brake valve11connect hole to hose bracket 8 Jacket 9 Transition tie in ...

Page 122: ...y 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 ...

Page 123: ...Brake System BR 12 ...

Page 124: ...ernal Trims and External Trims BF 4 Seat BF 11 Cab Mounting BF 12 Cab BF 13 Chassis Frame BF 14 Air conditioner and Heater BF 15 Construction of the Heater BF 18 Air Flowing Direction BF 19 Check the Leakage of the Refrigerant BF 20 Air conditioning System BF 22 Schematic Circuit of Air condition System BF 25 ...

Page 125: ...to soil or damage them Apply seal glue on necessary place when assembling Be careful not let the glue flow out of the parts when applying When replacing the metal parts extarnal plate of the body be sure to take rust prevention measures Clip and Fastener The following codel and pictures and symbols are subiect ot the clip and fastener in the BF section The clip and fastener must be replaced if dam...

Page 126: ... 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 5 Disassemble reinforcement seal washer and i 6 nstallation board for the lights ...

Page 127: ...Cab BF 3 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 ...

Page 128: ... Internal trims Side ard floor trims Passenger area Caution Wrap the tip of flat bladed screwdriver with a cloth when removing metal clips from garnishes Disassembly of the side inner trims Disassemble the sun visor Disassemble the rearview mirror 1 Instrument frame welding ass y 2 Oil can cap 3 Instrument frame welding ass y 4 Instrument panel upper cover ass y 5 Ashtray assy 6 Block cover Small ...

Page 129: ... seats Disassemble the safely belt Disassemble the door guardrail Disassemble the rear window glass Door trims Disassembly of the door trims Disassemble lock knob Disassemble inside seal Disassemble inside handle escutcheon rear door Disassemble pull handle Pull out regulator handle ...

Page 130: ...guard board of door rear door Roof trims Disassembly of the roof trims Single seater cab Remove part of headlining from corner and gradually peel headlining off Double seater cab Disassemble the screw and roof bow Remove headlining by peeling if off starting with middle portion ...

Page 131: ...Cab BF 7 Cab External Trims ...

Page 132: ...Front lower cover and lower cover board Side external cover board Front and rear windows Cab door seal strips Door and window seal strips Front pedal cover and pedal mat option Front upper finisher Front grille Front corner panel ...

Page 133: ...Cab BF 9 Front and rear window Cab door seal strip ...

Page 134: ...Cab BF 10 Door outside molding Foot step shield and mat ...

Page 135: ...an accident whatever the nature of the accident is the belt assembly must be replaced If any part of the belt has quality problems it must be replaced instead of repairing it If there is any cut looseness or damage on the texture etc replace the assembly Wine oil or other material should not be sprayed into the buckle hole lock so does not the huckle and the knob ...

Page 136: ...ar arm assy 2 Tilting bracket assy 3 Torsion bar 4 Left bracket front mounting 5 Retainer lower assy 1 Left connecting bracket assy rear mounting 2 Upper cushion assy 3 U suppot welding assy 4 Rear mounting lower cushion assy 5 Right connecting bracket assy rear mount ing ...

Page 137: ... 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 2 Hand brake operation and brake drag wire 3 Electric system wire harness and tube Note Different model has different shape of cargo body ...

Page 138: ...ng cross member 8 Damper cross member 9 Lifting eye end bracket 10 Rear leaf spring cross member 11 Hook bracket 12 Right side member 13 Fixed end bracket 14 Lifting eye end bracket 15 Engine rear mounting cross member 16 Rear leaf spring cross member 17 Fixed end bracket 18 Sub spring bracket 19 Stiffening plate rear bracket of rear spring 20 Stiffening plate rear bracket of front spring 21 Bolt ...

Page 139: ...ea The refrigerant should avoid the fire because its combustion will produce toxic gas The temperature can t be higher than 40 too much when fill the refrigerant Don t warm the refrigerant container with the fire because it may cause the container exploded Note Don t wash the surface of the condensor and evaporator with vapor Please use the cold water or compressed air Don t wash the contaminative...

Page 140: ... 8 Lubricating as the figure showed when install the pipe and don t put the lubricating oil on the screw thread 9 The O ring should be put about on the seat of the pipe 10 Insert the guide pipe into the screw pipe fitting then screw down follow the required torque 11 After connecting the pipe make sure there is not any leakage If there is dismantle the leaky part of the pipe and change the O seali...

Page 141: ... It is used to adjust the tmperature of the outlet Ventilating slide switch It is used to introduce the external air It is used to circulate the internal air Air conditioner swich Start the engine put the fan switch at your wanted place then press the air conditioner switch The indicator light will go on when the air conditioner is working Press again the air conditioner switch to stop it The air ...

Page 142: ... Wind channel ass y 3 Middle air pipe 4 Right air pipe ass y 5 Left door defroster hose ass y 6 Defroster nozzle ass y 7 Right door defroster hose ass y 8 Wind inlet channel ass y 9 Plastic nut ass y 10 Heater ass y 11 Air blower ass y 12 Heater control ass y 13 Water inlet tube ...

Page 143: ...Air conditioner and Heater BF 19 Air Flowing Direction Note The specific operate method refer to its maintenance tool manual ...

Page 144: ...es sure of the high pressure pipe will be down and the pressure of the low pressure pipe will be up but it is easier to check the leakage at the high pressure condition Check Clean the checking part with a piece of cloth before checking the fitting of the pipe carefuly Compressor check the shaft seal the hole of the bolt and the around of the electromagnetic clutch Oil storage container check the ...

Page 145: ...e 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 ...

Page 146: ...et 3 Evaporator exhaust pipe 4 Bracket assy evaporator inlet and outlet pipe 5 Pipe assy connecting evaporator and conden sator 6 Pipe assy connecting evaporator and com pressor 7 Pipe assy connecting compressor and con densator 8 Compressor assy with clutch 9 Condensator assy with drier and bracket ...

Page 147: ...ode outlet inlet temperature lower and upper and the A C switch Checking condition The engine is running and the temperature is in normal condition Approach 1 Check the blower fan Move the fun switch to the 1 position the fan should be in the speed of 1 Then move to the 2 position Check the other speed of the fan 2 Chexk the ventilation Move the switch to the position check if the air is blown to ...

Page 148: ...l fresh air will be blown into the cab by the blower 4 Temperature lower checking Move the switch to the lowest position Check the cold air from the vent 5 Temperature upper checking Move the switch to the highest position Check the warm air from the vent 6 Check the A C switch Move the fan switch to the position of 1 4 and press the air conditioner switch the indicator will goes on ...

Page 149: ...Air conditioner and Heater BF 25 Schematic Circuit of Air condition System ...

Page 150: ...Air conditioner and Heater BF 26 ...

Page 151: ...on 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 EL 12 Horn EL 13 Fog Lamps EL 15 Instruments EL 16 Instrument Panel EL 17 Speedometer EL 19 Tachometer EL 22 Water Temperature Meter and Fuel Meter EL 24 ...

Page 152: ...rent A 45 Battery A h 90 Light name Bulb specification Bulb type Remark Front headlamp H4 75 70P P43t 38 Fog light H3 70 PK22s Front combination light PY21W BAV15s Turning light R10W BA15s BA15d Front light Side turning light R10 BA15s BA15d Doom light QT24 5SV SV8 5 Inspection light QT24 21 BA15s 19 Rear combination light P21W BA15s BA15d Reverse light PY21W BAU15s Turning light P21 5W BAY15d Bra...

Page 153: ...tact not good Main supply switch failed One position failed Fusible wire and fuse burnt When turn on the one position switch the switch has not good contact Recharge or replace Make earth line steady Make line steady Replace one position switch Replace fusible wire Replace or repair main supply switch Trouble Cause Remedy Engine can not start and starter runs abnormally Fuel cutoff solenoid fuse b...

Page 154: ... on but left right turning signal light doesn t go on Left turning light right turning light s joint doesn t contact well Check the circuit from turning signal light switch to lamp When turn on the switch the light continues to go on but does not flash Flasher failed contact maintains engage Front rear bulb failed Replace flasher Replace bulb Turning signal light flashes too quickly Flasher failed...

Page 155: ...d breaks away Wiper arm s tightening bolt loosens Wiper motor assembly failed 1 Internal coil burns out 2 Wiper motor overlade because of current over powering The rectifier is polluted carbon rotary bearing is seized wiper arm connect not well motor wears constant speed gear fails Find out cause and replace fuse Check and repair Replace wiper switch Check and repair Tighten bolt Check and repair ...

Page 156: ...f the complete truck are connected as follow In the normal conditions the output of alternator reaches ignition switch lighting and instruments by the way of two fusible wires If the alternator fusible wires are burnt the above systems will continue to operate using the battery power But if the engine stops at the time the systems can t start until replace the fusible wires The fusible wire must b...

Page 157: ... if the electrolyte is found insufficient Charging for over half an hour after filling in order to let the filled distilled water fully fix with the former electrolyte Electrolyte level above the top of the battery plate 15 20mm Battery plate Electrolyte Battery Two batteries 6 QW 90DF are in series Type Less maintenance Nominal voltage V 12 Nominal capacity A h 165 ...

Page 158: ...f servicing Use the alternator with built in rectifier and electric regulator Operation principle The alternator produces self excitation field and operates normally when the charging indicator lamp is extinguished Vehicle model DFA1101GZ5AD6J 907 Nominal voltage V 28 Adjusting voltage V 28 0 3 Nominal current A 45 Nominal revolution r min 6000 Starting revolution r min 1150 Output current A 18 20...

Page 159: ...the damaged parts Short circuit between the 3 phases and rotor winding and casing Diode damaged Regulator failed Charging current is too small the battery is insuffi cient No charging at low speed Output voltage is over low Exclude the trouble and replace the dam aged parts Diode is partly damaged The rotor winding has 1 phase or 3 phases bad contact Slipping belt The instrument indicator sometime...

Page 160: ...nd chassis frame As soon as fuse is burnt the electromagnetic main supply switch will automatically cut off the battery nega tive earthed circuit So there will be no electricity in the complete truck Specification Trouble analysis Vehicle model DFA1101GZ5AD6J 907 Nominal voltage V 24 Nominal power kW 3 7 Pinion teeth 10 Pinion module 2 54 2 1167 Brake torque N m 40 Brake current A 800 Brake voltag...

Page 161: ... 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 Note The exhaust brake indicator lamp comes on which only indicates the exhaust brake switch is ready for operation not indicates the exhaust brake is operative ...

Page 162: ...Electric and Instrument EL 11 Hazard Warning System When the hazard warning switch is in the alarm position the left and right turning signal lamps will flash simultaneously ...

Page 163: ...Electric and Instrument EL 12 Accessories Wiper motor Power 50 Revolution Low speed 40 High speed 60 6 2 3 ...

Page 164: ...al 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 1 To horn 2 To power supply 3 To horn button ...

Page 165: ...Electric and Instrument EL 14 Electric wiring diagram ...

Page 166: ... 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: ...Electric and Instrument EL 16 Instruments Structure This part consists of air pressure meter fuel meter water temperature meter tachometer and speedometer Name of the indicators and warning lights ...

Page 168: ...1 Water temperature meter 40 80 100 120 Nominal voltage V 24 1 Panel assembly 2 Speedometer 3 Washer 4 Self tapping screw 5 Warning lamp pattern piece 6 Big case 7 Soft printed circuit board 8 Nylon rivet 9 Speedometer lighting bulb holder 10 Small warning signal lamp bulb holder assembly 11 Big warning signal lamp holder 12 Oil pressure gauge assembly 13 Fuel level gauge 14 Water temperature gaug...

Page 169: ... method The three small meters can be replaced after the transition connecting parts have been removed which should be fit and tightened after the meters are replaced Reassembly and check Reassemble the removed parts in the reverse order of removal and tighten screws when reassembling Check if there is any part assembled wrongly or any scratches damages and so on Then attach the connectors the tac...

Page 170: ... to reset the meter indicator to zero and then release it before using this speedometer The red figure at the far right with the white background indicates readings in units of 0 1km Note Do not press the reset button during the driving period Do not pull or turn the reset button when press it Technical parameter Type Magnetic inductive Speed indicator range km h 0 140 Mileage counting figures km ...

Page 171: ...inum cover 10 Needle shaft 11 Hairspring 12 Needle Working principle Drive of speedometer The flexible shaft driven by transmission main shaft mounted on the back of the transmission is driven by pulling the square connector into the square hole at the outside of the speedometer turning shaft which drives the digital wheel through three sets of worm wheel and worm Indication of odometer When the f...

Page 172: ... side Transmission output shaft slipped Tighten the flange fork under the rec ommended torque The magnetic effect of the magnetic steel reduced Replace Needle indica tion error Hairspring deformed or deviate from the original position Move the hairspring to one side to adjust the indication of the needle Magnetic body cracked Replace meter Dimension of tyre is wrong Replace and use the recommended...

Page 173: ...aft coil assem bly bracket assembly upper and lower bearing and so on Auxiliary part Base housing screws and electrical connectors The needle seized or failed that can not return to zero Grease on the magnet Clean out the grease Hairspring deformed Replace meter Wrong assembling of the needle needle slack ened Tighten There are impurities absorbed on the magnet of the indication board Clean The da...

Page 174: ...e the hairsprings In addition do not break the coil output wire 1 Needle 2 Screw 3 Dial 4 Light guiding glass 5 Printed circuit board 6 Connection wire 7 Bracket 8 Blade connector 9 Base Trouble analysis Trouble Case Repair The instrument doesn t work Circuit broke Sensor damaged Instrument burnt out Check wire connection and connector with socket s contact Replace sensor Replace instrument Needle...

Page 175: ...lysis Water temperature meter Type Moving magnet Indicating range 40 80 100 120 Meter seat connection 3 M3 6g screw Fuel meter Type Moving magnet Indicating range 0 1 2 1 Meter seat connection 3 M3 6g Trouble Cause Method Fuel meter does not work Open circuit of the sensor resistance wire Replace Open circuit of the sensor and meter electric wire Connect Wrong indication of the fuel meter Sensor f...

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DongFeng DFA1101GZ5AD6J-907, Service Manual

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